C£
R60-20 R60-22 R60-25 R60-30
R60-35 R60-40 R60-45 R60-50
Elektro Gabelstapler
Electric Fork Truck
Chariot elevateur electrique
Carretilla elevadora elettrica
V)
Q
in
h
U)
STILLGmbH
Werk- Work- Manuel Manual
statt- shop d 'Atelier de taller
handbuch manual
R6022
-
R6029
R6042 - R6049
R6036I -R6039I
Ident-Nr.164518 (en)
Workshop Manual R60-20 - R60-50, R60-22i - R60-30i
_
Information relating to workshop manual
The workshop manual is valid for all of the listed This workshop manual has been prepared for
trucks. the truck types 6022
-
6029.
For newer truck types, supplements will be
provided in case of deviations. The supplements
will include valid truck types.
designation design truck typ
DC current AC current
R60-20 Swing axle 6022
R60-22 Swing axle 6042 6036
R60-25
Swing axle, short 6023 6043 6037
Swing axle 6024 6044 6038
R60-30 Swing axle 6025 6045 6039
R60-35 Swing axle 6026 6046
R60-40 Swing axle 6027 6047
R60-45 Swing axle 6028 6048
R60-50 Swing axle 6029 6049
© STILL GmbH Stand: 11/2003 ( Ersatz fur Stand: )
ÿ
5TILI
Workshop Manual 6022
-
29, 6036
-
39, 6042
-
49 01
Frame
The welded steel frame is of unit construction and
has a bolt-on cast iron counterweight.
The hydraulic oil tank serves as a frame
crossmember located underneath the floor plate.
Counterweight
The removable rear counterweight is secured to the
Sframe by four bolts (see sketch).
1 = hex hd bolt M 24 x 85 / 8.8
2 = spherical washer
3 = ball cup
4 = hex hd bolt M 24 x 70 / 8.8
5 = locking washer
The four counterweight bolts (1 & 4) should be
torqued to 660 Nm.
Weight of the counterweights :
6022 —> 650 kgs
6023 (short) —> 1078 kgs
6024 (long) —> 738 kgs
6025
6026
6027
6028
6029
—> 1143 kgs
—> 1454 kgs
—> 1401 kgs
—> 1687 kgs
—> 1965 kgs
Frame and Counterweight
'
STILL GmbH Stand: 2/2000 ( Ersatz fur Stand:
Workshop Manual 6022
-
29, 6036
-
39, 6042
-
49 01
Inside dimensions of battery compartment
Inside dimensions of battery compartment
6022 / 6023 6024 / 6025 / 6026 6027 / 6028
2.0 t/ 2.5 t 2.5 t / 3.0 t / 3.5 t 4.0 t / 4.5 t
*) 4 PzS 480 5 PzS 600 6 PzS 720
A 793 +/- 3 793 +/- 3 793 +/- 3
B 1032 +1-2 1032 +1-2 1032 +1-2
C 722 +/- 3 865 +/- 3 1013 +1-3
*) = standard battery size
A = height of battery compartment to under¬
side of - > handbrake cover
B = width of battery compartment
C = length of battery compartment
6023 —> 2.5 t short
6024 —> 2.5 1long
Battery dimensions and weight to DIN 43536 / 80 V
Height Width Length Weight (kgs)
4 PzS 480 784 (769) 1028 (1025) 711 (708) 1547
5 PzS 600 784 (769) 1028 (1025) 855 (852) 1872
6 PzS 720 784 (769) 1028 (1025) 999 (996) 2206
() = max. dimensions of battery tray in mm
'
STILL GmbH Stand: 2/2000 ( Ersatz fur Stand: (031
'll_L
Workshop Manual 6022
-
29, 6036
-
39, 6042
-
49 01
Jacking up the truck
CAUTION :
Before jacking up the truck :
Disconnect the battery and apply the parking brake!
To carry out certain maintenance tasks the truck
must be jacked up and securely chocked into
position.
Always make sure only jacks of suitable capacity
are used.
Before jacking up the truck, position it on level
ground and secure against slipping or rolling.
Jack up the truck by placing a jack at locations
shown in the figures, i.e. beneath the mast right or
left and beneath the frame at the front or at the
rear.
Never jack up the truck at rear counterweight!
When jacking up the truck observe safety rules
covering maintenance and service jobs on the mast.
Jacking up
© STILL GmbH Stand: 2/2000 ( Ersatz fur Stand:
1
(04)
5TILI
Workshop Manual 6022
-
29, 6036
-
39, 6042
-
49 02
Technical Data for Maintenance Service
>,
L
0
o
Functional Group 02
Steer axle
Wheel lock angle
0
CM 00
i
o CO
Toe-in 0 ± 1 mm
Wheel camber 0
0
Trail 0
0
Torque loading
Wheel hub MA = 225 Nm
Wheel nuts MA = 195 Nm
Axle bearings MA = 195 Nm
Steer cylinder fixing MA = 210 Nm
Nut on king pin MA = 290 Nm (6022-25)
MA = 310 Nm (6026-29)
Lubricants
Wheel hub bearings Grease F to DIN 51825-KP2K-20 lithium soap based
Grease F to DIN 51825-KP2K-30,lithium soap based
Stub axle bearings Grease FLto DIN 51825 - KPF2N-20, lithium soap based
STILL Ident No. 148659
M 5TILI
02 Workshop Manual 6022
-
29, 6036
-
39, 6042
-
49
Steer axle
Configuration of steer axle
The articulating steer axle suspended from the
counterweight is mounted in 2 neoprene blocks. The
stub axles are supported in the axle beam on tapered
roller bearings. Steering is limited by stop screws on
the stub axles.
1 axle beam
2 fixing plates
3 hex. hd. bolt
4 spring washer
5 neoprene blocks
Steer axle removal
CAUTION: Remove steer axle only with mast in
position on the truck! Risk of tipping!
- Apply the parking brake.
- Securely chock the front wheels to prevent
rolling of the truck.
- Slacken steer wheel nuts.
- Jack up rear of the truck at counterweight (x)
and place wooden blocks under the counter¬
weight in front of the axle.
-Remove wheels.
- Disconnect the hydraulic connections at steer
cylinder.
CAUTION: Prepare for oil spillage when
disconnecting the hydraulic connections! Catch
oil in a pan of adequate capacity and dispose
of the used oil in accordance with laws and
regulations.
- Remove the 4 socket head screws which retain the
steer axle in place.
- Slide a hand pallet truck under the steer axle
with wooden blocks placed on the fork ends of
the hand pallet truck.
- Using a lever, drive steer axle out of roll pins
and lower the axle onto the hand pallet truck.
Steer axle installation
- Reverse the removal procedure.
- The slots of the roll pins must face the direc¬
tion of forward travel.
-Torque the 4 socket heads to:
MA
= 195 Nm
CAUTION: Do not swap hydraulic connec¬
tions left and right!
m <£
a S-
N
1 1
0)
c/>
of
N5
O
O
o
CD
Q. O"
CD CD
_
<
S
Ojn
"o <
=
%
CD O
ÿ T
CQ Q):
=T ÿ CQ
<-r"
rr\ A?
C:
3
C_
CD
CD-
CD
~n
o
3
INSTILL
Workshop Manual 6022
-
29, 6036
-
39, 6042
-
49 02
Steer axle
o
o
o
CM
-b
»- c
CD CD
_Q
0
C/)
C/)
E
o
u_
ÿ
0 S3
-7-T 0
® 2
jU T>
c 0
N 13 >
O Q) 0
-C
c
w
050
0
05
jcp g)
o -35 >,
5
>
Q-
r ÿ o
o P O
0 >
i_
00
-Q "D
0
Wheel hub
-
Removal and Dismantling
1 axle beam
2 stub axle
3 radial sealing ring
4 tapered roller bearing
5 wheel hub
6 roll pin
7 hub cap
8 nut
9 washer
10 tapered roller bearing
11 wheel bolt
12 ball seat nut
-Slacken ball seat nuts (12) and remove
wheel.
-Pull hub cap (7) from wheel.
- Slacken nut (8)
- Remove washer (9) with roll pin (6).
-Withdraw the hub.
-Remove radial sealing ring (3) then remove
tapered roller bearings (4) and (10) from hub.
-If necessary, drive out of wheel hub outer
races of tapered roller bearings (4) and (10).
Wheel hub -
Reassembling and Installation
-Apply a smear of grease to the sealing lips of
the radial sealing ring.
-Before re-assembling the hub, repack with
grease F: cavity between inner race and
bearing cage of tapered roller bearings, and the
bearing spaces identified by an 'x' on the drawing.
-To reassemble the hubs, reverse the procedure.
-Tighten nut (8) while rotating the wheel hub.
Torque loading:
MA
= 225Nm
M 5TILI
02 Workshop Manual 6022
-
29, 6036
-
39, 6042
-
49
Steer axle
Checking the steering angles
The steering angle a must amount to 80° - 82°.
To facilitate the measurement use the comple¬
mentary angle b for the setting. It should amount
to 98° -100°.
IMPORTANT: Ensure that the wheel lock is
limited by the stop screws (1) and not by the
cylinder stroke.
Wheel angle stop adjustment
The wheel stop angle is limited by the stop
screws (1).
-By operating on stop screws (1), set both
steering angles to 80° - 82°.
-Check opposite angles.
-Check for adequate clearance between wheels
and truck frame.
-Check that the wheel lock is not limited by
the cylinder stroke.
turn right
turn left
m 92
w §
K- Q-
N
•
CD
CO
5T
N5
o
o
o
CD
Q. O"
CD CD
_
<
S
Ojn
"O < =:
%
CD O
ÿ T
CQ Q):
=T ÿ CD
<-r"
rn" A?
C:
s
C_
CD
Q.
CD
~n
o
3
INSTILL
Workshop Manual 6022
-
29, 6036
-
39, 6042
-
49 02
Steer axle
"O
1- c
ra to
.a
aj
W
Stub axle
-
Removal and Dismantling
1 nut
2 washer
3 king pin
4 plug
5 stub axle
6 hex. hd. screw
7 nut
8 spacing washer
9 wiper ring
10 tapered roller bearing
11 spacer
12 grease nipple
13 tapered roller bearing
14 wiper ring
15 O-Ring
16 spacing washer
w
-Remove the wheel.
-Press out the pin located between track rod and
stub axle.
-Slacken nut(1).
-Remove washer (2).
-Press the king pin (3) down through the stub
axle and remove the king pin.
I
VC \
(3
1
K ÿÿ2
n
0
15—
|
A
•
ÿ
0
11
i J
0
10
-
0
ÿ
9
»
«£•
E
o
LL „
CD
-7-T CO
o £
jU t>
c 0
N 13 >
O Q) 0
sz F-
<S>
O§0
w
O)
0
05
jro g)
o -35 >,
5
>
Q-
_c
£
°
o P O
0 >
i_
00
-Q "D
0
-Remove the stub axle from the axle.
-Remove from the stub axle: spacing
washers, 'O' ring, wiper rings, tapered roller
bearings and spacer (items 8-16).
ÿ
5TILI
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$39.99
STILL Electric Fork Truck R60-20, R60-22, R60-25, R60-30, R60-35, R60-40, R60-45, R60-50* Factory Service / Repair/ Workshop Man
Viewed 17 Times Today
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$39.99
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
This workshop manual is designed for the maintenance and repair of the STILL Electric Fork Truck R60-20, R60-22, R60-25, R60-30, R60-35, R60-40, R60-45, R60-50 models. It provides comprehensive procedures for maintaining, servicing, diagnosing, and repairing the vehicles. The manual includes step-by-step instructions, detailed exploded diagrams, and pictures to facilitate correct and efficient completion of the required tasks. It covers all repair procedures and is suitable for use by both professional mechanics and DIY enthusiasts.
Models Covered:
- STILL Electric Fork Truck R60-20
- STILL Electric Fork Truck R60-22
- STILL Electric Fork Truck R60-25
- STILL Electric Fork Truck R60-30
- STILL Electric Fork Truck R60-35
- STILL Electric Fork Truck R60-40
- STILL Electric Fork Truck R60-45
- STILL Electric Fork Truck R60-50
Service Repair Manual Covers:
- Frame and Counterweight
- Inside dimensions of battery compartment
- Jacking up
- Technical Data for Maintenance Service
- Steer axle
- Power axle
- Steering
- Service brake
- Electrical installation
- Configuration of the optional electrical equipment
- Hydraulic System
- Drive motor
- Pressure regulator I and II Function
- Mast Unit
- And more
Instant delivery eliminates shipping costs and waiting time for a physical manual. The manual is available for immediate access upon secure payment processing, suitable for printing on all pages. It is compatible with all versions of Windows and Mac, and requires Adobe Reader and Win for access.
