Still RX70-20, RX70-25, RX70-30, RX70-35 Forklift Truck Series 7300-7309 Workshop Service Manual

Illustrated Factory Service Workshop Manual for Still Forklift Trucks Models RX70-20, RX70-25, RX70-30, RX70-35 Series 7300, 7301, 7302, 7303, 7304, 7305, 7306, 7307, 7308, 7309

This manual contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your truck. This document is printable, without restrictions, contains searchable text.

Language: English
Format: PDF, 376 pages

Covered models:
   RX70-20
   RX70-25
   RX70-30
   RX70-35  

Contents:
   00 Product information
      Foreword
         Product overview for the RX7020-35, Facelift2016
      Safety information
         Parkingthe truck so it is secured for service work
         Working on live electrical components
         Working on Hybridcomponents
         Working on the LPG system
         Jacking upthe truck - front
         Jacking upthe truck- rear
         Securing the fork carriage
   01 Service
      Maintenance
         Maintenance instructions
         Maintenance -1000 hours/annually
         Maintenance - 3000 hours/every two years
      Operating materials
         Measuring and testing equipment
         Special tool
         Harnesses and hoists, 1.01-3.5 1
         Standardised tightening torques for standard-pitch threads and fine-pitch threads
         Standardised tightening torques for hosefittings
   02 Diagnostics
      Introductionto DiaMon
         STEDS-Navigator
         CAN box diagnostics
         Diagnostic set-up
         Starting DiaMon
      Working with DiaMon
         Reading out and clearing the error list
         Reading out access codes
      Working usingthe ABE
         Read error list
         Clearing error lists
   11 Electric motor
      Traction motor
         Generaltechnical data
         Electricalconnections
         Traction motor
      Sensors
         Pinsensor
         Temperature sensor KTY84
      Generator
         Generaltechnical data
         Alternator
         Alternator removal-installation
   12 Internal combustion engine
      Internal combustion engine
         Engine unit
         Starter motor
         Starter ring gear
         Alternator
         Alternator monitoring
      Diesel engine
         Generaltechnical data VW1.9ISDI
         Diesel engine VW 1.91SDI/TDI
         Engine control unit VW 1.91SDI/TDI
         Removing and install ingthe engine unit
      LPG engine
         Generaltechnical data VW 2.OISPI
         VW LPG -2.0 litre BEF
         Engine control unit VW 2.OISPI
         Removing and installingthe engine unit
   13 Internalcombustion engine - Attachment parts
      Air intake/filter
         Air filter system
         Air filter
      Cooling system
         Cooling circuit
         Water pump
         Coolant
         Checking, topping up and changing the coolant
         Radiatorsystem
         Radiator Removal and installation
         Fanwheel rotor -fan motor
      Diesel fuel system
         Fuel system
         Fuel filter
         Low fuel warning threshold
      LPG system
         LPG system
         Evaporator module
         Removing and installingthe evaporator
         Suction module
         MAP/MAT sensor 0B6
         Actuator unit
         Gas shut-off valve monitoring
         Shut-down due to lack of gas
         Maintenance and test specifications
         Testing for leaks inthe LPG system
         Testing CO level in exhaust gases
         Servicing the LPGfilter
         Servicing the 30-bar high-pressure relief valve
   14 Internalcombustion engine - Exhaust system
      Exhaustsystem - Diesel
         Exhaust system
      Exhaust system -Particle filter
         General technical data -Eberspácher
         Structure ofthe Eberspácher particlefilter
         7.5 kW Eberspácher particlefilter
         Regeneration
         Maintenance instructions
      Exhaustsystem - LPG
         Exhaust system
         Lambda control system
         Lambda sensor
         Three-way catalytic converter
   22 Mechanical drive axle
      Driveaxle 8.30
         Generaltechnical data, Carraro 8.30
         Drive axle
         Wheel drive
         Checking the oil level,changing the oil
         Removaland installation of the drive axle
         Traction motor
         Service brake
         Differentialgearbox
   30 Chassis, bodywork and fittings
      Chassis
         Floorplate
         Working with gas springs
      Counterweight
         Counterweight
   42 Steering system
      Hydraulic steering
         General technical data
         Steering system
         Steering— error detection
         Steering unit
         Priorityvalve
      Steering wheel and steering column
         Steering column
         Steering axle
         Generaltechnical data
      Swing axle
         Swing axle Removaland installation
         Wheel hub
         Steering angle
         Tie rod
         Axle stub
   50 Operating devices
      Drive and brake actuation
         Brake actuator
         Replacing the brake cable
         Actuating force of the handbrake
         Parking brake switch 1S3
         Brake sensor 1B2
         Accelerator- single-pedal
      Dual pedal
         Accelerator -dual pedal
      Operating devices
         Joystick 4Plus
         Axle assignment- Joystick 4Plus
         Generation2 mini-lever
         Axle assignment -the mini-lever
         Tip switch
         Axle assignment -fingertip switch
   56 Display elements
      Operating console
         Direction indicator module (Fabli)
      Display
         Display and operating unit, generation 2 (ABE 2)
         ABE 2 Installationand removal
   60 Electrics/electronics
      General
         Generaltechnical data
         Overview of the controllers
         Overview of electrical components
         Software compatibility
         PAN process
         Parameter management
         Error ring buffer
         Intermediatecircuit
         Insulation measurement
         Hybridcomponent insulation measurements
         Traction motor temperature monitoring
         Temperature monitoringfor the traction converter
         Availability of drive mode and driving behaviour
         Driving mode— driving behaviour Description
         Blue-Q = IQ
      Wiring
         CAN bussystem
         CAN bus connections
         Power cables
         Maintenance guidelines for power cables
         Repair-Contact elements
      Electrical system
         Fuse box
         Fuses inthe fuse box
         Relays in the fuse box
         Sensor system
         Vertical lift mast position
         Installingthe lift mast-vertical position
         Tilt angle sensor 7B46
         Load measurement
         Load measurement pressure sensor
      Additional electrical installation
         Option Board
         CAN-Power-Port (CPP)
         CPP 1/CPP3
         CPP2B
         Soot CPP (CPP5)
         Relay-Power-Port
   64 Electronic controls
      Truck control unit
         Truck Control Unit2 (TCU 2)
         Truck Contrail Unit (TCU) Removal and installation
      Converter
         SVAC converter
         SVAC Hybrid IIconverter
         Removing and installing the converter
         Brake resistor
      Hybrid components
         Hybrid IIfunction
         Functional test for hybrid systems
         DC/DC converter
         DC/DC converter Removaland installation
         Storage module— energy accumulators
         Storage module Removal and installation
         Forced ventilation
   69 Batteries and accessories
      Starter battery
         Starter battery G1
         Working with batteries
   70 Hydraulics
      General
         General technical data
         Releasing the pressurefrom the hydraulics
         Tilt operating speeds
         Operating speeds for lifting
         Operating speeds for lowering
      Safety check
         Forwardtilt safety test
         Lowering safety test
         Safety checks of hose assembly
      Basic hydraulics
         Basic hydraulics
         Fan motor control unit
         Fancontrol valve
         Steering hydraulics
         Operating hydraulics
         Variable displacement pump
         Hybridvariable displacement pump
         Pump regulator
         Variable pumpRemoval and installation
         Hydraulictank
         Hydraulic oil
         Returnfilter
         Breather
         Intakefilter
         High-pressurefilter
         Conical nipplefittings (CNF)
         Boltedjoint
   71 Working hydraulics
      Tilt cylinder
         Masttilt
         Tilt cylinder Removaland installation
         Changing the set of seals2200-5000 kg -LSP 500
      Auxiliary hydraulics
         Attachments
         Second operating function for attachments
      Accumulator
         Accumulator
         Checking the accumulator
   76 Valves
      Servo hydraulics
         Generaltechnical data
         Directional control valve block
         Directional control valve function Lifting
         Directional control valve function Lowering
   80 Load lift system
      Mast bearings
         Carraro MaLis mast bearing
   81 Lift mast
       Lift mast
         Generaltechnical data
         Hosesafety valve of triplex mast
         Support roller play (108/117/130)
         Loadchains -Checking and cleaning
         Run-out barrier
         Working on lift masts
         Lift mast- Removal
         Lift mast- Installation
      Telescopic lift mast
         Telescopic lift mast (130 MaLiS)
         Adjusting the load chains Telescopic lift mast (130 MaLiS)
         Removing the support rollers inthe lift mast
         Assembling the lift mast after replacingthe support rollers
         Outer load chains and chain rollers
      NiHo lift mast
         NiHo lift mast (130 MaLiS)
         Adjusting the load chains NiHo lift mast (130 MaLiS)
      Triple mast
         Triple lift mast (130 MaLiS)
         Adjusting the outer load chains Triple lift mast (130 MaLiS)
         Adjusting the middle load chain Triple lift mast (130 MaLiS)
         Removingthe support rollers
         Assembling the lift mast after replacingthe support rollers
         Outer load chains and chain rollers
         Middle load chain and chain roller
      Lift cylinder
         Liftjack
         Working on lift cylinders
         Removingand installingthe outer cylinders
         Disassembling/assembling the outer cylinder
         Middle cylinder
         Disassembling/assemblingthe middle cylinder
         End position damping, type B (bottom)
         End position damping, type A (top)
   84 Load support
      Fork carriage - 2500-3500
         Removing and installing the fork carriage
         Forkwear protection
   Annex
   X Circuit diagrams
      Hydraulics
         Servo hydraulics