STILL R50-10, R50-12, R50-15 Electronic Fork Truck Service Repair Workshop Manual

ce R50-10 R50-12 R50-15/16 Elektro Gabelstapler Electric Fork Truck Chariot elevateur electrique Carretilla elevadora elettrica u < Is _i h ÿ -i o > (A 111 Q (A V) D in STILLGmbH Werk- statt- handbuch Work¬ shop manual R5001-R5034 Ident-Nr.164534 (en) Manuel d 'Atelier Manual de taller

Workshop Manual 5001 -34 Frame and counterweight The rigid electrically welded steel plate chassis frame and body is of unit construction and has a bolted-on type counterweight. The hydraulic oil tank forms an integral part of the frame, and is situated between the leg and battery compartments. The removable rear counterweight has fixing holes through which pass the screws with hexagonal recessed hole holding the power unit in place. The counterweight is bolted to the chassis by means of 3 bolts (see sketch). All of the 3 counterweight mounting bolts are torqued to 710 Nm. 1 =hex. hd. bolts M 30 x 100, 8.8 2 =C-shaped washer 3 =hex. hd. bolts M 24 x 160, 8.8 4 =washer 5 =spacertube 6 =cone seat 7 ÿspherical washer Weight indication for counterweights: 490 kgs=1.0-tonne capacity units 685 kgs=1,2-tonne capacity units 925 kgs=1 ,5-tonne capacity units z 1 2 Detail Z EinzellieilZ i i STILL GmbH Stand: 11/2004 ( Ersatz fur Stand: 07/91 ) 'll_L

Workshop Manual 5001 -34 01 Frame and counterweight without roller frame* with roller frame* 1.0-tonne unit Cushion lyres supereiaslic tyres 10 tonne unit pneumatic & supereiastic lyres 12 lor* Cushion tyres leuoil Poeurn, ÿ SF 1.5-to Cushion lyres nnc unit Fneum. + SE a Top oi silent blocks** to " lop ol remnvahtn side plate (mm) 640 ÿ 4 640 + 4 640 *4 640 +4 ~ W 640 ÿ4 64° •} p Top ol silent blocks'* to on der side ot hood frnm) 065 ÿ3 665 I* 665*3 665+3 B65 +3 665 +3 p Length ol battery compart- merit area (mm) 352 * 3 470 *3 470 *3 470 +3 506 +3 S06 ÿ 3 n Width ol battery compart- merit (mm| 859 t5 859 15 859 t 5 Ub8 * b 859 x 5 859 t 5 E Ground to top ol rof er Irame 177 t5 187 a: 3 1//t3 18/ ±3 177 *3 187+3 p lop ot roller platform to lop ol removable side plate (mm) 6I3 + 6 - s 613 * | 613 1 5 613+6 613+6 613 +G 5 Top Ol roller platlorm to un der side of cover jmm) 638 f§ 4 638 + § - 4 630 *5 - 4 638 +5 - 4 038 +5 - 4 638 ÿ 5 -4 U Distance between LH side M Iratne section and battery latch (mm) 830 *_l 836 830 : jj 836 »| -6 836 836 • 5 -6 ÿ Dstance between long chan J net bars ol chassis frame (mm) 590 ÿ 3 590 ÿ 3 590 + 3 590 + 3 590 1 3 590 t 3 l( Weight ibqu red in battery compart monl (kgs)*** 451 451 567 58/ 65/ 057 | ienat n ol hat I ery compart - ment (mm) with extra ballast ~ 445 ' 3 - 4 440 ' 3 - 4 481 1 3 - 4 481 ' 3 - 4 enabling the battery to be slid out sideways on which the battery is located *** Extra ballast weight may be added or removed to compensate for different sized batteries without changing dimensions of the truck STILL GmbH Stand: 11/2004 ( Ersatz fur Stand: 07/91 ) 'll_L

Workshop Manual 5001 -34 Front axle The wheel hub is supported on two tapered roller bearings of equal size. The wheel hub and the axle end are precision engineered, allowing for tolerances that eliminate the need for readjusting the bearing clearance by adding or removing shims. Max. axial play of bearings = 0.35 mm. Attention! Watch for correct positioning of disc washer. The wheel hub is secured in place by means of an M 16 8.8 type haxagon cap screw which should be torqued to 210 Nm. When installing or removing the wheel hub, special care should be exercised so as to prevent any grease emanating from an exposed tapered roller bearing from contacting the brake drum. The wheel hub is sealed from the inside by means of a V- shaped grease seal, and is protected from the outside by a hub cap. When repacking the wheel hub with wheel bearing grease do not refill the bearing housing with grease exceeding 1/3 of its volume otherwise grease may contact the brake shoe linings. The front wheel rims are secured by means of wheel bolts. In order to forestall damage to the wheel hub or rim, it is necessary from time to time to check the wheel bolts for torque. Tighten the wheel bolts with a torque spanner to 210 Nm. STILL GmbH Stand: 11/2004 ( Ersatz fur Stand: 07/91 ) 'll_L

Workshop Manual 5001 -34 03 Power unit Transmission type: Gearbox capacity: Grade of oil: Spur-type reduction gear 1.5 litres High-pressure transmission oil (OG to MIL - L 2106) SAE 80 Power from the horizontally arranged D.C. drive motor is transmitted to the drive/steer wheel via a triple reduction precision gear drive operating in an oil bath. Power unit removal (motor flange-connected to the reduction gear) 1) Disconnect the battery plug 2) Chock front wheels to prevent rolling of the truck 3) Disconnect motor cables from contactor panel 4) Remove retaining bracket from rear cover latch 5) Remove stop (item 1) as well as screw located opposite it. Next, install flat bar as shown on sketch 6) By means of a sling secure power unit to overhead guard 7) Remove steering chain 8) Remove screws with hexagonal recessed hole (item 2) by means of which the power unit is held to the counterweight 9) With the aid of a chain hoist raise rear of truck about 200 mm from floor and place blocks beneath the counterweight 10) By releasing sling lower the power unit, carefully manoeuvring it clear of truck by pulling it towards you CAUTION: When placing power unit on floor, make sure it is so positioned that oil is prevented from gaining access into the drive motor Power unit installation Install the power unit in the reverse order of removal. Screws with hexagonal recessed hole torqued to 210 Nm flat bar 30 x 8 Vi STILL GmbH Stand: 11/2004 ( Ersatz fur Stand: 07/91 ) 'll_L

Workshop Manual 5001 - 34 03 Power unit © STILL GmbH Stand: 11/2004 ( Ersatz fur Stand: 07/91 ) 2 M 5TI

Workshop Manual 5001 -34 Power unit Item Description 1 Bleeder screw 2 Washer 3 Hex. hd. screw M 12 x 70 8.8 MA~ 50 Nm 4 Pinion 2 5 Outer races of tapered roller bearing fitted by use of a hydraulic press and Loctite grade 601 6 Hex. hd. screw M 12 x 70 8.8 MA= 80 Nm 7 Face sealed with Loctite 572 8 Outer race of tapered roller outer bearing pressed in flush with gear face 9 Pinion 3 forced in with 135 000 Nm (13 500 kg) 10 Cover sealed with Loctite grade 572 11 Pinion shaft 12 Shims,(axiall play = 0-0.1 mm) 13 Hex, hd. screw M8 x 16 8.8 sealed with Loctite grade 572 14 Washer + slotted nuts 15 Oil tiller and oil level plug 16 Nut lock 17 Cover sealed with Loctite grade 572 18 Oil drain plug 19 Tapered roller bearing (adjusted without a notable clearance and secured in place with a lock nut) 20 Radial seal (before installing it, its cavity must be filled up to 50 % with grease) STILL GmbH Stand: 11/2004 ( Ersatz fur Stand: 07/91 ) 'll_L

Workshop Manual 5001 -34 04 Superelastic tyred wheels 1 Superelastic tyre 18x7-8 2 Rim without rings- rear 3 Spring washer 4 Crown nut 5 Rim without rings- front 6 Superelastic tyre 18x7-8 7 Wheel bolt (ball seat type) Torque loadings Wheel bolts- front M 14x24 Grade 10.9 MA: 195 Nm Crown nuts- rear M 14x 1.5 MA: 170 Nm ± 10 % Wheels and tyres © STILL GmbH Stand: 11/2004 ( Ersatz fur Stand: 07/91 ) 1 M 5TILI

Workshop Manual 5001 -34 06 Operation Power from the front steering chain is transmitted to the rear steering chain via a steering gear (incorporating an anti-kickback device) whence the steering forces are transmitted to the ball race mounted power unit via a deflecting shaft. Power assistance is provided by an electric motor. Motor speed and direction of rotation are predetermined by a set point adjuster which is situated in the steering column and is designed as a magnetoresistor adjuster. Power supply is via slip rings. The signals emitted by the set point adjuster are processed by an electronic control unit which with the series power component forms an assembly (u 100) which is housed in a sealed box attached on the left mudguard under the floor plate. Control current and motor current are protected by fuses. The electronic steering control unit is connected directly across the battery and, therefore, cannot be disconnected via the keyswitch. Steering system _ _ <£3 _ tfcfb © STILL GmbH Stand: 11/2004 ( Ersatz fur Stand: 07/91 ) 1 5TILI

Workshop Manual 5001 -34 Steering 1 steering column 2 anti-kickback steering gear 3 power steer motor 4 deflecting shaft 5 steering control unit u100 © STILL GmbH Stand: 11/2004 ( Ersatz fur Stand: 07/91 ) 2 M 5TILI

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STILL R50-10, R50-12, R50-15 Electronic Fork Truck Service Repair Workshop Manual

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