2000 STILL R70-20, R70-25, R70-30 Diesel & LPG Forklift Workshop Manual (P/N 164544)

The 2000 STILL R70-20, R70-25, and R70-30 workshop manual, publication P/N 164544, covers diesel and LPG forklift service and repair. Dedicated ASM/R70i sections address the induction-drive equipment used on R7065, R7066, and R7067 trucks.

• Diesel engine repair: Mercedes-Benz OM 601 and Volkswagen ADG procedures cover engine removal, cylinder-head work, valve timing, fuel injection, lubrication, and cooling.

• LPG engine and fuel system: Volkswagen ADF engine repairs, ignition testing, evaporator overhaul, mixer service, and optional three-way catalytic converter diagnosis.

• Electric drive systems: DC motor and generator servicing, plus ASM induction-motor, synchronous-generator, AC-AC converter, and cooling-system coverage.

• Axles and brakes: Carraro reduction gears, the alternative AE25 power axle, steer-axle repairs, service-brake components, and parking-brake adjustment.

• Steering and hydraulics: Hydrostatic steering, Danfoss priority valves, hydraulic control blocks, pump checks, and pressure testing.

• Masts and cylinders: Telescopic, Hi-Lo, and Triplex mast assemblies, chain adjustment, carriage rollers, and hoist- and tilt-cylinder repairs.

• Electrical diagnosis: Controller and console checks, sensor tests, calibration, fault-memory access, wiring diagrams, and connector arrangements.

The material is suited to forklift service technicians familiar with electrical testing and workshop measuring equipment. Engine procedures call for specialist tools, and the LPG section specifies trained personnel for gas-system maintenance and repair.

Diesel Engine Procedures and LPG Repairs

OM 601 diesel: The engine extract includes timing-chain renewal, prechamber sealing-surface machining, cylinder-head work, injector testing, and injection-pump timing. Some procedures originate from Mercedes-Benz vehicle documentation; only the operations applicable to STILL trucks belong to the forklift repair scope.

Volkswagen diesel: ADG/028.B coverage includes generator-unit removal, toothed-belt installation, injection-pump timing, hydraulic tappets, oil-pump inspection, and cooling-system service. The belt procedure distinguishes the semi-automatic idler introduced from engine number 003255.

The injection-pump instructions identify a specific damage risk: loosening the pump-head bolts can displace the head and break the distributor plunger. Pump replacement and timing are covered; internal pump repair requires dedicated test equipment.

Volkswagen LPG: ADF/026.2 coverage includes cylinder-head and valve-gear repairs, TSZ-H ignition and Hall-sensor testing, and evaporator disassembly and reassembly. Mixer and Lambda-control diagnosis address idle and running faults, supported by a Lambda control circuit diagram.

Drive Axles, Motors, and ASM Service Limits

Carraro coverage explains the differential, epicyclic reduction gears, and brake disc packs through sectional illustrations and repair procedures. The AE25 alternative has its own gearbox construction and torque tables.

Steer-axle drawings accompany hub, kingpin, track-rod, and steering-cylinder work. DC motor and generator sections include brush inspection, armature work, insulation checks, and seal replacement.

Separate ASM sections describe the induction motor, permanently excited generator, braking resistor, and their cooling circuits. Coverage includes converter removal and installation, but the converter enclosure must remain closed.

The ASM generator instructions also prohibit further internal dismantling. The rotor and starter ring gear form a balanced assembly requiring replacement together.

Hydraulic Steering, Brakes, and Mast Work

Danfoss steering-control and priority-valve descriptions accompany hydraulic pump checks, control-spool sealing, and pressure-test procedures. Hydraulic circuit drawings and cooling schematics distinguish conventional and ASM arrangements, including their different retarder and heat-exchanger layouts.

Brake sections cover wet multidisc components and the alternative drum-brake arrangement. Mast work includes chain wear and adjustment, carriage removal, roller positioning, cylinder seals, lowering valves, and hose-failure protection.

Frame and counterweight construction data accompany the chassis precautions. Observe the manual’s jacking, support, and heavy-component handling requirements before removal work.

Electrical Fault Tracing and Controller Setup

Battery maintenance, alternator checks, current sensors, and coolant sensors are covered alongside controller inputs and connector pin assignments. The DC-drive documentation distinguishes tachogenerator-equipped Linde axles from pulse-sensor-equipped Carraro axles, helping technicians select the matching feedback checks before diagnosing a drive fault.

Relay-base layouts and electrical function diagrams connect console indications with the relevant circuits. Controller replacement and parameter-transfer procedures, pedal calibration, and the system-diagnosis reference section support work beyond mechanical component replacement.

A Sample of Lubrication and Sensor Specifications

These examples represent a small selection of the manual’s service data. Carraro reduction-gear refilling calls for approximately 1 liter of transmission fluid per side; steer-axle hub-bearing lubrication includes Grease F to DIN 51825-KP2K-20.

For electrical diagnosis, coolant thermistor 6B11 is specified at 87 ± 5 ohms at 90 °C. The VW ADG oil-pressure check requires at least 2.0 bar at 2,000 rpm with engine oil at 80 °C.

PDF Search Limitations and Diagram Detail

Search and drawing readability: Text search is severely limited by character encoding, and embedded PDF bookmarks are absent. Relay diagrams have clear lettering, while some small hydraulic and Lambda-circuit labels remain faint or fragmented when enlarged.

Supplied as one printable PDF with 450 pages, comprising one cover page and 449 manual pages. The total includes the engine-manual extracts, system-diagnosis references, and one repeated mast-cylinder page.