Still Fork Truck R70-20,-25,-30,-35,-40,-45: DFG R7032-R7034, R7048-R7050, TFG R7038-R7040 Workshop Manual

Still Fork Truck R70-20,-25,-30,-35,-40,-45: DFG R7032-R7034, R7048-R7050, TFG R7038-R7040 Workshop Manual

Original Illustrated Factory Workshop Manual for Still Fork Truck R70-20, R70-25, R70-30, R70-35, R70-40, R70-45.

Original factory manuals for Still Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text

Covered models:
DFG R7032
DFG R7033
DFG R7034
DFG R7048
DFG R7049
DFG R7050
TFG R7038
TFG R7039
TFG R7040

Format: PDF, 512 Pages
Language: English

Contents:

2. Steer Axle
Contents
Technical Data for
Maintenance Service
Mechanical configuration of Steer axle
Steer axle removal
Steer axle installation
Wheel hub -Removal and
Dismantling
Wheel hub- Reassembling and
Installation
Wheel angle stop adjustment
Checking the steering angles
Stub axle -Removal and
Dismantling
Stub axle – Reassembling and
Lubricating the steer axle with
Installation
grease
Track rod removal
Track rod installation
Steer cylinder removal
Steer cylinder installation
3. Power Axle
Technical Data for Maintenance Service
Power Axle/ Description
Spur-type reduction gearbox/
Sectional view
PowAxle removal and installation
Toothed hollow shaft / Sectional view
Toothed hollow shaft / Adjusting instructions
Wheel hub removel and installation
Half-shaft removal and installation
4. Wheels and Tyres
Technical Data for Maintenance Service
Synoptical Table on Tyres
Superelastic tyred wheels
Pneumatic tyred wheels
6. Steering
Technical Data for Maintenance Service
Operation of the steering
Steering unit removal
Steering unit installation
Priority valve
Cleaning the priority valve
Steer cylinder disassembly
Steer cylinder reassembly
7. Brake, Technical Data for Maintenance Service
8. Electrical Installations
Technical Data for Maintenance Service
Electrical installation – General description
Testing the insulation resistance
Driving controls
-Dash panel
– Directional control switch
-Warning horn
-Travel sender unit
– Angle of rotation sensor, hydraulics
– Control valve switches
– Foot brake switch / Parking brake switch
Engine speed sensor
Tachogenerator
Alternator
Throttie positioning solenoid (LPG model)
Servomotor injection pump (diesel model)
Shutoff solenoid
Shutoff valve
Coolant temperature sender
Batteries
Truck wiring
Fuses
Contactor panel
– Main power fuse
– Glow plug relay (series resistor) (diesel model)
– Contactors, starting/driving
– Current sensor
with p.c.b.
Electronic Controller
– P.c.b. ‘traction control circuit’
– Pc.b. ‘engine starting via generator’
– Pc.b. ‘servomotor’ (diesel model)
– P.c.b. ‘throttle valve regulator’ (LPG model)
– Pc.b. ‘charge compensator’ (LPG model)
– Power board
– Rc.b. ‘solenoid stop control’ (dieselmodel)
– Pc.b. ‘control circuit fuses’ (LPG model)
– Base plate, relay
-Table on engine speeds for p.c.b.
Electric fan
– Coolant temperature sensor
Connectors
– Hand tool- refer to issue 1, will not be reprinted –
S-D.
10. Maintenance
Technical Data for Maintenance Service
Operation of Lift and Tilt Hydraulics
Directional Control Valve block complete with operating levers
– Operating Unit (7032-34/7038-40)
Directional Control Valve block complete with operating levers
– Operating Unit (7032-34/7038-40/ 7048-50)
Directional Control Valve block
– Mechanical configuration
Directional Control Valve block
– Function
Directional Control Valve block
– Connection block
Directional Control Valve
– Hoist/lower functions
Directional Control Valve
– Tilt function/Hyd. Ancillary Equipment
Directional Control Valve
– Hyd. Ancillary Equipment with
secondary pressure limiting valves
Directional Control Valve block
– Fitting restrictors-tilt valve block / Block seals
Directional Control Valve block
– Shuttle valves
Anti-cavitation valve
-Operation
Hydraulic pump
– Operation/Removal & Installation (7032-34/7038-40)
Hydraulic pump
– Operation/Removal & Installation
Hydraulic tank
– Hydraulic oil change/Removal & Installation (7032-34/7038-40)
Hydraulic tank
– Hydraulic oil change/Removal & Installation (7048-50)
Hydraulic tank
– Filling capacity
Return line filter
– Description Maintenance
Hydraulic fittings & unions
– Assembly
Speeds
– Lift/lower/tilt
Hydraulic Circuit Diagram
– (7032-34/7038-40)
Hydraulic Circuit Diagram
– (7048-50)

11. Contents:
Technical Data for Maintenance Service
Drive motor
Drive motor, construction
Wiring diagram
Neutral plane
Position of motor terminals
Connection of motor brush and temperature monitoring device
Inspecting and changing the motor brushes
Drive motor removal (7032-34/7038-40)
Drive motor installation (7032-34/7038-40))
Drive motor – Dismantling (7032-34/7038-40)
Drive motor reassembly (7032-34/7038-40)
Drive motor removal (7048-50)
Drive motor installation (7048-50)
Drive motor – Dismantling (7048-50)
Drive motor reassembly (7048-50)
Generator
Generator, construction
Wiring diagram
Neutral plane
Position of generator terminals
Connection of carbon brush and temperature monitoring device
Connection for generator operation
Connection for motor operation
Inspecting and changing the carbon brushes
Generator removal (7032-34/7038-40)
Generator removal using a hydraulic lift or an inspection pit
Generator installation (7032-34/7038-40)38-40)
Generator – Dismantling (7032-34/7038-40)
Generator reassembly (7032-34/7038-40)
Generator removal (7048-50)
Generator installation (7048-50)
Generator – Dismantling (7048-50)
Generator reassembly (7048-50)
External fan cooling
Description (7048-50)
Description (7032-34/7038-40)
Fan removal
Fan installation
Adjusting V-belt tension
Replacing the V-belt
Clean air filter
Fan – Dismantling
Fan – Reassembling
Brush wear monitoring facility
Operation
Wiring in DC machines at brush gear
Connection of wires to male plug with contact pins
Wiring diagram
Meaning of signal emitted by brush monitoring unit
Testing brush holder contact for proper function
Checking indicator light as well as wiring
Thermal monitoring
Thermal switches in drive motor and generator
Connection of leads to connector half with pin contacts
Operation of the thermal switches
Checking the thermal switches
Checking temperature warning light incl. leads
Changing the thermal switches
General hints
Insulation resistance
Measuring insulation resistance
Turning down the commutator on a lathe
Permissible minimum commutator dia
Undercutting the mica
13: Pressure Regulator
Technical Data for Maintenance Service
Pressure Regulator Unit I and II Operation
Pressure Regulator Unit – Pressure limiting valve
– Pressure gauge
Directional control valve block – Fitting restrictors
– Pressure limiting for sideshift clamps
15: Diesel Engine
Technical Data for Maintenance Service
Deutz Diesel engine / Generator
Diesel engine, general description
Cylinder head
Valve clearance adjustment
Injection pumps / Commencement of delivery
Installing the injection pumps
Pencil-type glow plugs
Compression pressure
V-belts
Exhaust turbocharger
Cooling system
Coolant pump
Thermostat
Oil filter
Fuel pump
Fuel system
Air filter
Exhaust system
20: Elevating Mast
Technical Data for Maintenance Service
Mast types 1 Removal of mast
Telescopic mast
Hi-Lo mast
Triple mast
Carriage stops
Support rollers
Hoist cylinders
Lowering valve
Line failure safety device
Cushioning device for cylinder
22: Fork Carriage
23: Fork Arm
24: Mast Pivots
25: Tilt Cylinder

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