1995–2002 Still R70-20 to R70-45 Diesel & LPG Forklift Workshop Manual (P/N 164537)

This Still GmbH workshop manual, Ident-Nr. 164537 (en), covers 1995–2002 Still R70-20, R70-25, R70-30, R70-35, R70-40, and R70-45 diesel and LPG forklifts. It applies to model types DFG 7032–7034/7048–7050 and TFG 7038–7040.

Supplied as a single 512-page PDF.

• Engine repair: Variant-specific engine removal, timing-system service, cylinder-head work, compression testing, and valve-clearance adjustment, with separate diesel and LPG sections.

• Electrical diagnosis: Stilltronic R70 SCR troubleshooting, generator-starting tests, diagnostic flowcharts, wiring diagrams, and connector views for tracing control-system faults.

• Motor and generator repair: Removal, disassembly, brush inspection, insulation testing, commutator machining on a lathe, and mica undercutting procedures.

• Power axle service: AE 25 - 02 gearbox disassembly, differential inspection, wheel-hub and half-shaft removal, and toothed hollow-shaft bearing adjustment.

• Steering and brakes: Hydrostatic steering diagnosis, priority-valve service, cylinder resealing, hydraulic servo-brake repair, automatic adjuster inspection, and parking-brake cable adjustment.

• Hydraulics and masts: Pump and control-valve service, lift-chain tension adjustment, carriage inspection, and hoist- and tilt-cylinder disassembly and resealing.

Suited to experienced forklift technicians, especially for electrical diagnosis, where the procedures assume familiarity with test meters and dedicated adapters.

VW, Deutz, and Mercedes-Benz Engine Coverage

VW diesel ADG (028.B): The engine section covers timing-belt replacement, static injection pump timing, valve-gear inspection, and hydraulic tappets. It warns that loosening the injection-pump head bolts can shift the head and break the distributor plunger.

VW LPG 026.2: Cylinder-head and timing-belt work is accompanied by TCI-H ignition testing, including the Hall sender and ignition coil. The fuel-system section explains the IMPCO mixer and vaporizer/pressure regulator.

Deutz BF 4 M 1012 E: Procedures address cylinder-head gasket selection from piston projection, individual injection-pump installation and shimming, turbocharger replacement, and cooling-system service. Valve adjustment diagrams support the related inspection and setting work.

MB OM 601: Coverage concentrates on engine/generator removal, mounts, lubrication, cooling, and fuel-system components. For further Mercedes-Benz engine service instructions, the text refers to separate workshop manual 7062–70, Group 15; this file does not provide a full internal OM 601 overhaul section.

Stilltronic R70 Electrical Diagnosis and Drive Machines

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. Wiring diagrams and circuit schematics distinguish DFG glow-plug circuits from TFG ignition and throttle-positioning solenoids.

Fault isolation: The S-D section provides 20 diagnostic test stages and meter pinouts. Generator-starting checks help distinguish wiring faults from controller faults, with procedures using diagnostic meter 147587 and R70 adapter 351476. Separate tests address tachogenerator 6B7 and speed sensor 6B9.

Deutz engine management: The EMR engine management unit and SERDIA diagnostic interface have their own sections. The text explains the engine-specific assignment of the EMR unit and identifies the equipment needed for diagnosis.

Motor and generator repair coverage extends to thermal monitoring and brush-wear wiring diagrams. The generator section warns that reversed field connections can make the engine crank backward and damage it.

Chassis, Power Axle, Steering, and Brakes

The chassis section details mounting points for detachable fuel and hydraulic oil tanks, the rear counterweight assembly, and the cab's rubber anti-vibration mounts.

Gearbox sectional views and exploded assembly drawings explain the double-reduction spur-type gearbox. Mechanics can review the toothed hollow shaft, differential assembly, and drive motor mounting details, including bearing and shim adjustment.

The hydrostatic servo-steering section covers the Danfoss priority valve, OSPC/OSPO steering control units, and steer cylinder layouts. Brake coverage addresses the Perrot hydraulic servo brake, automatic adjuster mechanisms, and parking brake cable rigging.

Hydraulic Circuits, Lift Masts, and Specifications

Hydraulic circuit diagrams distinguish types 7032–7034/7038–7040 from 7048–7050, including their different pump drives. Control-valve sections cover pressure balancing, attachment pressure regulation, and resealing.

Telescopic, Hi-Lo, and Triplex mast sections document chain adjustment, rollers, carriage stops, and hoist-cylinder construction. Fork arm dimension diagrams support carriage and fork inspection; tilt-cylinder procedures cover disassembly and seal replacement.

Component-specific torque tables, fluid capacities, pressure-test data, wear limits, and electrical test values accompany the relevant service procedures.

Inspecting and servicing industrial forklift electrical circuits and high-pressure hydraulic lines requires appropriate protective gear and strict adherence to standard workshop safety protocols.

File Format and Readability

Page breakdown: One cover plus 511 workshop pages, including the 162-page S-D diagnostic section. These are all included in the 512-page total.

Text search and navigation: The PDF is partially searchable. Many text sections support search, but image-based diagnostic flowcharts and some diagram labels do not. No embedded PDF bookmarks are present.

Diagram readability: Small wiring and connector labels require zooming. An annotation in the TCI-H ignition illustration is cropped at the right edge.