1994–2004 STILL R 70-15 and R 70-16 (R7011/R7031) Diesel-Electric Forklift Workshop Manual (P/N 1640726)

This STILL workshop manual covers the 1994–2004 R 70-15 and R 70-16 diesel-electric forklifts (R7011/R7031), publication Ident-No. 1640726 (ex145 907). It combines mechanical repair documentation with Stilltronic R70 electrical diagnostics.

• Frame and axles: Counterweight mounting, steering-axle removal, kingpin bearings, power-axle half-shafts, and wheel hub bearing replacement.

• Steering and brakes: Hydrostatic steering pressure checks, steering-cylinder seal replacement, and Perrot hydraulic servo-brake and parking-brake adjustment.

• Lift and tilt hydraulics: Gear-pump replacement, control-valve servicing, anti-cavitation valve checks, and attachment pressure regulation.

• Diesel engine: VW Industrial Engine 068.5 maintenance, throttle-linkage speed settings, automatic preheat diagnosis, and glow-plug relay testing.

• Electric drive: Motor and generator disassembly, brush inspection, commutator service, and u200 logic-board and u36 power-unit configurations.

• Masts and cylinders: Telescopic, Hi-Lo, and Triple mast chain adjustment, support-roller checks, and hoist- and tilt-cylinder seal work.

• Fault diagnosis: Test-stage flowcharts, connector views, voltage and continuity checks, and final fail-safe and electrical-braking checks.

Suited to forklift technicians familiar with electrical test equipment; the diagnostic section assumes correct use of the specified meters and test tools.

Axles, Hydrostatic Steering, and Perrot Brakes

The power axle section describes the double-reduction spur gearbox and differential, then documents axle-housing installation, half-shaft removal, hub installation, and tachogenerator drive-seal replacement. Exploded views identify the gear and differential assemblies, with related torque and bearing-clearance specifications.

Steering coverage follows the separate hydraulic circuit, Bosch steering pump, and Danfoss OSPC 100 ON hand pump. It includes pump removal and installation, pressure testing, and steering-cylinder repair; a defective hand pump is specified for replacement.

The Perrot servo-brake section explains brake-shoe and parking-brake adjustment, master-cylinder pushrod clearance, brake-drum machining limits, and brake-fluid requirements.

VW Diesel Maintenance and Electric Drive Repair

The engine section covers lubrication and cooling-system service, Bosch distributor-injection specifications, and throttle-linkage adjustment. Its starting-system troubleshooting distinguishes quick-glow and normal-glow installations and includes automatic preheat relay d88 and warning-lamp tests.

Motor and generator repair coverage extends to disassembly, brush replacement, bearing work, commutator skimming, and mica undercutting. Generator removal is described for different workshop access arrangements, including use of a lift or inspection pit.

The generator disassembly notes warn that an unprotected puller can damage the armature-shaft driving dog. Pulling the pulley and commutator end bracket together can also break the bracket.

Stilltronic Controls and Meter-Specific Fault Finding

The electrical section maps the u200 logic board, u36 power unit, c26 safety contactor, and associated relays. It distinguishes plug-in traction modules, zero-braking configurations, and power units with an integrated safety relay.

Diagnostic coverage includes start-delay unit u37, current sensor n35, tachogenerator m10 polarity and speed feedback, and electronic charge compensator u21. Both older discharge-resistor arrangements and the later charge-transfer circuit are described for the two 12 V/44 Ah starter batteries connected in series.

Comparison tables distinguish the test stages and pin assignments for the digital diagnostic meter P/N 147587 and red/green meter P/N 301723. This helps technicians select the correct test points for the meter in use. The u200/u36 schematic diagram and illustrated connector checks support the fault-finding charts.

Lift Hydraulics, Mast Chains, and Cylinder Service

The hydraulic sections explain control-valve construction, pressure and flow regulation, SVC 47 E anti-cavitation valves, and pump-drive seal service. A lift/tilt circuit diagram shows the relationship between pumps, control valves, cylinders, and return filtration.

Mast oil-flow and chain-routing views distinguish Telescopic, Hi-Lo full-free-lift, and Triple arrangements. The procedures cover UVV chain inspections, carriage stops, support-roller clearances, lowering valves, line-failure safety devices, and cylinder seal replacement.

Follow the manual's support and electrical-isolation precautions when working on raised masts, heavy assemblies, and drive electronics.

A Preview of Hydraulic and Electrical Test Data

These examples represent a small selection of the hydraulic and electrical specifications in the manual.

The lift/tilt gear pump is rated at 16 cm³/rev, with the control-bank pressure-relief valve set to 230 bar. The separate hydrostatic steering circuit specifies a 90-bar relief setting.

Motor/generator-circuit insulation resistance must be at least 200,000 ohms, tested at a minimum of 500 V DC.

Searchable Text, Diagram Detail, and PDF Contents

Search and diagram limitations: Main text is searchable, but labels within several diagram images are not. There are no embedded PDF bookmarks. Small terminal labels in the u200 schematic are partly difficult to read even when enlarged; the illustrated diagnostic checks benefit from zooming.

One printable, English-language 251-page PDF contains the workshop and S-D diagnostic sections. The total includes the title page: 1 cover page, 142 workshop pages, and 108 diagnostic pages.