Still Fork Truck R70 20 R70 25 R70 30 Factory Service Repair Workshop Manual

R70-20 R70-25 R70-30 Treibgas-Gabelstapler LPG Fork Truck Chariot élévateur au GPL

Werkstatthandbuch DFG R7062R7063 R7064 TFG R7068R7069 R7070 Ident-Nr.164544 (en) STILLGmbH

Workshop manual

Diesel-Gabelstapler Diesel Fork Truck Chariot élévateur Diesel

Manuel d´Atelier





           

     

 



  



   



                

          









         

  

   

 

   

 



 



 

 

   

 

   

  

   

    

   

    

   

    

              

  

               







  

 

                   

 

                                           



  

 





                 





  



   

 

                 







                 

 

    

      

    









   

                              







 

 





 

  



 

 

      







                       

   





 









  



                   











           





      



 



       



                                         









        



       

    

  

 

    



 

       

    



 

    

       

   

    



   

       

   

  

 

  

 







                                    



 

 





   

 

 

 























































































                          









                                   





 









  



     

              



      



    









 





  





  



   

   



    

   

  

    

   



           

 



       

   



       

   



     

    



     

   



    

   



   





   

   









      





                   



   









                                            

  





    

    

    







        

            

 

      

 

  

 

     

 

          

 

 

  

   

 

        

   

     

     

       

   

                                         







        

       



  



  

     

















 





 



    



 







 







  



   



 



 







  



 



  



  



  



       



       



  



  



  



 



      







  



  







       





  

                                               

   







                             



 

 

            



             

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

                             



 

 

                                                      



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

    

                

                       







   

                 

           







       

   

           

   

  

     

  

 

   

        







                                 

   

                                 

   



        

 

 











 



   

 

 





   









                 





             



           



     







      



 

   

 



    







   



 

   



    

   



  



     



   





     



                

   

 

 

         

 

                             











  

                                

  

      







               



 

           







  

  





         





 





    











      

 

 

 

        

  

 

  

   

          







             



                                                                                  









    

     



 

           

              













 





















 

  







                   



                                    





                                        







                           



 

 







   





      

          



  



    





 



 





                                             

                                









       

       



    



  

   

      

 

  

  

                

  

   







 





  



 















 

         



         



         



        



 



 









  



  









    



 







 



 







             

        

            

        

             

        

        

         

             

                     

 

          

            

            

            

  

           

    

     

             

          

             

         

  

        

                      

  

        

        

        

      

                                 

  

                                                   

 

                                      

 

           

   

      

  

                        

           

                                           

 

  

             

  

             

                       

            

                        

       



        

      



                           

                

                        

   







    





    

                                 

 

                     



 

      



  

                                 





 





 









                

    

    

  

    

                  

    

    

  

  













 

  





















  

 



 





 















 

 











 



 



 







 





















 







    





           



 





                        





 



 











  



     















 

   





 









                                                                                            



                             







 











 













  

 

      

   

 

  

 







                                                                                 

  

  



   



 

    



 



  



 

     

   

   







 

 

 

        











  











 









 

   









 

 



 







  



                                                     









                                                                   

 







                                



 







  

   

         



           

 

 













                                      

    

  

   

                    

           

 









                                                               







      

        

     

      











      



  



                           

       

           

 









                     



            





                                      



 

 

 

 

           

 









                                   

            

                          







                                                   



             



  



    









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

                                        

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        

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          

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Workshop Manual

7062 - 64, 7065 - 67 ASM, 7068 - 70

08

Drive transmitter, 2-pedal type 2-pedal control with double potentiometer Since the third quarter of 2001, the trucks are being provided with a newly developed 2-pedal control fitted with a redundant potentiometer (double potentiometer).

The redundant potentiometer consists of two individual contra-rotating potentiometers in a common housing mounted on the left below the bearing bracket.

When the truck control system is activated, the stored parameters are checked for valid ranges of values.

Simultaneously measured is the sum of the values between the two contra-rotating potentiometers; this must be less than a specific limit value (ideal value 0 Volt ).

If the measured value is higher, the following error message will appear on the console display: ERROR 10 Mechanical adjustment of the potentiometer is unnecessary. The voltage values in the neutral position, forward and reverse actuation are measured during necessary calibration by the truck control system. Truck operation is only possible when all values are correct. Provided all values are within the valid ranges, they are stored. If the limit values are exceeded, the following error message will appear on the console display: ADJUST

ERROR 09 (calibration error) Parameterisation When retrofitting a two-pedal control, the parameter address must be adjusted: Address 08A Drive mode selection Value 05 Mode 5 2-pedal, redundant pot.

Value 00 Mode 0 2-pedal with 2 potentiometers Value 01 Mode 1 1-pedal standard

Calibration - Jumper between Pins 7 and 8/X165 - Press F2 key ( NOT F1!! ) The direction lamps on the console indicate actions to take.

There are three conditions: 1. Both direction lamps flash –> drive transmitter pedal in neutral position 2. Forward direction lamp flashes –> move drive pedal forward up to mechanical stop and hold until both lamps flash 3. Reverse direction lamp flashes –> move drive pedal back up to mechanical stop and hold until both lamps flash.

Calibration is complete.

If the error message ERROR 09 should appear on the console display, this may be due to the following: - Incorrect operation - Calibration timeout - Floor plate is not adkisted correctly mechanically - Incorrect VALUE in Address 08A

STILL GmbH

Position as per: 3/2003 ( Replaces version:04/02)

Neutral position Address 076---> R7065-67 Address 08F--->R7068-70 Mechanical wear compensation Value 96 = 300mV (100mV...500mV) Resolution 2mV (decimal 50...250) Full drive Address 077---> R7065-67 Address 090--->R7068-70 Mechanical wear compensation Value 96 = 300mV (100mV...500mV) Resolution 2mV (decimal 50...250) Causes - Parameterisation error, no reset - Calibration error - Drive transmitter voltage not reached - Potentiometer adjustment error - Floor plate incorrectly adjusted mechanically 16

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                                                                                                 

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                      



          



     





              

   

   

                                        









                        



 



      

        



         







    



    

      

    

R7068-70 from Version V1.47 R7065-67 from Version V4.34  Note        

  

 



    

 





                                   



  

 



 

  





 





  





  





  

  





  







 



       





 



          



 

                    







  









 

 

 

 

 

 









  

 







  

 

 

  



   

 



       











                                   

 

 



















                               









  

  

     







 

 

 

 

 

 







  

 

 

   

 

 



    



  











                                               

    

                                     





 



  



   

 

 









    



                     

    







 

  



 



 









  











 



                               

                  

         

 





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

                                                  

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           

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                                                                                        

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                  

                   

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

           

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

       

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                      





                        

               



     

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Workshop Manual

08

7062 - 64, 7065 - 67 ASM, 7068 - 70

Current sensor Current sensor 1U1 Incorporated in a plastic housing, the current sensor is of the Hall effect type that is located in the air gap of a ring with magnetic conductivity.

Mounted to the LH section of the chassis frame, the current sensor is accessible after removing the floor plate.

Function A conductor of the armature circuit passes through the ring. When current is flowing the conductor generates an output voltage which is proportional to the current. If no current is flowing through the armature, the current sensor will supply at its calibrated output around 4.8 volts. This equals half the supply voltage 10.0 volts) from which must be deducted the voltage consumed by the sensor itself.

The redundant sensor has a second uncalibrated output for monitoring the output signal.

The calibrated output signal is only interpreted by the control as an armature current when the uncalibrated output has similarly detected a current in the armature circuit flowing in the same direction.

In the event of fault, e.g. a faulty signal at the calibrated output, caused by a dalty Hall sensor, the check measurement at the uncalibrated output then prevents undesired movement.

Current limit has been adjusted at the factory to 450 amps..

Example of calculation As soon as the armature is traversed by current, the output voltage will be modified by around 4.67 mV/A. This means that in the case of 450 A of armature current, a voltage of approx. 6.9 volts... ( 450 A x 4.67 mV/A = 2101,5 mV = 2,1 volts ) will be present in the opposite direction.

R 7068 - 70 with redundant current sensor Connection 1 GND (body) 2 18/X20 A4 ( I = 0 : 3.90 - 4.85 volts) 3 24/X21 A4 ( I = 0 : 4,90 - 5.1 volts) 4 20/X20 A4 (ca. 10 volts)

R 7062-64/68-70 with standard current sensor Connection 1 GND (body) 2 18/X20 A4 ( 2 - 7 volts) 3 20/X20 A4 (ca. 10 volts)

NOTE: Trimming of the actual zero position occurs automatically every time the key switch S1 is turned ON . As a result, the actual values will always deviate from the values as per the above example.

IMPORTANT: The fitting position of sensor 1U1 varies according to drive axle design. Before removing sensor note direction of arrow. The direction in which arrow points indicates the direction of armature lead run from generator to drive motor.

Sensor Standard Redundant

SERVICE ADDRESS 155 155

B2

F2 F1

CE - axle

VALUE 00 01 AE - axle

STILL GmbH

Position as per: 9/2002 (Replaces version: 2/2000 ) 31



 

                                   



      

                                                             



                               









                                            

                             

         

     

      

      





            









                             



                   

Workshop Manual

7062 - 64, 7065 - 67 ASM, 7068 - 70

08 Fuse base Fuses

Fuses (version from 7/2002) A plastic housing for accommodating the common printed circuit board A7 for fuses and relays is mounted on a supporting plate on the left-hand side under the engine hood.

The cover is held in place with four clips for easy removal.

The positions of the fuses, relays and connectors are shown in a diagram on the inside of the cover.

Note Fuse for preheating 9F6 (75A) and fuse for radiator fan 7F1 (50A) are located directly at the positive pole of the battery G2 (see chapter on battery).

D es.

Value Terminal

1F11

20A Fan 9F17

1F13

20A 12Volt battery/fuel level transmitter

1 F14

10 A C ontrol supply

1 F15

5 A optional

1F16

5A optional

1 F17

10 A 24 Volt supply controller A4

1 F18

1 A 30/S 1 on 24 Volt

1 F20

5 A 15/S 1 on A4

2F11 4 F1

20A S upply hydr. controller/ Joystick 10 A Horn 4H1

5 F11

20 A S upply relay box 2

5 F12

20 A S upply relay box 1

7F2

10A

2, 3/X 214 , frei

9F1

10A 1/X 214, free

9 F8

5 A 12 Volt additional consumers

9F11

10A 24Volt - additional consumers , heating

9 F12

10 A 12 Volt starter terminal 50/ 9M1

STILL GmbH Position as per: 1/2002 (Replaces vesion: 2/2000 ) 35

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

                   





  

 

 

   

 

 

 

  

 

   



 

      

  

 

      

 

 

    

  

 

    

 

 

   

 

 

   

  

 

      

  

 

     

  

 

  

 

 

  

 

 

    

 

 

   

 

 

     

  

 

  





























    







 

     







 



     

  



    

  



     





         





          



 

Workshop Manual

7062 - 64, 7065 - 67 ASM, 7068 - 70

08 Fuse base - relays

Relays (version from 7/2002) Relay 9K2 energises the starter solenoid 9M1.

Relay 9K3 switches the current for the heater plugs (about 30 – 50 A) 9E13 – 9E16. The preheating and afterheating time is determined temperaturedependent by the controller A4.

Relay 9K16 energises for DFG the cut-off valve 9Y2 for the fully supply and for TFG the cut-off valve 9Y4 for the gas supply.

All three relays are activated via the controller A4.

Relay 9K18 is activated via the key switch S1/15 and connects the supply for the fuses 1F11, 1F20, 2F11, 4F1, 9F11 and starting relay 9K4 when the key switch is set to ON. TFG Relay 9K4 supplies the spark control unit 9A1 with voltage from the alternator 9G2 when the key switch S1 is set to OFF until the residual gas is consumed.

Relays 5K2 und 5K8 are only used in conjunction with the front and rear relay boxes. The relays are automatically activated during parameterisation of the relay boxes -> see Group 09.

R elay

V/Resistance

Circuit

9 K2

24 V / 255 ohm

starter relay

9 K3

24 V / 255 ohm

preheating relay

9 K4

24 V / 255 ohm

postheating relay

9 K16

24 V / 255 ohm

fuel cut-off s.v. 9Y2

9 K16

24 V / 255 ohm

fuel cut-off s.v. 9Y4

9 K18

24 V / 255 ohm

key switch S1 / 15

9 K26

power supply starting aid solenoid valve 24 V / 255 ohm 9Y7 (LPG model only)

5 K2

24 V / 255 ohm

power supply relay box 2

5 K8

24 V / 255 ohm

power supply relay box 1

STILL GmbH Position as per: 1/2002 (Replaces version:

) 36a





      



         

 

                     



             



      

   







 

    

 

 

    

  

 

    

 

 

    

   

 

    

   

 

                

 

    

    

 

    

    

  

   







     



















                                                       







                                                        





      









 







                                                    









                                                

  





     

 

         

           

       



 

                                                

 

     



 

 

       

   

 



 











 

                

     

                                                           





                           







            



           



               

            

 

 

                   

           

 

 

                  

 

     



 

 



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

                                                                                                                 

 

       

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 

          

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



  

 



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

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

                                                          

                      



                                   



  

  

         

    







                                                           

           

                                 



        





        

   

    

   

    

   

    

    

     

           

  



     

     

  

 

  

 

     

   

     

    

       

       

       

       

      

    

                             

  

                                                    

   

    



     



    

 

      

        



 

  

    

         

      

   



    

  

  

       

 

                   







    





    

           

      

        

 

          

          



  

                                         

 

  







                                    

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                                 

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                                                 

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                            

                          

        

                           





                           

                                     

     





  









      





                         

 

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

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 

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

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



                         

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



                                                   

  

                          









    







    



   

  





                               



                   AC voltage                    







                                                                          

      

       

                             

       

           

     









    







 





































                                                                                                                 

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

                                                     



       





      













 









                         

                          

  

                  

 



         



  





        













 











                    

              

   

         

  

                  

         

  







   



    

        

    

  

                          









   





                    



            





                                    

 

     

 

 



 

                                  









 

 

















































      

 









              



       























                





















































































                                      

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

                                       

          



  

               

                                         

 

 







   



 



   







   



 



   







   



 



   







        



                                            

                                 

             



          



                 



 

            









 







 

            



 

          

    

  











 









 

                      



      

 



 

 



                 

    

             

 

             



  

  

            

    

 





   

   

 

   

 

   

  

 

 



 



    

 

 





 

 

 

 























  

    



 

    







 









   





 

 





















 

     

 

 



 

 



  





 

 







 

               



  

  







       





 

   

   

 

 

   







 

 







      

    



 

 

 

    

  







 

 















































   







       





   





 





   





   

   

 

 

 

  

   









   









    







 





 

 

  

















































  



  

 









 

 

 

 

 



 

 



     

 

 

 





 

 

 





 

 





       

    

    

   

    

  

       

           

  

    

    

   



      

                

  

                                  

   

             

      

         

      

             

           

       

     

   

    

  

         

               



      

      

     

    

                        

                                                                     

          

  

           

                     







        

               

             

   

             

           

 





 







 



  

 











    

 

      



  





  



                                    

                                           

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     

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





                                                          

                    

                    

  

            

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

    

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

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



                                                                                                                    

                                                                                  



     









    



  

                          

                                   

                                      

   



     









                            

   

                         

                                   

 

  

    



     



    









                                                                   

                                                       







   

  

      



     





   



                                                 

                                                  

     



    









                                                   

                                     

     

    

       







                                                                                                                                                      



 





 

 





 

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



                     

     

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 

 

                                     

      



 



  



 







                                        

                                        



                                                  



                  

    

      

                             





                                











 







  

          



 





            



               

 



    

 

    

    

   

   





                                                                           

      









              



  

 





 



    



 

 

     

      





                  

                                           







                            





 

 

 

                                  

                       









                                                                        



   











 



 

 

  



               

                       

 

         







                   

          







 

  

      

  

  

    

  

            

     

 

    

   

 

 

  

      



           

     



   









                           

      



 

             







            







            







        







       







    

    

   

   

    

 

       

           

   

 

      

   



      

               

   

                                                    

       

      

      

             

        

     

     

   

    

   

     

   

  

            

                      

    

    

    

                                                                

     

     

         

  

             

  





  

                          

             

      



     









                                                       

                  

                          

          

          

 

              







    











         

     

          



                                                                                        

                           

                







                                                                                          



                                  



  

   

       

   





                                                          

      











  



 





 









   



 

     

      



                  

                                  







                            



  

                                 

                                                







 

                               



                        





 

          

  



   

   

   

   

       

                    

      

     

      



   









                        

                     

       







          

       

      

   

     

           

        

   





   





  





  





 





   





    

    

 

 





 



 

    

    

    

   

       

             

           



          

      





   





   

   

 

 

               

                

                







            

  

  

           

   



   



  

    

  



  

  

 



   



  

    

 



   



  



                  

                           

     



    



                

                      







                                                                                     



  

 

  





                                      

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  

            

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



                                                               





 

                                                                







  

                    

 

                                                  



                                                                









   

                                     



                



                 









              

       

   



  

 

    

       

  



        

  

   





  

                          







                                              

  

           









                         











  



          



  







                        



                             



            









 





               

   



  



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

                                                                                               

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

                                                                                  

 

 

  

 







                           

    

  



                     





 









                                            













  





       





   



 

 

 

 

 







 



  

 







  

 

 

  

    









 



                                                          









                                     

      



      

     

     



                       







   

                             

          

   



  



                                                 





  

     

   











 











 





 











 





 



































                             

                 

 





  















 













 

   





 









                                                                            











                

                

  



   



  



  



 



  



   



       

    

       

        

      

      

 

      

 

   

     

   







          

               

  



  







  



  



 



  



   



   

   

   

     

  

 

    



   







   





  



                              

                                 

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       

                                                                               

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       

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

                                            

      

                          

    

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



     

                                                                                                                                       

 





 











                                                       



                      





    

          

        



























                            

               

                                         

                      

           

              

                     







    



 



   

                    

         







   





                           

   



    



    



         

 



                                                    









                             

            

       

 

        



                                                                



    

     

     

                     

                               







    

        







      

       

                    

    

 



  



                             

                    



 





                 

           







         

     

       

  

        

  

                           

                                                

          

                      





  









     

  

  

         

  

  

     



 





 

 



 



     















 



 



 

  







      

  

  



  

 

  



     



  

   



 



      

 

               









  







       

 



 



 



 



   



 





 

      

           

   

      

   

           

      

                                             

    

  

    

  

    

    







              

  

   

     

  















 

        



      

              

   







       











 















 

  



 



 



      

             

                       







       

                     



                     

  

     



             

             

 

 

     





 

       

                   

   

        

 



 



 



                                    

    

     

                 











       

 



                 



 

   

  

 





 





 







 



       

 





















 





  









 







          

  

  



 



 



       

  



  

   







         



   





 



 



       

        



 

 







         

  

 





 



 



       

 













        

 

 





 



 



       

     

 







       

 

   

   

     



 

   

  

 





 





 







 



       

    

 







   



   



   



   



   

     









        

   

 

  



 



 



       

          

            

         







                        



 





 

       

        

 

       



   

       



   

     



                         



   



             



 





   







    



   

      



       

 

      

    



                       

 

         



 

          

    

                            



       

       





 



       





       

       

 



 

       

       



       

      









               

 

 

   

    

    

              



  

             

 



 



       

        

  

     

  







       

   

      





 



 



       



           

 

     

 

 

  

 



    

 

 

   







                    

 



 



 



       

         







   

 

 

    

    

    





 















                 



            





           

  

       





 

      

               

          

 







      

        

      











        

        

 

 

  



 



      

  

 











        









 



 



      

 

    

 



              







            



 



 



      



 



      

                                 

     





 



 

    

  

  

 

   



     

        





 



 





       





                   







       

 

        



       

      

      



 





       



          





  

       

       







       

 







 



         

            

       

  



   



       

   

 

        



 



 

 



      

 

                



   



    

       



     



 



 

    

    



       



 

 







        

  

 

 

    



  



 



       

           







          

             

             







   







 



       

        

   









            

   

 

  





 



       

 

  

    



   



       

 

   

 

     

          





   



 

           

  

  

  

 

   

   



                   





 





 

  

          

   

      

     

                   

  

          

   

        

              

     

     



  

   



   



      

 

  

      

    



    

    

    





 

  

 

   

   

   

  



   



    

  



            



 





 



      

 

      

     

 

    

 

     

 











                                              



 



 

                        

     

             

       



     





 







     

    

 

  



 



 



     



 











     



    

  



 



 



     

    

          









 



  





 

 



       



   

            





     

            

 

     





   



 

   

 

   



   



     

           

        



 



 

      

      



      



 







          





   



 





 

     

       

     



 

      

      

   







               







 





           









 







     

   

   

    



 

  



 



     



   







   

         

   





       

  

  

   

 

  



    

   

   

  

   

 

 

                

               



 

 

  

                        

 

             

   

      

   

             

                     







             



                        



                                                                    



  

        

         

        



                                     







   

              

            



                                     







 

                 

 

 

       



                                      







    

                          

                 



              

       

                  







     

                          

                    



           

 

   



   







  

                                  







             

     

            



      







        

    







   



 



  



    

   







   











 

   









       

 

   

 

      

          

      

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



                  

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



                                  







          





    

     

     

                                











      





       

       



  

 

 

       

   



           

 

             







    

                                 

   







                                                      







 

   



     

         

    



   

  

  

 



               



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

                                                    

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    

   

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



                                     

 



 

 





  

    



                      









      











   





 

           











                               







   















  









  

       



                      



      





         

                 

      

        









       

   

         





   

         



      



      



   



  



 

  



    



 



    



 



  



 



  



 



    



  



       



        

       



 



          



 



      



 



  



 



      



 



      



        

       



    



       



      



     



      



     



 



     



      



     



    



     



   

     



   

     



   



 

 

    







  



     



   



 







 



  



 



 



 



   



 



  



 



      



   



       



   



       



   



 



   



   



   



    



  



    



 



      



 



     

 



        



 



        



 



  



 



    



 



    



 



         



 



      



  







  



  



  



   











    

  

  



 



  



      



  



    



  



   



  



    



  



    



  



       

  



     

  



    

       



 

       



    



       



 



       



  



       







       



   



  



    



         



      



         



     



         



       



  



 



         







         

 



 



 



 

 

  

 

    



 

   

 

   

  

  

 

       

  

  



  

     

     

   



  



  

 

   

 



    

 

  

       

 

 

  

 

      







       

  

                              

  





    

                              

                    









                  



    



  

 

 



       







 



       



   



   



 



   



   







   







  



       



       



   

   

   



                                   

       







  

     

                  







             

                

                 

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



    

                                              







      

 

  

 

           

      

 

      

     

    

        

      

      

      

 

    

      

      





   

 

 

 

    

    

    

       

  

   

         

   

    

      

     

    

    

       

    



  

      

    

      



  

 

  

                                                       







              

 





    

   

  

 

    

           

  

                        

      

 

      

                              

 

                                   

 

 

       



    

                                             

   

             



   

  

     

        

             



                          

        







   

                    

         



                    

    

  









   

 

 



    

      

  

 

           

     

     





  

                  

 

                  



   

 

              

     

 

              

  

 



                                 

  



                                             







    

                                  



             









      





  

                             

  

 

 

                               

  

      

  

           

    

                           

     

      

   

                 

   



     

     

  

       

 

                        

   



    

         

 



  

                                    







    

   

    



                         

 

    







         

   

  

 

 

 

  





  





 





 





  





                           



                     

               







    

                                



                     







  

     

          

        







  

 







   

        





                  









 

   



 

  



  



 







   



  







   

         



  

       



      

                      



  

              

  







  

 

      

   

          

 

   

             

             



         

 

           

  

                         

        

 

    



 





                                       

 





 





  

    



                      







  

                                    

     

  

 

 

 

 

 

 

 

       







      

                

  

  

 

   

   

  

   



    

   

 

     

  



  

 



 

  



 

 

  

 



  

 

  

  

 

   

  

  



   

    

                    

    

 



  

 

 



 



 







    



 



   











  























  



 







   









  



  



 







 



  



 



 







 











    







 









                                   

          

          

    

          

      





                 



            



  



      











                                                  







  

       



                       







                

   

    

   

   

            





 

       

   

 

    



   

             



            





   

              

           

                            

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

                             



                  



   

                

         







    



 

 





 

 

                                    







                                

           



                    









   

   

  

   

  

  

 

   

 

  

  

      





 





 





                      





 





 



   









    

     



 



  



 



            

      



 

        



 

   



     

 



       

  



  

        

   

            

  

          



  

              



  

            



   

            



  

        



  

        



  



  

       



  

 



  

 



   

     



    



  



   



    

    



      

   

 



      

   

 





   



     

   



     

        



   

      



    



   



   



    



     



   

   

  

    

  



 



      



    

         



    

        



        

     



      

  





      







    

        



     

         



     



        

   



   

                              





   

                        

                    







                     

     

    







   



   

 



          



   







   

   

  

  



        











   

   

 



  







        







     

 



 











       

    



  

      



  

   



 

 



   

 

  



  

       



 

           





     



  

           



  

           



 

            





      



  

     









     















   

    



 







  



   

  



 

   





 

   







  



 

  



  

     



 

    



  



 



 



 



  



 

    



  

      



 

    



    

 



  

     





     



 

      



 

     



   



     



 



 

   



    

 



 

 



  



 

    



 

   

 





      



  

  

  







      





 



 







 

   



  

   



  

    



  

   















 

    





 



 

     



 



  

   



 

 



 

 



  

   



 

 



  

 



  

    



 

 

 

 

 





       

   









         

        

     







       

                     

















                



           

   

 



  

 



 















       

         





                           

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                     

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

                             

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



                             









                

        



     



  



 







 



 



 



 







 







                                         

           







       

 



   

      

      

      

       





    

   

 

 

     

  

       

     

         

       

              

      

      

     

 

           

      

  

 

     

          

    

    

                     

      



      

  

       

      

        

           

                   





             

    

  

       

 

                               

  

      







 

       

       

       

             

         







                      





  



      

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







                    



     



      

    





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



                   







 



 







               



             





               





        



 









                        







            



     







 

  

 

 







            



    

      





  

   









              



      



       







   





 

  



 

























   

   

            







  

                            

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20-25

Workshop Manual 7062 - 64 7068 - 70

Hoist cylinders Removal of outer cylinders (Hi-Lo (full free-lift) and Triple masts -Bring the mast to the vertical position -Raise the fork carriage -Extend outer cylinder pistons by approx.

20 cm -Place a block of wood between the upper cross member of the outer mast and the upper cross member of the inner mast (for the triplex mast) -Remove circlip from upper piston fixing (cross member) -Completely lower the mast, allowing the system to become non-pressurized

1

-Disconnect upper and lower hydraulic connections -Remove the fixing clamp -Should the piston fail to lower by gravity, assist with a screwdriver or similar tool NOTE: Cylinder head (1) is fixed with Loctite 243 (three spots on circumference to ensure even spread) Piston cover (3) is secured and sealed with Loctite 275 (Part No. 524199) on the whole surface.

2

Torque loadings for piston cover vary according to piston diameter, viz.: Cylinders without cushioning device 32/37 mm torque loading = 150 Nm (+ 30) 46/52 mm torque loading = 500 Nm (+100) Cylinders with cushioning device 32 mm torque loading = 70 Nm (+10) 46 mm torque loading = 150 Nm (+30) 52 mm torque loading = 350 Nm (+50) Do not remove piston cover when replacing packing!

For operation of the cushioning device (2) see page 21.

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3

Workshop Manual 7062 - 64 7068 - 70

20-25 Hoist cylinders

Cylinder removal - Telescopic mast - Bring the mast to the vertical position - Extend hoist piston (by around 20 cm) until the upper fixing is accessible for circlip removal - Remove circlip from upper piston fixing - Place a block of wood between the upper cross member of the outer mast and the upper cross member of the inner mast - Completely lower the mast, allowing the system to become non-pressurized - Disconnect lower hydraulic connection - Remove the fixing clamp Changing the packing - Grip cylinder body firmly in a vice - Screw off cylinder head with C spanner B 52 - 55 . If cylinder head will not move, preheat with a flame The cylinder head is secured with Loctite 243 (3 spots on circumference for even spread) 1 = double wiper 2 = U seal 3 = cylinder head 4 = bleeder screw 5 = O-ring seal 6 = guide bush 7 = piston cover 8 = piston 9 = cylinder tube

The piston cover is secured with Loctite 275 Torque loading = 500 Nm (+100 Nm)

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

                                           



        





       

      



  

         

  

  



  











              



 

       



              



   

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   





20-25

Workshop Manual 7062 - 64 7068 - 70

Hoist cylinders 1

2

3

4

5

B

A

B

Cushioning device for cylinders Fitted to Hi-Lo and Triple-stage masts, the function of the cushioning device is (during transition from 2nd to 1st stage of lift) to hydraulically slow down the piston rod of the outer cylinder endowed with such a device just before it reaches the end of its stroke. This feature reduces the hydraulic/ mechanical shock normally encountered when the load is lowered completely.

1 - piston cover 2 - piston 3 - restrictor orifice 4 - pressure spring 5 - snap ring

Operation When the piston rods are pressurised the piston (2) by the force of compression spring (4) is, during the hoisting operation, moved towards the cylinder bottom until the snap ring (5) is against piston cover (1). Flowing from chamber A, the oil under pressure continues to pass via restrictor orifice (3) through chamber B until hydraulic balance has been achieved.

During the lowering operation, first piston (2) will (before the piston rod has reached the end of its stroke) contact the cylinder bottom. Piston (2) is shifted in direction of the piston rod, whereas the hydraulic fluid under pressure is directed from chamber B to chamber A via restrictor orifice (3) causing mast movement to be hydraulically slowed down through hydraulic balance.

21

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

  







    





     



 



 

    







  





        



  





  

   









 











  









       



 



 

 



 



 

     



   

20-25

Workshop Manual 7062 - 64 7068 - 70

Tilt cylinders Dismantling Grip the cylinder body in a vice at its base.

Remove screw union from cylinder head (thread protrudes into the bore).

Knock down cylinder head (9) a bit with a punch..

Press in the snap ring (11) with a probe through the small hole in the cylinder and lever out with a screwdriver (see figure).

With a strong pull on the cylinder rod pull the head out of the body.

14

13

Grip piston rod in vice with > protective jaws !

1 = hex nut 2 = spacer

12

3 = piston guide ring 4 = piston seal

11 10 9

8

7

5 = piston 6 = piston rod

6

7 = circlip 8 = U seal 9 = cylinder head

15

10 = O-ring 11 = snap ring

5

12 = wiper

3

13 = washer

1

4

2

14 = eyebolt

24

20-25

Workshop Manual 7062 - 64 7068 - 70

Tilt cylinders Assembling Check all parts for wear..

Piston (5) is sealed on piston rod (6) with Loctite 270.

Hex nut (1) and spacer (2) are sealed with Loctite 270.

Torque loading = 450 Nm ( ± 25 Nm ).

X

Once the piston guide ring, the piston seal and the cylinder rod packing have been installed, insert the cylinder head into body, ensuring cut out in cylinder head points towards connection hole.

16

During assembly observe dimension X = 65 ± 8 mm !

6

Before installing the cylinder pins lubricate with grease the bores into which they fit The self-aligning spherical bushings at both tilt cylinder ends are peened over from both sides to prevent lateral displacement (see figure).

For dimension L and piston stroke see table page 27.

16 - Hex nut Torque loading = 150 Nm (+50 Nm)

L

Hub

5

1

25

2

20-25

Workshop Manual 7062 - 64 7068 - 70

Tilt cylinders Mast tilt angle a

Ă&#x;

h4 h h1 h3 h5

h2

When carrying out repairs on the tilt cylinder be careful not to modify the tilt angle as set at the factory, as otherwise stability will be impaired.

h = O.L.H. (Hi-Lo & Triple masts - h = h1)

a = forward tilt

h2 = free lift :160 mm (telescopic mast)

Ă&#x; = backward tilt

h3 = rated lift

h1 = height, mast lowered

h4 = maximum height, mast extended h5 = free lift (Hi-Lo & Triple masts)

26





                                           



        





  

   

  

  



 

  

   









  

   









   

   









    

   









   

   









  

   









 

   





   







         

                      





 

     









       

  

   

   

      

 

  

    

 



           

 



   

 



     

 



     

 



    

 

   



   

 

     

 

   

 

   

 

       

 

 

   

 

 

       

 

 

       

 

 

 

 

 

      

 

 

         

 

 

   





     









        

  

   







     

 

 

 

 







      

 

    

 

    

 

   

 

   

  



   





 

  

 

  

  

  

    







    

 

 

 

 





    



 

 

 

 

 

 

