Still RX70-22, RX70-25, RX70-30, RX70-35 Diesel / LPG Fork Truck Forklift Service Repair Workshop Manual

Workshop literature STILL ELECTRONIC DOCUMENTATION SYSTEM Diesel/LPG forklift trucks RX70-22 RX70-25 RX70-30 RX70-35 C€ 7321 7322 7323 7324 7325 7326 f. , . . , . ... 7327 7328 7329 7330 flTSt 111 IHt f a IOgISt I C S Hybrid 171866 EN -05/2012

History of changes r Edition 05/2012 • Version 4 • Various corrections and alignment with stan¬ dard workshop manual • Introduction re-summarised • Chapter 00 — "Maintenance" and "diagnos¬ tics" added • Chapter 12 — "Alternator monitoring" added • Chapter 13 — "Low fuel warning threshold" and "Gas shut-off valve monitoring" added • Chapter 22 — "Power unit", "Differential gearbox and brake" added • Chapter 49 "Brake system" revised • Chapter 60 — "Electrics and electronics — General", adaption to Hybrid • Chapter 64 — "Hybrid components" added • Chapter 70 — "Basic hydraulics", "Variable displacement pumpHybrid" added Edition 03/2010 • Version 3 • Various corrections and enhancements • Facelift integration • Chapter 00 "About RX70-22 - 35" added • Chapter 00 "Safety information" expanded • Chapter 12 - revised, all documentation about internal combustion engines is now contained in separate workshops manuals • Chapter 13 - revised, all documentation about internal combustion engines is now contained in separate workshops manuals • Chapter 14 - "Particle filter exhaust system" added • Chapter 42 "Steering systems" added • Chapter 49 "Brake system" revised • Chapter 50 "Operating devices" added • Chapter 56 "Display elements" revised, all documentation about the display operating unit is now contained in a separate workshop manual • Chapter 60 "Electrics / Electronics" revised and expanded • Chapter 69 "Batteries and accessories" added • Chapter 7 1 "Auxiliary hydraulics" revised and expanded * Chapter 76 "Valve", hand lever and servo hydraulics revised and added • Chapter 81 "Lift mast" revised and expanded • Chapter X - "Circuit diagrams" added Edition 03/2007 • Version 2 • Truck types 7329 and 7330 added • Various corrections • Chapter 00 - "Product information" added • Chapter 11 - "Electric motor" added • Chapter 12 - "Internal combustion engine" expanded • Chapter 13 "Internal combustion engine / Attachment parts" added • Chapter 22 - "Mechanical drive axle" added * Chapter 49 - "Parking brake" added • Chapter 64 - "Electronic controls" expanded • Chapter 70 - "Hydraulics" added • Chapter 76 - "Valves" added Edition 11/2006 • Version 1 • First issue • This version 1 is continually being extended and replaced by updated versions. 171866 [EN] I

Header r Documentation This workshop manual contains all the informa¬ tion required to assist the trained service engi¬ neers with all work, repairs and maintenance on this truck. In addition, some of the components have been deliberately excluded from this work¬ shop manual and are explained elsewhere in order to ensure a clear overview. Changes may be made at short notice and at any time, and are communicated via Service Information docu¬ ments. The additional documentation comprises work¬ shop manuals, special documentation and oper¬ ating circuit diagrams. Workshop manuals • Display elements — display • VW 1.9 I SDI/TDI (BTX/BEU) • VW 2.0 I TDI (CBHA) • VW2.0ISPI (BEF) • FleetManager™ Special documentation • Error list • Overview of truck software • STILL Flasher • Overview of consumables • FEM 4.004 test log book Operating circuit diagrams • Seethe circuit diagram overview Symbols Used The signal terms Danger, Warning, Caution, Note and Environment note are used in this document as hazard warnings or for unusual information that requires special identification: A DANGER means that failure to comply involves risk to life and/or major damage to property can occur. A WARNING means that failure to comply involves risk of serious injury and/or major damage to property can occur. A CAUTION means that failure to comply involves risk of material damage or destruction. 171866 [EN] III

Header ffl NOTE means that particular attention is drawn to com¬ binations of technical factors which may not be evident even to a specialist. The instructions listedhere must be complied with as otherwise environmental damage may result. For your safety, additional symbols are also used. Please heed the various symbols. Changes and retrofitting Warnings before making changes to the truck If the truck is used for work not listed in the guidelines or truck-specific original operating instructions and has to be converted or retrofitted accordingly, you should be aware of the following: • Any structural modification can affect the handling and stability of the truck, and can result in accidents. • Without authorisation from STILL, no changes that affect the stability, the load capacity and the safety systems may be carried out. • Operation of the truck without an overhead guard at a lift height of over 1800 mm is prohibited. • It is prohibited to install and use restraint systems that are not approved by STILL. • It is prohibited to drill holes in the overhead guard or to perform welding on it. • When carrying out welding on other parts of the truck, it is essential that the battery and all connections to the electronic controls are disconnected. • Only for electric forklift trucks: It is prohibited to drill holes in the area of the driver's seat into the battery hood because hydrogen can enter through the bores into the driver's cab. ENVIRONMENT NOTE 171866 [EN]

Header r CE conformity > With the CE declaration of conformity, STILL con¬ firms that the truck complies with the standards and regulations valid at the time of marketing. The CE conformity mark is shown on the name- plate and indicates compliance with the above regulations. A subsequent structural change or addition to the truck can compromise safety, thus invalidating the CE declaration of conformity. In this case, a new CE declaration of conformity is essential for the structural changes. The company that was instructed by the truck operating company to carry out the change is responsible for issuing a new CE declaration of conformity. The contractor of the operating company must also fulfil the following prerequisites: • Construction documents, test documents and assembly instructions associated with the change must be archived and remain accessible at all times. • Check that the capacity rating plate, decal in¬ formation, hazard warnings and the operating instructions are consistent with regard to the changes and modify if necessary. The change must be processed by a design office that specialises in the area of industrial trucks. The change must be planned, checked and implemented in accordance with the standards and directives valid at the time. CE-Symbol Working with spare parts Warning regarding non-original parts Original parts, attachments and accessories are specially designed for this truck. We specifi¬ cally draw your attention to the fact that parts, attachments and accessories supplied by other companies have not been tested and approved by STILL. A CAUTION Installation and/or use of such products may therefore have a negative impact on the design features of the truck and thus impair active and/or passive driving safety. We recommend that you obtain approval from the manufacturer and, if necessary, from the relevant regulatory authorities before installing such parts. STILL accepts no liability for any damage caused by the use of non-original parts and accessories without approval. 171866 [EN] V

Header Working with electronic controls It is not generally permitted to open controls. STILL's liability and the warranty are no longer applicable once the seal has been damaged. In exceptional cases, personnel authorised by STILL are allowed to open the controls. VI 171866 [EN]

r 00 Product information Foreword oo- 1 About RX70 2.2t - 3.5t 00- 1 Safety instructions 00- 3 Working on live electrical components 00- 3 Working on Hybrid components 00- 4 Jacking up the front of the truck 00- 4 Jacking up the rear of the truck 00- 5 Securing the fork carriage 00- 6 Maintenance 00- 9 Maintenance instructions 00- 9 Maintenance — 1000 hours/annually 00-11 Maintenance — 3000 hours/every six months 00-13 Diagnostics 00-15 Measuring and testing equipment 00-15 Special tool 00-16 Standard torques 00-17 1 1 Electric motor Traction motor 11- 1 General technical data 11- 1 Electrical connections 11- 1 Traction drive 11- 2 Traction motor 11- 4 Speed sensor 11- 6 Pin sensor 11- 6 Temperature sensor 11- 8 Temperature sensor KTY84 11- 8 Alternator 11-10 General technical data 11-10 Alternator 11-10 Alternator removal-installation 11-11 12 Internal combustion engine Internal combustion engine 12- 1 Engine 12- 1 171866 [EN] VII

Engine unit Removal and installation 12- 3 Starter ring gear 12- 8 Starter motor 12- 9 Alternator 12-10 Alternator monitoring 12-11 Diesel engine 12-12 General technical data VW1.9ISDI 12-12 General technical data VW1.9ITDI 12-13 Diesel engine VW 1.91SDI/TDI 12-14 Engine control unit VW 1.91SDI/TDI 12-15 General technical data VW 2.OITDI 12-18 Diesel engine VW2.0ITDI 12-19 LPG engine 12-21 General technical data VW2.0ISPI 12-21 VW LPG -2.0 litre BEF 12-23 Engine control unit VW 2.01 SPI 12-24 13 Combustion engine — attachments Air intake /filter 13- 1 Air intake 13- 1 Air filter 13-2 Cooling system 13- 4 Cooling circuit 13- 4 Coolant 13- 5 Checking, topping up and changing the coolant 13- 7 Radiator system 13- 9 Radiator Removal and installation 13-10 Fan wheel rotor -fan motor 13-11 Diesel fuel system 13-14 Fuel system 13-14 Fuel filter 13-14 Low fuel warning threshold 13-15 LPG system 13-16 LPG system 13-16 Impco components 13-17 Evaporator function -gas mixer 13-18 Suction module 13-21 VIII 171866 [EN]

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Still RX70-22, RX70-25, RX70-30, RX70-35 Diesel / LPG Fork Truck Forklift Service Repair Workshop Manual

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