Still R70 Series: R70-20, R70-25, R70-30, R70-35, R70-40, R70-45 1995–2002 Diesel and LPG Fork Truck Manual (P/N 164537)

• 838-page technical resource covering 1995–2002 Still R70-20, R70-25, R70-30, R70-35, R70-40, and R70-45 diesel and LPG forklifts.
• Applies to model types DFG 7032–7034/7048–7050 and TFG 7038–7040.
• Official Still GmbH publication (Ident-Nr. 164537), incorporating technical updates through 2002.
• Provides comprehensive exploded-view mechanical diagrams and detailed electrical schematics.
• Details the VW engine, MB OM 601 engine, Deutz BF 4 M 1012 E engine, EMR engine management unit, SERDIA diagnostic interface, TCI-H ignition system, tachogenerator 6B7, and speed sensor 6B9.
• Features essential wiring diagrams, hydraulic circuit diagrams, gearbox sectional views, fork arm dimension diagrams, valve adjustment diagrams, and diagnostic test sequences.

Mechanical and System Coverage

Understanding the mechanical intricacies of the Still R70 series is essential for effective fleet maintenance and advanced repair. This PDF documentation provides an in-depth look at critical forklift subsystems, starting with the chassis frame construction. You will find specific details on the mounting points for detachable fuel and hydraulic oil tanks, alongside the rear counterweight assembly. The manual breaks down the cab structure and outlines the exact configuration of rubber anti-vibration mounts. Moving to the steering system, the guide covers the hydrostatic servo-steering setup. This includes the Danfoss priority valve, OSPC/OSPO steering control units, and steer cylinder layouts. The power axle section offers a thorough breakdown of the double-reduction spur-type gearbox. Mechanics can review the toothed hollow shaft, differential assembly, and drive motor mounting details. For braking systems, the resource outlines the Perrot hydraulic servo brake, automatic adjuster mechanisms, and parking brake cable rigging. To help workshops avoid outsourcing expensive labor to specialized dealers, the guide provides essential step-by-step instructions. Mechanics can confidently tackle setting the static injection pump timing, calibrating valve clearances, turning down the commutator on a lathe, and adjusting the mast lift chain tension on Telescopic, Hi-Lo, and Triplex masts in-house.

Electrical and Specification Highlights

The electrical sections detail the Stilltronic R70 SCR control system. This part of the manual covers the power board, contactor panel, and electronic controller functions vital to the forklift's operation. Wiring diagrams and circuit schematics map out specific components for both diesel (DFG glow plug systems) and LPG (TFG ignition and throttle positioning solenoids) models to simplify complex troubleshooting. Proper reference values are crucial. Note that inspecting and servicing industrial forklift electrical circuits and high-pressure hydraulic lines requires appropriate protective gear and strict adherence to standard workshop safety protocols. The technical parameters listed inside provide exact benchmarks for routine maintenance. For example, the gearbox oil capacity is rated at 3.75 liters. Fastener specifications highlight a 225 Nm steer axle nut torque and a 210 Nm requirement for the steering cylinder fixing screws on models 7032 through 7040. By utilizing the provided factory test stages and diagnostic meter pinouts, technicians can successfully trace complex faults without resorting to trial-and-error component swapping, directly lowering repair overhead.