Still RX70-16 RX70-18 RX70-20 Diesel LPG Forklift Trucks Workshop Manual 175719 – PDF DOWNLOAD

Table of contents

00 Product information

Foreword 00- 1
Product overview forthe RX7016-20 00- 1
Safetyinformation 00- 2
Parking the truck so itis secured for servicework 00- 2
Working on live electricalcomponents LL 00- 2
Workingonthe LPGsystem 00- 4
Securing theforkcarriage 00- 4
01 Service
Maintenance 01-1
Maintenanceinstructions 01- 1
Maintenance-1000 hours/annually 01- 3
Maintenance — 3000 hours/everytwoyears 01- 5
Operatingmaterials 01- 6
Measuringandtestingequipment 01- 6
Specialtool 01-7
Harnessesand hoists 01-7
Standardised tightening torques for standard-pitch threads and fine-pitch threads 01- 9
Standardised tightening torques for hose fittings 01-9

02 Diagnostics

IntroductiontoDiaMon 02- 1
STEDS-Navigator 02- 1
CANboxdiagnostics 02- 2
Diagnosticset-up 02- 3
StartingDiaMon 02- 4

WorkingwithDiaMon 02- 5
Reading outand clearingtheerrorlist 02- 5
Readingoutaccesscodes LL 02- 6

Workingusingthe ABE 02- 7
Readerrorlist 02- 7
Clearingerrorlists 02- 9

11 Electric motor

Traction motor 11-1

Generaltechnicaldata 11-1

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Electricalconnections 11-1
Drive unit 11- 2
ReVSENSOr 11- 4
Pin Sensor 11- 4
Temperature SeNSOr 11- 6
Temperature sensor KTY84 11- 6
Generator 11- 8
Generaltechnicaldata 11- 8
Generator 11- 9
Removing and installingthegenerator 11-10

12 Internal combustion engine

Internal combustionengine lL 12-1
Engineunit 12- 1
Engine unitRemoval and installation 12- 2
Startermotor 12- 4
Starterringgear 12- 5
Alternatormonitoring LL 12- 7
Retrofitting the 110-A alternatorfor TCU1 12- 9

Dieselengine 12-11
SDlgeneraltechnicaldata 12-11
VW-Dieselengine 12-12
Engine controlunit ECU -two-part 12-13

LPGengine 12-16
LPGgeneraltechnicaldata i 12-16
VWLPG-20litre BEF 12-18
Engine controlunitECU 12-19

13 Internal combustion engine – attachment parts

Airintake /filter 13- 1
Airintake 13-1
Alrfilter 13- 2

Coolingsystem 13- 3
Cooling circuit 13- 3
Coolant 13- 5
Checking, topping up and changing thecoolant 13- 6
Radiatorsystem 13- 8

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Radiator Removal and installation 13- 9
Fanimpeller-fanmotor 13-11
Dieselfuelsystem 13-13
Fuelsystem 13-13
Fuelfilter 13-15
Lowfuelwarningthreshold 13-15
LPGsystem 13-17
LPG system 13-17
Impcocomponents LLL 13-18
Evaporator function-gasmixer 13-20
Suctionmodule 13-22
MAP/MAT sensorOB6 13-24
Chassismodule 13-24
Actuatorunit 13-26
Gas shut-offvalveunit 13-27
Gas shut-off valvemonitoring 13-27
Shut-downduetolackofgas 13-28
Maintenance and test specifications 13-29
Testing forleaksinthe LPGsystem 13-30
Testing COlevelinexhaustgases 13-31
Servicingthe LPGfilter 13-33
Servicing the 30-bar high-pressure reliefvalve 13-34
Evaporator-maintenance LL 13-35
Safetyvalve-1 7bar 13-38
LPGeylinderftank 13-40
LPGeylinder 13-40

14 Internal combustion engine – exhaust system

Exhaustsystem-diesel 14- 1
Exhaustsystem 14- 1
Exhaust system – particle filter 14- 3
General technical data-Eberspacher 14- 3
Eberspacher particlefilter 14- 4
7 5kW Eberspacher particlefilter 14- 5
Regeneration 14- 8
Maintenance instructions LL 14-10

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Exhaustsystem—LPG lL
Lambdacontrolsystem
Lambdasensor
Three-way catalyticconverter

22 Mechanical drive axle

Driveaxle AD20-E02
Generaltechnicaldata
Driveaxle
Removal/installation ofthe driveaxle
Drivewheelunit
Removal/installation of the drive wheel unit
Repairing thedrivewheelunit
Tractionmotor
Servicebrake LL
Gearboxoil

31 Chassis

Counterweight

Counterweight

34 Driver’s place

Bonnet -cover-insulation
Bonnet

42 Steering system

Hydraulicsteering
Generaltechnicaldata
Steeringsystem
Steering—errordetection LL
Steeringunit

Priorityvalve

Steering wheel and steeringcolumn

Steeringcolumn LLL

Steeringaxle
General technical data, swingaxle
Swingaxle

Swing axle Removal and installation

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Wheelhub oe 42-15
Steeringangle 42-17
Tierod 42-18
Axlestub 42-19

49 Brake system

Mechanical servicebrake 49- 1
Brakesensor1B2 LL 49- 1
Changing the brake cable Servicebrake 49- 2

Parkingbrake 49- 4
Changing the brake cable forthe handbrake 49- 4
Actuating force ofthehandbrake 49- 5
Parking brake switch 1S3 49- 6

50 Controls

Singlepedal 50- 1
Accelerator—single-pedal 50- 1
Dualpedal 50- 4
Accelerator—dual-pedal 2nd generation 50- 4
Controls 50- 8
Joystick 4Plus 50- 8
Axle assignment -Joystick4Plus 50- 9
Joystick 50-10
Joystickoperation LL 50-12
Generation2mini-lever LL 50-14
Generation 2 mini-leverActuation 50-16
Tipswitch 50-18
Generation Tmini-lever 50-20
Axleassignment LLL 50-21

56 Display elements

Operatingconsole 56- 1
Direction indicatormodule (Fabli) 56- 1
Display screen 56- 3
Display and operating unit, generation2(ABE2) 56- 3
ABE 2Installationandremoval 56- 4

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60 Electrics / Electronics

General 60- 1
Generaltechnicaldata 60- 1
Overviewofthecontrollers 60- 2
Overview of electricalcomponents 60- 3
Software compatibility 60- 4
PANDroCesS 60- 5
Parametermanagement LL 60- 6
Errorringbuffer 60- 7
Intermediate circuit 60- 7
Insulation measurement LL 60- 8
Traction motor temperature monitoring LL 60-13
Temperature monitoring, traction inverter with aircooling 60-15
Drive mode — driving behaviour Availability 60-15
Driving mode — driving behaviour Description 60-16
Blue-Q=1Q 60-18

WIRING 60-20
CANbussystem 60-20
CANbusconnections 60-21
Powercables 60-22
Maintenance guidelines forpowercables LL 60-23
Repair-Contactelements 60-23

Electrical system 60-25
Fusebox 60-25
FUSES 60-25
Relaysinthefusebox 60-27

Sensorsystem 60-28
Vertical liftmast position 60-28
Tiltanglesensor7B46 LLL 60-29
Tiltangle sensorparameters 60-31
Installation of the vertical lift mast position 60-32
Load measurement LLL 60-35
Load measurement pressure SeNSOr 60-37

Additional electrical installations 60-38
OptionBoard 60-38
CAN-Power-Port (CPP) 60-40
CPP CPP 3 60-40

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CPP 2B 60-42
Soot CPP (CPP5) 60-43
Relay-Power-Port 60-43

64 Electronic controls

Traction hydraulics and working hydraulics control 64- 1
Truck Control Unit (TCU) ee 64- 1
TCU, generation2(TCU2) iii 64- 2
Truck Controll Unit (TCU) Removal and installation 64- 2

Inverter 64- 5
Inverter 64- 5
Inverter Removalandinstallation 64- 7
Brakeresistor LLL 64-10

69 Battery and accessories

Starterbattery 69- 1
Starterbattery 69- 1

70 Hydraulics

General 70- 1
Generaltechnicaldata 70- 1
Depressurisingthe hydraulics 70- 3
Lifting operatingspeeds LLL 70- 3
Tilting operatingspeed 70- 4
Loweringoperatingspeeds LLL 70- 4

Safetycheck 70- 6
Forwardftiltsafetytest 70- 6
Lowering safetytest 70- 6
Safety checksofhoseassembly 70- 7

Basichydraulics 70- 8
Basichydraulics 70- 8
Fanmotor 70- 9
Steering hydraulics 70-10
Working hydraulics 70-11
Hydraulic pump 70-12
Hydraulic pump Removal and installation 70-13
Hydraulicoil 70-14
Returnlinefilter 70-16

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Breatherfilter 70-17
Intakefilter 70-18
High-pressurefilter 70-18
Conical nipple fittings (CNF) 70-19
Boltedjoint 70-19
71 Working hydraulics
Tilteylinders 71- 1
Masttilt 71-1
Tilt cylinder Removal and installation 71-1
Changing the setof seals (1500-2000kg) 71- 2
Auxiliary hydraulics 71- 5
Attachments 71- 5
Second operating function forattachments 71- 6
76 Valves
Servohydraulics 76- 1
Generaltechnicaldata 76- 1
Valve blockcomponents 76- 2
Valve block Removal and installation 76- 3
Directional control valve block 76- 4
Directional control valve function, lifting 76- 5
Directional control valve function, lowering 76- 7
80 Load lift system
Mastbearings 80- 1
Mastbearings, 1 0t-2 0t 80- 1
81 Lift masts
Liftmast 81- 1
Generaltechnicaldata 81- 1
Hose safety valve of triplexmast 81- 2
Supportroller play (108/117/130) 81- 5
Load chains – Checkingand cleaning 81- 6
Run-outbarrier 81- 7
Workingonliftmasts 81- 9
Liftmast—removal 81-10
Liftmast—installation 81-11
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Telescopicliftmast 81-14
Telescopic liftmast (108/117/130) 81-14
Adjusting the load chains Telescopic lit mast (108/117/130) 81-15

NiHoliftmast 81-17
NiHolift mast (108/117/130) 81-17
Adjusting the load chains NiHo lift mast (108/117/130) 81-19

Triplexliftmast 81-21
Triple lift mast (108/117/130) 81-21
Removing the supportrollersintheliftmast 81-23
Assembling the lift mast after replacing the supportrollers 81-26
Outerload chainsandchainrollers 81-28
Middle load chainand chainroller 81-30
Adjusting the outer load chains Triple lift mast (108/117/130) 81-32
Adjusting the middle load chain Triple lift mast (108/117/130) 81-33

Lifteylinder 81-35
Liftjack 81-35
Workingonliftcylinders 81-36
Outercylinder 81-36
Disassembling/assembling the outercylinder 81-39
Centrecylinder 81-41
Disassembling/assembling the middle cylinder 81-43
End position damping ofoutercylinder 81-46
Middle cylinderenddampener 81-47

84 Load support

Forkcarriage 84- 1
Forkeartiage 84- 1

X Circuit diagrams

Hydraulics X- 1
Servohydraulics X- 1