WORKSHOP - MANUAL R 70-15 / 16 R 7011 / 7031 Ident-No.: 1640726 (ex145 907) © STILLGmbH_ Stand: 8/1994 ( Ersatz fur Stand: ) te =- Workshop Manual_R 7011(R 7031, R 7001) 01 Frame and Counterweight Frame ‘The welded steel frame is of unit construction and has a bolt-on cast iron counterweight. ‘The hydraulic oiltank serves as a frame crossmember between the leg and engine compartments. The front cowl is bolted to the frame. Counterweight ‘The removable rear counterweight is secured to the frame by 3 bolts, (See sketch), Allthe counterweight bolts should be torqued to 710 Nm. 1= Hex hd bolt M24 x85 DIN 933 Ball cup DIN6319D 28 ‘Spherical washer DIN6319C25 Hex hd bolt M24 x60 DIN 933 = Spring washer DIN127A24 ‘Weight of the counterweight: 900 kgs © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) o1R7011(R 7031, R 7001). 02 Technical Data for Maintenance Service ~ Workshop Manual Trail Axle Tal axle mounting bolts MA = 195 Nm Wheel hub bolts MA = 22.6 Nm Axial play of wheel hub 0.15 025 mm Wheel lock angles 80 - 820 the complementary angle to 180° is measured Press force for steer max. 68 KN cylinder mounting pin Press force for bellerank max. 42 KN mounting pin © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) on ASDescription ‘The articulating steer axle suspended from the coun- terweight is mounted in neoprene blocks. King pins are mounted in needle bearings for easy steering ‘Steering is limited by stop screws on the axle, Ar- ticulation is limited by stops on the counterweight. Steering axle removal For steering axle removal, disconnect the power steer cylinder pipes and remove the cap screws (3) hold- ing the fixing plates in position. To install the steering axle, reverse the removal pro- cedure, Torque loading: MA = 195 Nm. Note Do not interchange hyd. connections left and right! Wheel hubs ‘The wheel hubs are mounted on taper roller bear- ings. The wheel hub and the end of the axle are pre- Cision engineered, to eliminate the need for adjusting the bearing clearance by adding for removing shims, Axial play = 0. 15 - 0.25 mm, Wheel hub removal Pull hub cap (4) from wheel. Remove locking bolts (1) securing thrust washer (5). Next, remove thrust washer (5) together with roll pin (6). Remove the her race (2) of outer taper roller bearing from the end of the axle and withdraw the wheel hub (7), Wheel hub installation. When installing the wheel hub (7) tighten the hex head locking bolt (1) while rotating the wheel hub. Torque loading: MA = 22.6 Nm. ‘Secure locking bolt (1) with Loctite 242. Prior to assembly, apply grease between inner race and cage of taper roller bearing, ‘Only inner and outer races (2) of same make should be used. When installing the wheel bearings, the correspond- ing bearings spaces must be repacked with grease as shown in figure (3). Before re-assembling the hub, carefully grease the sealing lip of the sealing ring (8). Grade of lubricant to be used: Lithium soap based grease. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) - Workshop Manual_R 7011(R 7031, R 7001) 02 02 Trail/Steer Axle i- Workshop Manual_R 7011(R 7031, R 7001) 02 Trail/Steer Axle Setting both steering angles ‘The wheel lock is limited by the stop screw (1). Note: Ensure that the wheel lockis limited by the stop screw and not by the cylinder stroke, and that there is suf- ficient clearance between the piston rod and the stub axle. Checking the steering angles The steering angle 4 must amount to 80° -82°, see figure, To facilitate the measurement use the com- plementary angle B for the setting. It should amount 0 98° - 100°, Greasing the stub axle bearings Operate the linkage during greasing Note: In order to ensure that the bearings are sufficiently greased, the axle must not be off load, i.e. the truck should not be chocked up. Rechtakurve QL , of = 80% 82°Lenkanschiag 30° - 82° steering lock © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 03 AS- Workshop Manual_R 7011(R 7031, R 7001) 02 Trail/Steer Axle Stub axle king pin bearings Removal: 7 Remove grub screw (1), RS Using a chisel (or similar too}) open needle bearing at the top of the king pin. 7; Ye on Drive king pin down, forcing out bearing at the bottom of the king pin. ‘Then drive out king pin in the opposite direction. Installation: Pack lower bearing (6) wth grease, sparingly apply it 4 loctite grade 270 to the outside, and press it into its bore until fush Install oil seal (2) ‘The sealing lip must point away from the bearing Install stub axle with thrust bearing (3) into axle beam. ‘Compensate for any play by adding shims (4) Max. permissible axial play = 0.1 mm. Grease shims and machined surfaces. 2 Install oil seal (5). The sealing lip must point away from the bearing Install stub axle king pin and lock with grub .screw 1). Install grub screw (1), with thin coating of loctite grade 242, Pack upper bearing (7) with grease, sparingly apply loctite grade 270 to the outside, and press iti. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 04 ASTrail/Steer Axle Track rod and steer cylinder bearing at stub axle jounting/steer cylinder ease nipple Track rod bearing on steering bell crank .earing inserted with Loctite 270 steering bell crank © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 )Detail ‘Ww’ Steer cylinder mounting at axle beam snap ting roll pin filister head cap screw (Secured with Loctite) washer oil seal ball joint ll seal pin Press force: 68 KN at the maximum Detail “Y” Bellcrank mounting 1 = locking ring 2= washer needle bearing pin oil seal shim (quantity as required) 7 = washer (must always be fitted) 8 = grease nipple = snap ring Press- force: 42 kN at the maximum © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 06R7011(R 7031, R 7001). 03 Technical Data for Maintenance Service ~ Workshop Manual Power Axle Torque loading Power axle mounting bolts 195 Nm Torque loading ‘Axle housing mounting bolts 120 Nm Axial clearance Hollow shat: 0.05 mm at the maximum Axial clearance Wheel hub: 0.07 mm pre-load - Axial clearance Wheel hub: 0.21 mm slackness Grade of grease lithium soap based grease Torque loading Wheel hub/Slotted nut 180+20 Nm Gearbox oil Capacity: approx. 2 litres Grade SAE - 80 MIL = L- 2108 API-GL4 © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) on ASPower Axle Description The power axle consists of a double reduction The long axle housing (3) with the double sspur-type gearbox (1) comprising differential assem- reduction spur-type gearbox (1) are rigidly bolted to bly with two-bearing driving pinion, to which a D.C. the frame as a complete unit. electric motor (2) is flange mounted, as well as of @ long axle housing (3) and an axle housing which is, an integral part of the gear case (1) © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 02Power Axle Double reduction gear and differential © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 )"Workshop Manual_R 7014(R 7031, R 7001) 03 Power Axle = gear case with integral axle housing 3 = cylindrical pin 4=Allen head screw 5= sealing ring 6 = screw plug (oil drain plug) 7= grooved ball bearing 8=differential 9 10 1" 12 19= taper roller bearing jothed hallow shaft "ring seal him 0.1, 0.3, 0.5, 1mm ing Y ring seal © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 05 aAxle housing installation Clean contact areas of gear case and axle housing Provide ‘©’ ring seal (2) with a smear of grease and place it on the recess of the axle housing (3). Next, assemble the axle housing with the gear case Apply loctite grade 270 to the 12 screws (4) and torque to 120 Nm. © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 06_ Workshop Manual_R 7011(R 7031, R 7001) 03 Power Axle Half -shaft removal = Jack up truck securely from one side, otherwise Half -shaft installation drain gearbox oil Clean sealing surface of half-shaft (7) and apply - Remove wheel nuts loctite grade 573 to sealing surface ~ Remove drive wheel Install shaft (7) - Remove screws (10) securing shaft (7) to hub. Us- Torque shaft mounting screws to MA = 35 Nm ing two of the screws drive out the half shaft (7) Replace drive wheel. Watch for correct align- ‘Two appropriate tapholes exist in the shaft flange ment of holes for wheel brake adjustment = Remove shaft (7) Torque wheel nuts to 195 Nm Note: When carrying out repairs or maintenance operations on the half-shafts remove only one at a time. Reason: Should both half-shafts (long and short shafts) be removed at the same time, the position ofthe halt-shaft location inside the diferential will be modified, making half-shaft installation impos- sible Jack down the truck Check half -shaft for leaks © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) o7Wheel hub removal ~ Jack up truck securely from one side (otherwise drain gearbox) - Remove half-shaft as described in section ‘Half -shaft removal’, page 9 ~ Remove brake drum (5) ~ Remove slotted nut (1) = Remove washer (2) Important: Note the position of the washer which is may be tured off at one side = Place fiting tool (self-made tool - see figure) into axle housing, and using a puller, pull wheel hub from axle housing. ~ Inner race (8) of bearing can now be withdrawn from axle housing using puller. Power Axle 4 —t- 1B | ee 4 © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 )"Workshop Manual_ R 7014(R 7031, R 7001) 03 Wheel hub installation = Thouroughly clean wheel hub ~ Press both taper roller bearings complete only into whee! hub. | - In the event of repairs of maintenance work on the wheel hub the taper roller bearings must always be replaced with new ones comprising a sealing ring @). Note: ‘The taper roller bearings are provided with sealing rings which are installed at the factory with a special device. The taper roller bearings should therefore never be disassembled ~ Check grease filing of bearings, repack with grease if necessary. Grade of lubricant to be used: lithium soap based grease ~ Position wheel hub on axle housing - Place fitting tool (self-made tool - see figure) on ‘outer bearing, and using a twoarmed claw puller or extractor slide hub with taper roller bearings on axle housing (puller claws behind brake anchor plate) Note: Do not hit or apply blows with a hammer, otherwise the sealing rings could fall off their locations, ~ Fit washer (2) to axle housing (watch for correct fitting position) ~ Install new slotted nut and torque to 180+20 Nin ~ Install brake drum (hole for wheel brake adjustment should align_with opening in wheel hub) ~ Axial clearance betw een 0.07 mm preloaded and 0.21 mm slackness ~ Install half -shaft (seepage 9) © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 09 ee.- Workshop Manual_ R 7011(R 7031, R 7001) 03 Replacing the shaft sealing ring | Remove the wheel nuts of the LH front wheel and pull wheel from the lift truck, By passing an Allen key through a hole in the frame loosen and remove screws securing tachogenerator to axle gearbox. Remove tachogenerator together with driving dog, Using a drawing point or similar too! remove shaft sealing ring (1) by pulling it in your direction, Apply grease to new shaft sealing ring (1)-see sketch, Lightly lubricate the borehole with oil. Install shaft sealing ring (1) into the borehole provided to this end, and using a guide tube (see tool assem- bly drawing below) bring it into its correct position Note: Check driving dog (2) in hollow shaft (3) for correct press -in depth (15 mm) and truth, Refit driving dog and tachogenerator. Refer to Func- tional Group 08 “Tachogenerator’ Install the front wheel in reverse order of removal, Torque wheel nuts to 195 Nm. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 09 AS~ Workshop Manual R.7014(R 7031, R 7001) ‘Synoptical Table on Tyres Pneumatic tyres front front rear Size Trackimm 18x7-8IC 11 16PRSTD. 897 16x6-8 18x7-81C 1 166-8 10PRSTD. 882 16PR 907 10PR 882 Superelastic (puncture- proof) tyres front rear front rear front rear front rear * Overall lowered height 18x7-8DIN 16x6-8 DIN 18x7-8DIN 16x6-8 DIN 18x7-8SIT 16x6-8 SIT 18x7-8SIT 16x6-8 SIT 807 882 997 882 807 882 997 882 Ball seat nut: Torque loading = 195 or 210 Nm © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) o1 Mast Tele Hi-Lo Triple Tele Triple Tee Hi-Lo Triple Tee Triple Tee Hi-Lo Triple Tee Triple 04 Wheels and Tyres OLH* 2731 1931. 2731 1931 2731 1931 mm 2730 2530 1930 3230 3230 2730 2530 1930 3230 3230 2730 2530 1930 3230 3230 i- Workshop Manual_R 7011(R 7031, R 7001) 04 Pneumatic tyred wheel 1-6= Tyres frontAB. ap As isk wheel without rings ide ring X 11-16 = Tyres rear AB 11-13 = Tyre, COMPL. 16x6-8 10PR 12 Note: ‘Where the axie is fitted with spacers, ball seat type wheel nuts on spacer must be checked for correct, torque at regular intervals to which end itis necessary to remove the wheels, Torque loadings Ball seat type whee! nuts front and rear M14x1.5 MA: 195 Nm Ball seat type wheel bolts (for increased track width) M 14x24 Grade 10.9 MA: 195 Nm. Important: ‘Torque loadings for ball seat type wheel nuts/bolts: 1) without aftertreatment (black nuts/bolts) 210Nm 2) galvanically aftertreated (bright nuts/bolts) 195Nm © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 02 AS- Workshop Manual_R 7011(R 7031, R 7001) 04 Superolastic tyred wheel with lock rings yres front AB Superelastic tyre 18x7-8 Disk wheel without rings Side ring Lock ring Ball seat nut 6 = Spacer B Ball seat bolt B 10- 13 = Tyres rear AB 10 = Superelastic tyre 16x6-8 11 = Disk wheel without rings 12 = Side ring 13 = Lock ring Note: ‘Where the axle is fitted with spacers, ball seat type wheel nuts on spacer must be checked for correct, torque at regular intervals to which end it is neces- sary to remove the wheels! Torque loadings Ball seat nuts front and rear M 14x 1.5 MA: 195 Nm Ball seat bolts (for increased track width) M 14x 24 Grade 10.9 MA: 195 Nm Important: Torque loadings for ball seat nuts/bolts: 41) without aftertreatment (black nuts/bolts) 210 Nm 2) galvanically aftertreated (bright nuts/bolts) 195 Nm © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 03 AS- Workshop Manual_R 7011(R 7031, R 7001) 04 Superelastic tyred wheel without lock rings 'yres front AB Superelastic tyre 18x7-8 Disk wheel without rings Ball seat nut Spacer Ball seat bolt 10- 11 = Tyres rear AB uperelastic tyre 16x6-8 isk wheel without rings Note: Where the axle is fitted with spacers, ball seat type wheel nuts on spacer must be checked for correct torque at regular intervals to which end itis necessary to remove the wheels! Torque loadings Ball seat nuts front and rear M 14x 115 MA; 195 Nm Ball seat bolts (for M 14x 24 Grade 10.9 MA: 195 Nm \ereased track width) Important: Torque loadings for ball seat nuts/bolts: 1) without aftertreatment (black nuts/bolts) 210 Nm 2) galvanically aftertreated (bright nuts/bolts) 195 Nm © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 04 AS| Workshop Manual_R 7014(R 7031, R 7001) 06 Technical Data for Maintenance Service Steering pump Make Type Pump capacity Direction of rotation Hand pump (Steering wheel operated pump) Make Model Pump capacity Hydraulic pressure: Pressure relief valve ‘Shock cushioning valve Constant pressure when system is at rest Operating pressure is driven, and according to the size of the load Vebelt V-belt deftection © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) Bosch gear pump 8 om°/ round anti -clockwise (arrow on pump) Danfoss OSPC 100 ON 100 em*/round set to 90 bar 150 bar approx, 10 - 15 bar will vary according to the surface over which the truck SPZ 1250 LAZ DIN 7753 approx. 10 mm ot i- Workshop Manual_ R 7011(R 7031, R 7001) 06 Steering system Operation The hydrostatic power steering unit is a self -con- tained system operating independently of the hydrau- lic lifting and titing system. It incorporates a sepa- rate steering pump. There is no mechanical linkage between steering wheel and steering axle In the event of oil supply failure (e. g. defective starter, truck to be towed into workshop), the truck automati- cally reverts to emergency steering. The steering re- mains usable, but of course needs much more effort, Description of function with circuit diagram ower steering cylinder Steering unit ressure limiting valve shock cushioning valves = hoist pump Path of oil with steering in neutral position and en- gine running: ~ hydraulic tank (5) = steer pump (4) ~ steering unit (2) = power steering cylinder (1) Oil returning from power-steering cylinder through steering unit via. return line fiter (6) to tank. ‘The shock cushioning valves (2.2) (safety valves) pro- tect the steering system and the hoses against ex- cess pressure by road shock (e. g. truck strikes an obstruction such as a kerb, or drives over potholes. etc) © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 02 ASWorkshop Manual R 7011(R 7031, R 7001) Steering column adjustment Alter slackening the locking lever (anti-clockwise) the steering column rake can be adjusted within an an- gle of about 10 deg. To increase the tightness of the locking action, the locking lever must be pulled from the side against the spring pressure and turned anti-clockwise by about a quarter of a tum after which it should be engaged again. Hand pump ‘The steering wheel operated pump (2) is fixed to the steering column, Incorporated in the steering unit, the pressure limit. ing valve (3) and the shock cushioning valves are pre-set at the factory to the following values: Pressure limiting valve 90 bar Shock cushioning valves 150 bar ‘The settings should not be altered. A defective pump must be replaced with a new one. Pressure: Constant pressure when system is at rest: approx, 10 - 15 bar By - pass pressure: 90 bar Operating pressure: will vary according to the surface over which the tuck is driven, and according to the size of the load, © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 03Hand pump removal ~ Remove front and rear covers from steering column, Unplug connector and remove front cover with directional control switch, ~ Loosen steering column locking lever (2), unscrew bolt completely. Tilt steering wheel with steering column backwards. ~ Unscrew hydraulic connections T (tank) P (pump), L (LH connection), R (R H connection) and clearly mark them, ~ Loosen the four fixing screws (1) and remove the hand pump from under the shroud. Hand pump installation Install hand pumpin reverse order of removal. CAUTION: ‘The hydraulic lines that had been marked previously must always be re-connected to the same location, otherwise this could result in an accident! Repairs on the hand pump A defective hand pump must be replaced with a new one, © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) - Workshop Manual_R 7011(R 7031, R 7001)Steering pump drive Connected with the radiator fan (2), the pump (1) pro- viding hydraulic power for steering is driven by the generator shaft via a V -belt (3) Steering pump removal = Remove cooling air duct (5) = Disconnect hydraulic lines (4) = Unscrew V-belt tensioning lever (6) = Remove pump mounting bracket (7) from genera- tor end plate. (Loosen muffler pipe before unscrew- ing pump mounting bracket from generator end plate). ~ Remove pump bracket (7) with fan (2) and pump (). ~ Unscrew fan wheel (2) ~ Unscrew locating nut (8) of V-belt pulley (9) ~ Using a suitable puller, pull off V-belt pulley = Loosen the four fixing screws 0 0) securing the pump to the bracket and remove pump Steering pump installation Install steering pump in reverse order of removal. For V-belt tension adjustment refer to page 7 in this section © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 05Checking the oil pressure in the steering system Checking the oil pressure To check the oil pressure, connect a pressure gauge (1) to the feed line of the hydraulic steering cylinder (2) with an appropriate “T” fitting © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 06Workshop Manual__R 7014(R 7031, R 7001 06 \V- belt tension adjustment Loosen locking bolts (1) Loosen lock nut (3). Tension V- belt by means of tensioner (2) The tension is correct if bet can be depressed approx. 10 mm (see arrow). Tighten locking bolts and lock nut. V- belt replacement = Unhook tension spring (4.1) - Loosen bolted joint (4.2) = Remove cooling air duct (4) Unscrew tensioning lever (6). Disconnect hydraulic line (6) at steering pump (7). Atthis stage the V-belt can be removed and changed by passing it through the gap between loosened hydraulic connection (6) and hydraulic. pump (7), ‘Screw on tensioning lever (5), re-connect hydraulic line @) Replace cooling air duct (4). Note: New V-belts stretch excessively in the beginning. In order to forestall premature destruction of V-belts, due to slip, they should be retensioned after running engine for about 3060 minutes. © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) o7- Workshop Manual_ R 7011(R 7031, R 7001) 06 Power steer cylinder Power steer cylinder, location ‘The power steering cylinder is safely housed within the steering axle beam which provides full ~— protection, SN Steering cylinder removal ‘ > In order to disassemble the steering cylinder, the steer axle must first be removed. ew Operations to be performed AN 3 8 - Disconnect tubes from ftings on steering cylinder & | 6 4 - Slacken trail wheel nuts 1 1 ~ Chock up the truck Remove trail steer) wheels 4 A e Remove the 4M 18 cap screws which secure the 57 ‘axle mounting brackets to the counterweight. Pull steering axle assembly clear of machine 1 elbowsfitting Remove steering cylinder from trunnion (remove 2 hex nutM 16x 1.5 DIN 934 locking ring and washer) Torque to MA 180 Nm (secure with loctite 270) Reverse above procedure for assembly 3 piston 4° repairkitNo. 138727 Steering cylinder maintenance (packing & sealing rings) 5 piston. rod Unscrew piston rod (5) from eye end (8) (eyebolt). 6 __bush (head) Unscrew hydraulic pipe fiting (piston rod end) from 7 snapring cylinder. 8 — eyeend Remove snap ring (7) Pull out bush (head) (6) with piston (3) and piston rod (6), Replace the oil seals (4) Reverse above procedure to install cylinder. For the setting of the steering angle refer to Functional Group 02. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 08 AS| Workshop Manual_R 7014(R 7031, R 7001) 07 Technical Data for Maintenance Service Hydraulic servo-brake Maker Perrot Type Hydraulic servo-brake 170 x 40S Brake adjustment without drum Dia. 169.4 mm Effectiveness, handbrake 5-6 teeth of ratchet engaged Full braking action, handbrake 8-9 teeth of ratchet engaged Brake fluid 0.5 litres DOT 3/ DOT 4M 1L- W-B-680b SAE $ 1703 Clearance between rod and piston/master cylinder 1mm ‘Tuming out the brake drum on a lathe max. dia, 170.4 when using standard linings © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) on ASWorkshop Manual R 7011(R 7031, R 7001) 07 Construction Firmly bolted to the power axle beam of the truck, the brake is mounted to the brake backplate (27) forming an assembly with the support (25). Lined with brake linings of even length, the brake shoes (6 + 20) on one hand are retained against both sides (2 + 24) of the support by the tension of the tangentially arranged return or pull -off springs (7 + 19), on the other hand against the forked heads of the adjusting screws (13 + 17) of the adjuster unit (14), by the tension of pull-off spring (12). In axial direction the brake shoes are fixed in position by the leaf springs (8) and the pins (9). Wheel cylinder (1) is arranged below the support where it is protected against mechanical damage and thermal effects. Provided with forked heads the push rods (3 + 23) transfer the piston efforts to the brake shoes. Hydraulic Servo Brake For parking the truck the brake is provided with a mechanical additional control (handbrake/parking brake). The handbrake cable lever (10) is pivoted to the joint pin (4) which is riveted to the brake shoe web (6). The pressure member (21) is attached be- tween clearance (5) of cable lever and clearance (22) of the opposite brake shoe (20) Atits free end the cable lever is designed as a hook to which is attached the pulling bracket (11) of the cable (18) (encased in a protective steel sleeve), © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) i© STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) Workshop Manual R.7014(R 7031, R 7001) 07 Principle of Operation The pressure applied by the master cylinder to the brake fluid during braking is conveyed to the wheel cylinder (1) along pipes and via connection (26), whence itis transmitted to the push rods (3 + 24) via the pistons which are provided with seals. Since the effort on the wheel cylinder pistons is always equal both brake shoes are forced into contact with the brake drum. Upon rotation of the brake drum both brake shoes are then taken along, depending on the direction of rotation, whereby, for example, in the case of anticlockwise rotation brake shoe (6) with its head makes contact with point (2) of the support. The moment of reaction of brake shoe (20) is transferred to brake shoe (6) via the adjuster unit (14) to which are screwed the adjusting screws (13 + 17) which are fitted with r.h. and 1. h. threads. The procedure is reversed when the brake drum rotates clockwise. During anti-clockwise rotation of the brake drum total brake torque is absorbed at point (2) and at point (24) of the support during clockwise rotation. To park the ‘stopped truck the handbrake cable lever (10) is pulled in the direction of arrow via brake cable (18). Pres- ‘sure member (21) causes the brake shoes to make contact with the brake drum. Thus the braking proce- dure fully corresponds to that of the hydraulic brake operation. Adjustment Reliability and operation of a braking system are ef- fected by the adjusting means and correct shoe brake adjustment. Ba: adjustment is necessary 1) 2 when fitting the brakes when rezlining the brake shoes 3) when fitting new handbrake cables or re installing the cables after a repair 4) if adjustment of the brake had erroneously been carried out merely by operating on the adjusting nuts of the handbrake cables (to compensate for lining wear) ‘Should handbrake lever travel become excessive, the brake shoes must be re-adjusted 03 Hydraulic Servo Brake Adjustment without drum Adjustment with drum removed can be performed with the aid of a vernier caliper in which case the correct dimension is 169.4 mm over brake shoes. After this, refit the brake drum and adjust the parking brake by following the instructions under section “Hand (parking) brake adjustment” in this manual Basic adjustment is carried out as follows: 1. Chock up the truck 2. Remove wheels Release parking brake by pressing button and pushing lever completely forward Loosen both lock nuts of the brake cables at the head of the brake lever Using a screw-driver or similar tool, rotate ad- juster - accessible through an opening in the backplate (brake drum adjustment hole) - until shoes make contact with brake drum, this being noted by resistance when turning the drum by hand Next, back off adjuster by around 6 teeth to allow the drum to rotate freely Refer to section "Hand (parking) brake"Workshop Manual R 7011(R 7031, R 7001) Hand (parking) brake adjustment NOTE: Before adjusting the hand brake, the foot brake must be adjusted. 1, Release parking brake by,pressing button & push- ing lever down (lever must rest against dashboard cowling) 2. Check whether cable bushings seatproperly into their bearing block, just below the hand brake lever, and the opposits ends of the cables into their respective iocating holes on left- and right-hand brake backplates, 3. Adjust the nuts at the cable ends until the cable bushings j ust make contact with the underside of their bearing block, or there is a perceptible gap of 0.5 mm (Thus the free play at the brake shoe lever is compensated for) 4, Pull handbrake lever unti the 3rd tooth of ratchet is engaged. There must now be a drag on the brake shoes when the wheels are rotated by hand, Should, however, a somewhat higher re- sistance be felt on one of the wheel brakes, slacken the respective handbrake cable. 5. Braking must take effect the instant 5 to 6 teeth of ratchet are engaged, i.e. it should at this stage no longer be possible to rotate the wheels by hand. 6. Full braking action must be achieved when 8 to 9 teeth of ratchet are engaged. 7. After adjustment as outlined above, check that the brake cable ends protruding at the handbrake lever do not differ in height by more than 10 mm, otherwise it is an indication that the faults listed below exist: = Cable length wrong, ~ Wheel brakes have been adjusted so that theydeviate too much in diameter. = Due to one-sided dragging of handbrake, the difference has been compensated for by stretching one of the cables more than the other. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) General Remarks: Correct adjustment of the handbrake can be achieved only if service braking on each wheel is balanced, i e. the difference in braking power between one wheel brake and the other must not exceed 20 %. If the footbrake brakes unevenly, the handbrake should dis- play about the same percentage of uneven braking, Never attempt to adjust the handbrake evenly if the footbrake is out of adjustment. STHandbrake system 1 = Handbrake lever 2= Grp 3 = Push-button 4 = Spring 5 = Washer 6 = Thrust washer 7 = Lock washer 8 = Hox. nut M6 9 = Washer 10 = Brake cable, RH 11 = Brake cable, LH 125 Clp 13 = Hex hd screw MBxi6 8.8 14 = Spring ring (split lock washer) 48 = Switch 16 = Threaded plate 17 = Hex. hd screw MBx 16 18 = Spring washer © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 05 Hydraulic Servo Brake1 = Brake shoe, RH Brake shoe, LH 2 = Brake shoe 3 = Adjuster unit, manual 4= Return spring 5 = Washer 6=Pin 7 = Leaf spring 8 = Return spring 9 = Pressure member, RH Pressure member, LH 10 = Shackle 11 = Hex hd screw MBx10 8.8 12 = Plug 13 = Wheel eylinder 14 = Screw I. thread 15 = Sorew, th thread 16 = Spring washer 17 = Hex hd screw M6x25 8.8 © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) Hydraulic Servo Brake© STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R.7014(R 7031, R 7001) Workshop Manual 07 Master cylinder Linked to the brake pedal via a bell crank, the master cylinder is located behind the dashboard. Made of plastic material, the brake fluid reservoir (2) is directly positioned on the master cylinder so that brake fluid is always available, and pressure and/or volume compensation is achieved. ‘The air bleed hole in the reservoir cap (3) must aways. be open to allow brake fluid to flow into the master cylinder. The reservoir must always be filled with a sufficient quantity of brake fluid the level of which must be about 15 to 20 mm from the underside of the cap. Important Remarks: Never fillthe reservoir with mineral oil! ‘Only genuine brake fluid must be used! Hydraulic Servo Brake iWorkshop Manual Clearance between rod and piston ‘The hydraulic master cylinder is fitted with a protec- tive rubber boot (1) which prevents the entry of dirt and water. To allow the air contained in the rubber boot to es- cape when operating the master cylinder, the rubber boot has been provided with an air bleed hole, ‘When fitting the rubber boot the air bleed hole must always be directed downwards (see figure), otherwise water cannot drain out, R.7011(R 7031, R 7001 07 Hydraulic Braking System Result: 1. Formation of rust on master cylinder port which would cause damage to the secondary ‘cup (seal) and produce a loss of brake fluid. The master cylinder piston could freeze. fast in sub-zero temperatures. J Das Spiel an der Kolbenstange™—« Clearance between rod and piston cy \. Lufttoch airbleedhole A clearance of 1 mm is necessary between the pedal push-rod and master cylinder piston. ‘Tuming out the inside diameter of the brake drums on a lathe in the event of wear Turing out the brake drums on a lathe is permissi- ble in which case the inside diameter of the brake drum should following the machining operation not lose more than 0.2 to 0.25 % of its original thick- hess. In such a case it still is possible to use stand- ard brake linings of normal thickness. If in the event of a higher degree of brake drum wear (. i. scoring marks) more material is required to be removed from the inside surface of the brake drum, it is permissible to remove or tum off up to 0.75 % of © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) the inside diameter. In such a case it will be neces- sary to use oversize brake linings. Such oversize linings are, however, not available as replacement parts, oversize brake linings of a given make are procured on the local market (commercial type linings), the oversize brake lining thus procured must match the turn-off measure of the brake drum, i. e. the lining must if necessary be machined to obtain the thick- ness required. ST| Workshop Manual_R 7014(R 7031, R 7001) 07 Hydraulic Braking System = bracket (anchor plate) pedal assembly pedalpad spring bracket M6 hex nut washer joint thread bolt 18 hex nut 1&x35 hex hd screw washer 13 = MB hex nut DU bushing M12 hex nut = clevis pring pin (self-locking pin) master cylinder 8x30 hex hd screw 27 = cap screw tee fiting M6x35 hex hd screw 36 = screw plug © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 09 AS"Workshop Manual_R 7031(R 7011, R 7001) 08 Electrical System Parts Catalogue Contents, Designation Ref. No. Page Technical Data for Maintenance Service 1 Electrical system 2 Starter batteries ntmn2 089 5 Keys switch bt 086 7 Directional selection switch b2 sat 8 Start delay unit 37 621 8 Parking brake switch bt 08 7 Warning hom switch a9 o10 9 Waming hom nee cy 9 S-stage switch ‘Acceleration/deceleration a6 086 10 Brake switch, foot-operated brake a6 08 10 ‘Accelerator pedal transmitter 125 ost " Control Panel Assembly general 0812 16 =Relays 1,02,43,44 osi2 7 = Safety contactor, diode c26in22 0812 7 ~Power unit 36 0812 18 =P.c.b,, standard design 1200 osi2 2 =P. o.b., zero braking 200 osi2 2B Printed circuit board 1.200 with plug-in modules 200 - 25 -Fuses €2, €3, 64 0812 18 Electronic compensator wt os12 20 = Discharge resistor 21 0812 3 ~Current sensor 35 088 2 ~Tachogenerator mio - 13 Instrument panel, RH side general 088 33 ~Key switch (see above) bt E -Relay 14 086 Lights n73-hee 086 -Fuses e 1-6 086 - 5-stage switch (see above) 226 : - work hour meter a3 09 Circuit diagram/Schematic diagram Diagnostic instructions © STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994 ) a1 AST_ Workshop Manual R 7031(R 7011, R 7001) Technical Data for Maintenance Service Electronic SCR Drive Control (puise control system) ‘Siltronic R70) | ‘Accelerator pedal control transmitter potentiometer ‘Angle of rotation sensor, hydraulics Potentiometer Current draw: Travel speed reduction Electrical braking san sppox. 2008240 A Drive motor field excitation 12-35 A | Generator fel extation 0-16 A | Corentnivamate exer approxd00 A | Armatre votage 40-200 vets ‘Travel speed adjustable | ‘optional equipment rate of braking power can be selected by means of a 5:stage rotary switch Fuses for | Excitation (mot gen. feld) 350A | Preheating e2- 50A | Lighting control cwrcuit ed 16A | Power uit et 20ALTC Relays, auyiliary relays: 12 volts, 24 volts | Saty contactors 24 vols | Alternator ut 28 volis /55 A | Starter batteries nin ‘vos 44h | Excitation generator! motor field transistorized 24-volt power section Insulation resistance Electrical equipment (motor/generator circuit) Electrical machines 1000 ohms/ volt» — approx. 200 kohms 1000 ohms/ volt _ — _approx. 200 kohms Electrical protection, construction complying withVDE 0117, DIN 40050 Electical equipement: IP 23 © STILLGmbH Stand: 6/2003 ( Ersatz flr Stand: 8/1994 ) 03 AST."Workshop Manual_R 7031(R 7011, R 7001) 08 Electrical System m 1 Ge Tectrical system Electrical supply is by means of two 12-volt starter batteries which are connected in series. The truck is equipped with three electrical systems, General 1. Electrical system - IC engine The engine electrical system and also the electric starter operate on 12 volts. Both starter batteries are recharged via the 24-volt alternator, An electronic compensating device ensures that both batteries aways charge evenly. Cable connections comply with VIDE 0117. 2.Consisting of: 1 glow relay and 4 glow plugs the Glow Plug system operates on 12 volts. 3. Speed control ‘The speed control unit, the generator and the electric drive motor operate on 24 volts for excitation. Caution: Battery terminals or other electrical connections should never be disconnected while the engine is running. Failure to heed these precautions may result in deterioration of functional groups or electrical ‘equipment components, © STILLGmbH_ Stand: 6/2003 ( Ersatz far Stand: 8/1994 ) 04 The voltage supplied by the remotely excited d. c. generator will reach values varying from 0 to 200 voks, depending upon exciting current, engine rpm and load. Connections between d. c. generator and drive motor are the bipolar type, i.e. they are insulated from truck frame. Wiring is as follows: Main current motor! generator = VDE 0100. Contro! leads/excitation for electric motor, generator = VDE 0117. All control voltages are with negative against the body (frame), Testing the insulation resistance (earthing) ‘The insulation material used on industrial trucks must have a sufficiently high insulation resistance, Testing is only necessary in the motor/generator circuit. Check armature of both motor and generator and also the electrical connectors against the body. The resistance of the insulation must be at least 200 000 ohms. ‘The test should be carried out by applying adc voltage 0f500 volts at the minimum. The equipment used for checking for earthing must supply a current rating of at least 1 mA. ASTWorkshop Manual R 7031(R 7011 R 7001) 08 Electrical System a ‘Speed control This consists of: 1.Generator (remotely excited) m01 2.Electric motor (remotely excited) m2 3.Contactor support: with power unit and p.c.b.; safety contactor and relay ATravelsender 25 (accelerator pedal transmitter) 5.Current sensorn3s 6.Tachogeneratorm10 7 Direction control switch b2 8. Handbrake switch b21 9.0il pressure switch b86 on brake master cylinder 10. Altemator on 1. C. engine 11, 5-stage switch b36 for electrical braking characteristics adjustment Operation Aremotely excited d. c. generatoris mounted at the flywheel end of the M engine, and is connected to the drive motor by electric cables, The excitation of both machines is done through the power unit. Current regulation In the connecting cables between the two electrical machines there is connected a current sensor (n35), which serves to limit the maximum armature currents, ‘Speed regulation Operated by the accelerator pedal afield plate sensor, controlled by a magnet (hall effect transistor) gives out a voltage corresponding to the pedal position, Giving the travel speed required value. © STILLGmbH_ Stand: 6/2003 ( Ersatz far Stand: 8/1994 ) 05 Atachogenerator driven by the drive motor feeds in the actual value of travel speed in the form of a de, voltage. Required and actual values are compared in the p.c.b, (printed circuit board) and the desired speed is equalised. The travel speed is thus independent of whether travelling on the level or up and down inclines, ‘The regulation of the generator field is done in both directions, both travelling and braking. Thus a change of direction is also made across the generator field. Power regulation ‘The rpm of the engine is dependent on its loading, So that the rpm does not fall too low with heavy loading, there is a Required Value vs Actual Value comparison made between accelerator pedal voltage and alternator frequency. ‘The frequency of the alternator is a measure of the actual rpm of the engine, ‘The greatest fall off of rpm is 200 (i.e. 2750 + 50 rpm. = 200 rpm). Ata difference in rpm which depends on the engine characteristics, the power of the generator is regulated down via the power regulator. AST2 STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994} | Workshop Manual Generator field ‘The generator field is modulated from F1 to F2 or vice versa, depending upon whether forward or reverse is selected, and depending upon the load to which the drive is subjected. Maximum field current is attained {11 by depressing the accelerator pedal fully with truck jacked up, the foot brake being actuated at the same time. As the brake pedal is further depressed, the field current drops graudally due to the current or power limitation now becoming operative Example: The truck is moving in a forward direction on level ground. The field current flows from F2 to F1 Now the truckis driven up a gradient, accelerator pedal position remaining unchanged. As a result, the field current increases. On the gradient the accelerator pedal is released as a result of which the direction of ‘current flow through the field of the motoris reversed, whereas the armature current will circulate in the reverse direction at the same time in order to hold the truck on the gradient. R 7031(R 7011, R 7001) 08 Electrical System Motor field ‘The motor field is controlled only as a function of the armature voltage. ‘When the armature current varies from between 0 to approximately 100A, the field current will amount to about 7.5 amperes. As the armature current rises up 10 400A, the field current will linearly rise up to 25 A. ® Aeemerearenenanreiiesene® Serial execution from 1994 06Workshop Manual R 7031(R 7011, R 7001) Polarity of various voltages Polarity details are for travel Forwards’ Value in brackets are for travel ‘Backwards Electrical System Fl F2 scrmessarrananenaetemepet 2L35 -5,5 Volt Details: Generator; Voltage: 0 - 200 V Excitation current 0 - 16 A at 25 volts Drive motor: Excitation current 7.5A at J 35.0 A at J at 26 volts. 400 A ‘Tachogenerator: Voltage: 15 - 17 V with accelerator pedal being fully depressed Travel sender unit:Supply voltage: 10 V (approx.) Control voltage: (4.8 + 0.1 V) - (8.2. 0.1 V) (approx.) Current: generator-motor circuit 370 + 20 A max. 2 STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994} o7 = 0 amps. Armature current J, becomes more ve when accelerating fwds, and more -ve when accelerating backwards (= 0.4 volts per 100 A) EXCEPT: Excitation voltage (J - K) to drive motor. This always has the same polarity. ASTWorkshop Manual R 7031(R 7011, R 7001) Preparation for testing Before carrying out test: Disconnect connectors 1,3,4,6 of power unit u36 and p.c.b.u200 Testing the insulation resistance (earthing) After any repair work on electrical components and or electrical machines (generatoridrive motor) it will be necessary to test the insulation resistance before installation or putting the truck back into service again. The insulation material used on the truck must have a resistance of atleast 200.000 ohms (200 kohms) Testing against the body — figures 1, 2, 4 and § Testing armature against field winding —figures 3 and 6 Check armature and stator of both drive motor and generator and associated leads in the circuit. The test should be carried out by applying a d.c. voltage of 500 volts at the minimum. The megger used for checking for earthing must supply a current rating of at least 1 mA, 2 STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994} 08Workshop Manual R 7031(R 7011, R 7001) 08 Key switch, Hand (parking) brake switch Key switch bt The key switch is operated with a removable key preventing unauthorised use of the truck. Used for starting the diesel engine it is located on the RH section of the dash or instrument panel to Which its secured by a nut screwed on it. The starter or key switch has three positions: OF N'—START™ (key turned clockwise) ‘When released from the ,START™ position the key ‘switch will automatically return to the—-ON" position, ‘The key switch has three connections on its reverse’ 30/b1 (6 qmmlead) 50/b1 (6 qmm lead) 15/b1 (1.5 qmm lead) Sarting operation ‘The engine can only be started with directional control lever in neutral (see Direction Selection Switch b2). ‘The engine will not start unless around 2 seconds have elapsed after the starter has been operated (see Start Delay) Shutting down the engine Tum key to the--OFF*position. Key switch removal: See: Instrument Panel, Parking brake switch b24 Protected by a plastic shroud, the parking brake ‘switch is located at the right-hand side of the brake lever on a sheet- metal bracket to which itis secured by means of two screws. ‘The parking brake switch is actuated by a sheet-metal sector through which the brake cables pass. Upon releasing the parking brake the switch push rod is actuated by the actuator. Parking brake applied - switch open Parking brake released - switch closed Application of the parking brake operates the brake switch that cuts off the control voltage to safety contactor ¢26 which, in turn, cuts the traction circuit. Brake switch adjustment: The switch must be so adjusted, that the safety contactors caused to drop out the instant the parking brake is engaged beyond the 1st notch, Inspecting switch b21 Parking brake released: 41/021 - 4/b21 =continuity Parking brake applied: 1/021 - 4/b21 =no continuity 2 STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994} 09a Workshop Manual R 7031(R 7011, R 7001) 08 Start delay unit u37 ‘To avoid damage to starter and starting motor ring gear due to a faulty starting operation (hasty switching, loose connection in key switch etc.) the starting procedure is introduced with a delay. The starting procedure will be initiated only provided no open Circuit fault arises during the time delay. ‘Two seconds after the key has been tumed to the START position and the directional contro! switch b2 has been placed in neutral, the start delay unit will close the circuit between the battery and the start relay d4, Checking for proper operation Aid: 24 Vi21W test lamp 1 Disconnect both leads of the start delay unit from the electrical system. 2 Connect lead 1/1.37 to test lamp. 3 Connect lead 2u3/4u3 to positive terminal ofbattery at 4 Hold lead of test lamp against the negative (-) terminal of battery nthe test lamp must light after a time delay of around two seconds. 4 volt /21-35W 2 STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994} 10Workshop Manual R 7031(R 7011, R 7001) Warning horn switch b89 Closing upon being actuated, the foot-operated switch is mounted to the underside of the LH section of the floor plate. Removal Remove the mounting studs from the floor plate (accessible from below the leading edge of the floor plate), raise floor plate and disconnect L1 0 plug from ‘switch section mounted to the underside of the floor plate. Remove floor plate. Warning horn h89 ‘The waming hom is always mounted tothe LH section of the truck frame at height of front axle. To avoid disturbances to the electrical system it is wired in parallel with a capacitor for protection. ‘The waming hom operates on 12 volts. Hour meter The work hour meter g13 is operated only by the voltage supplied by the altemator u11. Itwill begin to register only provided the engine is running. (Hour meter designed for a voltage of 12-80 volts). 2 STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994} 1" ASTWorkshop Manual R 7031(R 7011, R 7001) 08 5-stage switch for electrical bral 5-stage switch b36 Acceleration/deceleration A5-stage rotary type selector switch b36 is located ‘on the dash or instrument panel. The corresponding ‘switching positions are displayed on a dial With the aid of this switch braking deceleration accomplished by releasing the accelerator pedal can be adapted to suit the operating conditions, ‘The values in the table below are achieved ifthe truck is braked out of full speed just by removing foot from the accelerator pedal (dynamic braking): Stage Run out distance 1 19-23 Meter 2 16-20 Meter 3 13-17 Meter 4 11-13 Meter 5 9-11 Meter Ifthe service brakes are used in addition (operation of brake pedal), braking power to stop the truck will correspond to stage 5, itrespective of brake switch position. The rate of acceleration of the truck - if the accelerator pedal is suddenly depressed - is determined by the switch position: ‘Stage 1 = moderate acceleration ‘Stage 5 = powerful acceleration The rotary switch can be tumed to a different position at any time - even while the truck is in motion. Electrical connection: (previous design) ‘Switch b36 is directly connected via connector L4 to P.c.b. u200 (printed circuit board) by means of two leads - in parallel o brake switch b86 (162/200, 262/ L200) Electrical connection: with plu .£.b. u200 in module ‘Switch b36 is separately connected via connector L4 to p.c.b, u200 (16Z/L-200, 262/ L200), and brake swith 86 to 26B/L200 and 308/200. ‘Switch removal To this end is necessary to first remove the dashboard, then carefully it off the protective cap on the rotary knob with the aid ofa knife. Loosen the nut exposed at this stage and withdraw the rotary knob from the shaft. Next, loosen nut of switch shaft and clear switch of instrument panel by pulling it downward, © STILLGmbH Stand: 6/2003 ( Ersatz far Stand: 8/1994 ) 2 ig characteristics b36 Ce- Workshop Manual_R 7031(R 7011, R 7001) 08 Accelerator pedal transmitter Travel sender unit u25 ‘The travel sender (transmitter u25) is mounted to the underside of the RH section of the floor plate which is located on the front cow! by two studs. The function ofthe transmitting device is twofold: mechanical and electrical mechanical: ‘The pedal is inked via a lever to the injection pump. electri ‘Operation of the pedal causes a permanent magnet to move past a totally enclosed field plate on transmitter u25. There is no physical contact between the magnet and the field plate (hall effect transistor) Linked to the accelerator, the transmitting device sends a pilot signal (which varies from about 4.5 -with pedal in neutral position - to 8.0 volts - maximum ‘output - depending on pedal position) into the logic unit (p. ©. b. u200) ‘The transmitter has been adjusted at the factory and should therefore not be dismantled! ‘The transmitter is connected via a 3-pole Econoseal" plug L25 to the p. c. b, u200: 1/u25 -D18/u200 (1/125) 21u25 - 224/200 (2/L25) 3/u25 - D28/u200 (3/25) Removal Unscrewed valve shroud, remove studs that locate the floor plate on the front cowl By loosening screw M6 disconnect linkage at pedal Disconnect plug L25 and lft out floor plate. ‘Two MB studs with nyloc nuts secure the transmitter to the underside of the floor plate. During assembly make sure that the gas throttle linkage at the pedal can move freely in the slotted hole! © STILLG@mbH Stand: 6/2003 ( Ereatz fur Stand: 8/1994.) 13- Workshop Manual_R 7031(R 7011, R 7001) 08 Current sensor 1 4 — B2/m01 oe A2im2 B2 Ope 2 | 3 (#20) ie Z L35 2 Current sensor n35 The current sensor in its function is similar to the hall effect transistor (field plate) that is dependent on the magnetic field. The effect the magnetic field has on the field plate varies according to the current flowing through the armature lead B2/m01 (generator) - A2/ m2 (motor) A voltage of around §.5 volts with armature current ‘amounting to zero is present at the centre connection = 2135 - of the field plate. If at this stage an armature current flows from generator to motor, the voltage at 2/n35 will vary at a rate of 0.4 volts per 100 A of armature current. Watch for correct direction of installation of the field plate (see above drawing) In cases of doubt pull off the protective cap from the protective tube and check the position of the control lead connections 1n35. 2in35 31n35 Voltage check against the negative(-) terminal of battery nt 21n35 - §.5 volts, 31n35- 10 to 11 volts The current sensor is connected directly to the u200 logic card and therefore has an effect on the power unit and the exciting current of the generator. © STILLGmbH_ Stand: 6/2003 ( Ersatz far Stand: 8/1994 ) 14 AST© STILLG@mbH Stand: 6/2003 ( Ereatz fur Stand: 8/1994.) 15 ~ Workshop Manual_R 7031(R 7011, R 7001) 08 Tachogenerator Tachogenerator m10 Be PN ‘The tachogenerator m10 is located on the gearbox sf 0S onthe Lifeide ofthe buck -onalevelwih heave | ~~ SS motor armature shaft i RN ‘The tachogenerator is coupled to the armature shaft ~~ aN by means of a diaphragm coupling, SN Lf y Mounted in a hermetically sealed injection moulded casing and fitted with a waterproof 'Econoseal’ plug a L11, the tachogenerator m10 supplies information to the p. ¢. b. (logic card) u200 on speed (rpm) and direction of rotation of the drive motor armature shaft (drive wheels). Removal Direct access to the tachogenerator is gained through ‘an appropriate aperture in the wheel arch of the LH front wheel, No need to remove the wheel Power to the tachogenerator pinion is transmitted via ‘a membrane type coupling which is inserted into the geared hollow shaft of the gearbox. After removal of the coupling for repair, first the ‘coupling must be inserted into the greasefree hollow shaft after which the tachogenerator can be installed During installation watch for correct alignment of the ‘coupling in the hollow shaft, Functional check (truck chocked up) Disconnect plug L11 Connect a voltmeter to 1/1L11 - 21L11 Turn drive wheel by hand (lock 2nd wheel) The voltage will steadily increase proportional to the rotation (around 5 volts). Forwards 1/L11 (-), 2IL11 (+) Backwards 1/L11 (+), 21- Workshop Manual_R 7031(R 7011, R 7001) 08 Alternator Alternator / Vee belt The alternator fulfils two separate tasks in the truck. 1. Charging both 12-volt batteries. Exciting the drive and generator fields. ‘The charging function is indicated via the charge lamp) 2. The indirect r. p. m. measurement of the engine. ‘The ratio of alternator to engine r. p.m. is constant. ‘The pulsing d. c. voltage (frequency) taken at the W-connector of the alternator is fed to the p. c. b With heavy loading of the engine its r. p. m. drops. and thus the frequency at connection W, ‘The modulation of the generator field is reduced the instant the frequency drops below a minimum. level. From this moment on no heavier loading can arise at the engine, ‘The result is: - The speed of the engine will not fall to more than 200 r. p. m. (the installation goes into ---stall-or speed droop). If the ratio of alternator to engine r. p. m. alters through: a) excessive slip of V belt b) defective vee belt ©} loose alternator 4d) defective alternator this leads to a false reading of engine r. p. m. There ensues a drop off in modulation for the generator field and problems with the driving characteristics of the truck © STILLGmbH_ Stand: 6/2003 ( Ersatz far Stand: 8/1994 ) 16 ASTWorkshop Manual R 7031(R 7011, R 7001) Starter batteries n1/n2 12 Vida A ‘Two starter batteries nt and n2 respectively are ‘accommodated in the rear truck compartment. The battery terminals are fitted with screwed connections (M6). Connected in series giving 24 volts together both batteries supply electrical power to the control circuit for the relays, key switch tured on, engine stopped A 12-volt lead extending from the positive side (+) of battery nil feeds both the glow plug system and the starter (12 volts) Due to the uneven battery drain during starting, an electronic compensator automatically compensates for the difference in battery state of charge. Note: It is not permissible to provide for an additional number of 12-volt consumers for accessories, Unless you work in the mA range (meters ete.) Maintenance If the state of charge of both batteries is uneven refer to section ‘Electronic Compensator’ of this manual Disconnect both batteries before carrying out any repairs! Never disconnect battery cables with engine running, as otherwise alternator u11 and power unit may get destroyed. Batteries Measuring the specific gravity ‘The specific gravity is measured using an acidimeter. ‘The avidimeter consists of a glass barrel, a rubber ball for drawing the acid out from a cell, and a hydrometer whose scale permits direct reading of the specific gravity During the charging procedure it will last a certain time until proper balance is achieved between the acid above the plates and the acid between and in the plates. © STILLGmbH Stand: 6/2003 ( Ersatz far Stand: 8/1994 ) 7 Reading of the specific gravity should therefore not be taken before 30 minutes have elapsed after termination of the charge Always make sure that the hydrometer float moves freely in the glass barrel, ie. does not get struck or knock against the rubber ball Battery capacity varies with temperature A fully charged battery reaches full capacity at 2c. For each 1° C of reduction in temperature there is 1% of loss in capacity, i.e. at 0° C there is already a reduction in capacity of 27 %. In other, words, there remain only 73 % of the battery capacity originally available, CeWorkshop Manual Electrical Control Panel Assembly ‘The below listed electrical components for control and ‘switching of the drive are mounted on a common panel housed in the reartruck compartment. A plastic cover has been provided for additional protection. 26 safety contactor cn - relay/engine monitoring a - safely relay ag relay/charge warning light 38 preheatistart relay 2 - fuse/giow plug system 3 - fuseffield excitation a - fuse/relay ut electronic compensator a. discharge resistor we power unit u200 - .c.b. (logic unit) m2 - freewheel diode plus the following connectors: oes control leads ic glow plug/starter system i365 Power unit, control leads L200 - p.c. bdconnector 1-Tlu36_- screwed connection/power unit Removal The control panel can be raised clear of the counterweight after loosening screw (1). Unscrew screws (2), (3), (4) and (5) and pull off the plastic cover from the top - all components are now readily accessible for inspection and servicing, Disconnect the negative terminals from nt and n2 batteries before carrying out any repairs! Reassembly is a reversal of the above procedure. ‘When lowering the control panel make certain that the guide slot at the bottom comes to rest on bolt ©. © STILL GmbH Stand: 6/2003 ( Ersatz far Stand: 8/1994.) R 7031(R 7011, R 7001). Contactor support or control panel 18Workshop Manual Safety contactor c26 ‘switches on the current for both motor and generator field excitation. Fitted to the contactor, diode n22 is connected in parallel with contact of ¢26. It acts as treewheeling" diode when the contact is opened, Diodes of different design are fitted. Relay d1/24 volts serves to monitor the engine. 1 pulls in on key switch ‘ON’ position (d1 will remain closed as long as charge warning light h73 remains it) Contact 87a/d1 - 30/41 is open Safety contactor ¢26 is prevented from closing, After the engine is started - engine running -alternator 11 will supply voltage via terminal D+: h73 goes off d1 drops out - contact 87a/d1 - 30/d1 will close - contactor c26 can pull in provided d2 is closed. Relay d2/24 volts pulls in if the fail-safe circuit (electronic sensing circuit) on p. ¢. b, u200 is reset (85id2- 6D/L200), Condition: Relay d1 must be in rest position (87a - 30/d1 closed) 2 via contact 30/d2 - 87/42 will cut out 26 if a fault ‘occurs in the electronic circuit Relay d3/12 volts is closed if key switch is turned to the ‘ON’ or ‘START position Ifthe engine is turned off - key switch to ‘OFF - d3 via contact 30/d3 - 8743: 1) will cutoff power top. c. b. u200, connection 8z/u200, 2) will cut off voltage to 86/d1 and 1/n73, h73 will light, d1 will pull in, cutting off control voltage to 86/d2 - 626 drops out - the electrical drive is cut out. Relay d4/12 volts (below dash panel) switches on the starter via 30/d4 - 87/d4 if key switch is turned to ‘START’ and direction contro! switch is in neutral position, and the time delaying the starting operation has elapsed (see page 11 NOTE: The coils of both relay d4 and safety contactor 626 are provided with a protective circuitry (n23, n24) © STILL GmbH Stand: 6/2003 ( Ersatz far Stand: 8/1994.) R 7031(R 7011, R 7001). 19 Relay, safety contactor feziuzo0 24 VOLT A K us i A DSA/17-124 BYX 6100 aT 30 A VOLT B @_ Workshop Manual_ R 7031(R 7011, R 7001) Power unit Incorporating two power control functions, the power unit u36 receives the control signals via the 6- pole L3 connector from p. c. b. 200. 1. Control of exciting current for field of drive motor m2. Junction F'1/m2 is connected via contact of ¢26 to +24 volts, Junction F2/m2 is connected in pulses to the ne- gative (-) terminal by the power transistors of u36 (1136 - 2/436). ‘The motor field is traversed by current in one direction only, ie. from F1 to F2. In the lower speed range of the engine a field current (basic current) of around 7,5 amps flows through the field coils of the drive motor, armature current amounting up to 100 amps. ‘When the armature current increases, the motor field current too will rise up to 30 amps at the maximum, 2. Control of exciting current for field of generator m01. ‘The generator field is connected tothe power unit across connections 3/u36 and 6/u36. The field a3 ft F2 current flows across 4136 (+) intothe powerunt, | cafpey across 3/436 and 6/436 through the generator eld and across s1us6 backttomine powerunttothe |*24V 3 m2 negative terminal of the battery. ‘The direction of curent low is reversed inside the power unit via a bridge circuit, depending on Position of directional control lever. ‘Thus the polar in the armature crcutis reversed ALS as a result of which the drive motor reverses ils direction of rotation. Note: ~ Batt Leads 5/u36 and 2/u36 must both be brought separately to negative battery terminal or negative junction. Do not interconnect leads 2/u36 - 5/436. ‘The power unitisfited with a semiconductor fuse el (20 amps) to protect the generator field against overloads, 11036: 236 Use only genuine fuses as per Parts Catalogue! No repairs should be carried out on the power unit © STILL GmbH Stand: 6/2003 ( Ersatz far Stand: 8/1994.) 20" Workshop Manual ‘The power unit actually ited as standard is available as installation kit for old R70-15 to 45 truck models. The conversion can be easily carried out by merely replacing the power unit and removing contactor 626 as the power unit of new design incorporates a safety reley c26, Once disconnected, all leads should be identified by a sticker ifthe original identification is no longer legible, Before starting the modification you are asked to carefully read the instructions and compare the truck design with the specifications and, where necessary, with the electrical circuit diagram. 1. With engine tured off, disconnect both starter batteries 2. Remove protective cover from contactor panel 3. Disconnect leads 1-7and connector L36 at. power unit, Install leads included in the kit. gos lead with lead 1/136 (1/L36 - 5/06, neg. battery) 5b. Join junction connector of insulation displa- cement connector fitted short lead with lead 8Z/L.200.(2/X8-8Z/L200, pos. battery) Sc. Join junction connector of insulation displa- ‘cement connector fitted long lead with shortened ead 7/u36 (sever ring terminal). (1X8 - 128/200) 6. Install new power unit, securing itn place using the 4 M6 screws. 7. Twist plug L36 180°, connecting it to power unit u36, 8. Plug insulation displacement connector into socket X8 of power unit. 9. Manually screw leads 1, 3, 4, 6/436 onto power unit, leads 2 and 5 together with lead coming from 1 /L36 (item 5) must be connected to connection 2/5 of power unit © STILL GmbH Stand: 6/2003 ( Ersatz far Stand: 8/1994.) Remove u200 logic card and power unit u36 Join junction connector of included lug fitted R.7034(R 7011, R.7001 24 08 Power unit 10. Disconnect all leads at contactor 26 and, if necessary, identify with a sticker. 11, Remove contactor c26 and diode n22. is the contactor panel fitted with an e3 designate-d power circuit fuse? ‘YES- continue with point 128 NO- continue with point 126, 2A Remove lead ale3 - 11026 13, Disconnect lead(s) b/e3 at fuse e3 and reconnect to connection E3b on power unit. 14, Remove fuse e3 15. Connectallthe other leads coming from 1/c26 to connection 1 AC26 on power unit. 16, Remove lead 18/¢26 - 4/u36. 17. Connectall the other leads coming from 18/¢26 to connection 4 on power unit. Continue with point 18. 2B Connect lead 1A/c26 - LS to connection E3b on power unit 13, Connect allthe other leads coming from 1/c26 to connection 1AC26,on power unit. 14, Remove lead 18/¢26 - 4/u36. 15. Connectall the other leads coming from 1B/c26 to connection 4 on power unit. Continue with point 18. 78. Connect lead a/c26 to connection ¢26a on power unit, 19. Lead(s) b/c26: 19a.Diesel powered mode: If only one single lead is, connected, remove the lead, 19b LPG powered model: Iftwo leads are connected! 41) Disconnect lead at relay d3, 2) connect lead coming from 5/u21 to connection 2/5 on power unit, orjoin both leads together, insulating them, 20, Tighten ail lead connections. 21. Check that p.c.b. u200 is firmly seated on ‘module, inspect for any damage, connect p.c.b. to L200 base socket and fit to power unit Recheck all electrical components and leads Wires for tightness and restore truck to normal operation. CARRY OUTA TESTDRIVE. AST~ Workshop Manual_R.7034(R 7011, R 7001 08 Printed circuit board u200 with plug-in modules Printed curcuit board u200 2 ‘Supporting block for zero, braking’ MODULE, Multi-socket connector block for ‘zero braking’ MODULE ‘Zero braking’ MODULE, Connector block for MODULE Variable MODULE Position mark. Connector block ‘Speed limitation potentiometer ‘Supporting block for MODULE = QDOO®© QOOO © OO 4) Screw for locking MODULE in place © STILL GmbH. Stand: 6/2003 ( Ersatz far Stand: 8/1994.) 22 Ct —R 7031(R 7011, R 7001). 08 Printed curcuit board with plug-in modules ~ Workshop Manual Teck ode Pied cro board wih pgin mode cope over are woDuLE wopuLe | Teva sfeesieergnems’ | sesetoad | “tacon | pos | “bo | speed (rpm) function braking limitation rooiror | 129072800 «160 A 7002703 Tooarosros | vatoraeso vis | vee | soteoo rouern7er | sop 2750 «150 | goroee s20008 1o00-90/200760 «150 es0eat 1250+30/-20/2750 +1-50 148998 so0090/ 207780 80 sesr70 7002703744 T gop 2580 80 > 7o0470sr08 | ev07sec0 «150 | tavete | serean | A | szomo8 7012718724 | soo zes0 «50 | cores 8 Tots n0 23 ¢ © STILL GmbH Stand: 6/2003 ( Ersatz far Stand: 8/1994.) 23, AST"Workshop Manual_R 7034(R 7011, R 7001 08 P.c. b. u200 P.c.b, u200 The p.c. b. u200 is secured to the power circuit with 6 screws and connected at its lower end via a 2x24 pin DIN connector to the electrical system The p. c. b. records all the information necessary for the driving operation, converting this information into drive signals which are transmitted via power unit u36 to motor and generator fields in the form of an exciting current. ‘The p. c.b. receives and compares information from, the following components and functional groups of the electrical system: 1 Directional control switch b2 - FORWARDS - NEUTRAL - REVERSE 2. Travel sender (accelerator transmitter) u25 - controlling truck speed when pedal is depressed for creep, higher or maximum speed 2.1. Travel sender u25 - dynamic braking (achieved by letting up on or removing the foot from the pedal) as a function of 3. brake switch b36 which governs the braking power via 5 stages 4, Current sensor n36 - rate of armature current (drive power) (comparing it with accelerator transmitter) 5, Tachogenerator m10 - sensing voltage 5.1. Direction of rotation of drive wheels (polarity of voltage) 5.2. Speed (rpm) of drive wheels (rate of voltage) 5.3. Motion and direction of motion when stopping the truck on an up or down grade 6. ‘W' connector of alternator u11, frequency indication, depending on engine rpm 7. Ifthereis an unbalance between any of the above mentioned information, the drive is regulated accordingly, relieved of load if necessary (speed droop) in order to prevent stalling of engine, f.i ‘when operating on a far too steep gradient. The truck will come to a complete stop without causing the engine to get stalled, even with accelerator pedal fully depressed, 8. Inthe event of damage to circuit components / open circuit the fail-safe circuit on the p.c. b. will become operative, cutting off via relay c12 powerto the field excitation, as a resu It of which safety contactor 26 will be caused to open (see ‘Start delay’) © STILL GmbH. Stand: 6/2003 ( Ersatz for Stand: 8/1904.) 24- Workshop Manual_R 7031(R 7011, R 7001) Printed circuit board u200 with plug-in modules Standard design The printed circuit board with plug-in type module is a further development of the previously used p.c.b. designs. From the outside the p.c.b. can be identified by multipolar sockets for plugging in various MODU- LES. Only one p.c.b. will henceforth be required for all truck models in this range. Adapting the p.c.b. to the relevant truck model is made by simply plugging in a MODULE. Each MODULE can be plugged in four different positions - identified on each comer by the letters A-D. ‘The required position can be determined by consulting the table; the comesponding code letter must always appear above the symbol © STILL GmbH. Stand: 6/2003 ( Ersatz for Stand: 8/1904.) 25R.7034(R 7011, R 7001) 08 ~ Workshop Manual P.c.b. u200 Printed circuit board u200 with plug-in modules Plugging in or changing MODULES MODULE should never be plugged in or chang inless the p.c.b. has first been removed. By rotating the tommy screw a 1/4 of a turn in a clockwise direction (Fig. 1), the splittype support is, spread apart, causing the MODULE to get locked in place. Rotating the tommy screw a 1/4 of a turn in an anti-clockwise direction (Fig. 2) causes the MODU- LE to get unlocked When plugging in the MODULE make sure all pins are straight and fitted in their respective sockets. it is only then that the MODULE must be pressed into the connector by exerting a moderate pressure with both thumbs, at the same time turning the tommy as, screw (Fig. 3). ¢ * i oe = j Ay KN ‘To pull outthe MODULE, insert yourindex and middle fingers under the edge of the MODULE and withdraw the MODULE, simultaneously pressing with both thumbs against the tommy screw (Fig. 4). © STILL GmbH. Stand: 6/2003 ( Ersatz for Stand: 8/1904.) 28Workshop Manual Printed circuit board u200 with plug-in modules ‘The technical advantages provided by the p.c.b. with plug-in module become evident when the truck is operating under arduous conditions. Here are some typical examples: ~ Abrupt braking: The vehicle will come to a smooth stop. ~ Stopping the truck on a gradient with a load on the forks: The truck will come to a smooth stop. ~ Abrupt reversal of he directional control (plugging) while the truck is travelling at top speed! The truck will smoothly decelerate and then gradually reaccelerate in the opposite direction in a continuous motion - Powerful electrical braking effect even ifthe foot brake is operated only to a small degree. Completely smooth acceleration from standstill to maximum speed even if the operator should jam the accelerator pedal to the floor. ‘The truck can be adjusted for maximum, speed of travel. Creep: potentiometerR 112 (Current limit level: potentiometer R 120 Travel speed limitation: potentiometer R 31 15 volts = 22 km/h, By means of the infinitely variable potentiometer R31 the truck's maximum speed can be pre-set at a lower rate’. To pre-set the truck’s speed at the permissible maximumrate, measu re vo Itage at m 10 tacho- generator terminals (30D/L200 - 22Z/L.200) \Mth truck jacked up) and adjust potentiometer R31 to obtain a voltmeter reading of 15 volts which corresponds to a travel speed of 22 km/h. CAUTION: Never set voltage to a rating higher than 15 volts Risk of accidents! © STILL GmbH. Stand: 6/2003 ( Ersatz for Stand: 8/1904.) R_7034(R 7011, R 7001) 27 R120 R112 R 31 Ce_ Workshop Manual_R 7031(R 7011, R 7001) 08 P.c.b. u200 ZERO BRAKING MODULE 4 [Before plugging in or withdrawing a MODULE, rem lp.c.b. u200 ‘Transforming the p.c.b. u200 into a design with ZERO BRAKING is possible whenever required by plugging in the ZERO BRAKING MODULE. This function can at any time be cancelled by simply removing the MODULE. MopuUL, ADJUSTMENT2 (1) Potentiometer controlling the ‘markspace’ ratio. (lured to the extreme right) By turning the potentiometer to the left the acceleration can be delayed, (2) Potentiometer controlling the braking current (lumed to the extreme right) By turing the potentiometer counter clockwise the braking deceleration can be varied to suit the requirements. Plugging operations are possible provided the accelerator pedal is recycled after the direction of travel has been changed, The degree of plug braking depends on the setting of the 5-stage switch b36. ‘With accelerator pedal unoperated the truck will not hold on a ramp. [To hold the truck on a ramp it is necessary to apph he parking brake or use the service brakes. 2 STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994} 31- Workshop Manual Electronic charge compensating circuit u21 Operation ‘The truck is fitted with 2 batteries connected in series. that are both charged by the 24-volt alternator ull Since 12-volt consumers are being employed, the batteries are subjected to uneven loads. The load, and hence the drain on battery nt is much higher ‘compared to the load placed on battery n2 and this, in view of starter motor u12 and auxiliary equipment such as ignition and injection systems. As a resutt. the voltage at the terminals of battery nl will become lower compared to the voltage at terminals of battery n2. ‘The function of the electronic charge compensating circuits to measure the difference in voltage between both batteries, at the same time feeding electrical power from battery n2 into battery nl The trans-charge current amounts to 11 amps at the maximum. The green LED (light-emitting diode) will light immediately charging current flow occurs from n2 to m1 Two line fuses (3) provide protection against excessively high currents in the event of a fault or possible damage caused by a reversal of the polarity across the battery connections, Breaking of fuse circuit is signalled by lighting of red LED (item 2) The fuses are soldered into the electronic card, Only original fuses Part No 523914 must be used as replacement parts. Fitting Mounted on a angular support, the p.c.b. is bolted vertically to the contactor panel close to the power unit. The electronic charge compensating circuit is connected directly via a 6-position connector to the batteries. Arranged in parallel, two leads each . are connected to one battery terminal - one of the leads conducting the charging current, whereas the other lead is used for measuring the current intensity. All six connections must absolutely be connected to the batteries. ‘Sequence of connections: Nint -4/L21 £ Ovolt test line Nint -51L21 —£0volt Pint Nin2 -21L21 #12 volts test line Pint Nin2 -3/L21 #12volts Pind -121 #24 volts test line Pind -6/L21 #24 volts 2 STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994} R 7031(R 7011, R 7001) 32 Electronic charge compensator L21 Ce2 STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994} Workshop Manual R 7031(R 7011, R 7001) 08 Retrofitting to older model trucks equipped with the old style electronic compensator (balance) Removal With starter batteries disconnected: Remove old style compensator u21 = Slacken screws maintaining fuse box e2/e3 and pre-glow relay d88 -Either remove connector L21 complete with leads or safeguard it against reuse by appropriate measures - If ited, remove double diode n211 with leads/isolate the leads Installation (installation kit 148522) (Refer to Parts Catalogue 7031, 0812) Fit fuse box and relay to mounting bracket -In place of the old style compensator fit new electronic charge compensator and mounting bracket -Route cable harness in truck and connect to batteries, ‘Sequence of connections: Electronic charge compensator Before connecting connector L21 to the electronic charge compensating circu: Check that the state of charge of both batteries is, equal. Recharge ordischarge the relevant battery as, necessary until the same charge level is reached ‘Once the connection is made: pre-heat or start engine then tum it off again. Check for proper function - green LED must light up. Important remarks Repair Before carrying out any repairs on the truck requiring the disconnection of battery terminal connections: Always first disconnect connector L21 from the circuit, with keyswitch bl tured off. Then disconnect the leads from the batteries, After any repairto the electrical installation reconnect the batteries first (cheek battery state of charge as instructed above) then connect connector L21 with the circuit Nint -4iL21 £0 voltttest line Nint -5IL21 £0 volt Pint Nin2 -2/L21 +12 volts test line Watch for correct polarity! Pint Nin2 -3/L21 #12 volts Pina -121 +24 volts test ine Pina -6/L21 +24 volts HHH srr scene_ Workshop Manual_R 7031(R 7011, R 7001) 08 Electronic compensator u2 ischarge resistor r21 The truck is fitted with two 12-volt/44 An starter batteries The electric control system of the truck operates on 24 volts. ‘The glow plug and starter system, however, operates on 12 volts and is supplied with electrical power by batieryn1 As a result current drain and state of charge vary {rom one battery (n1) to the other (n2). The electronic ‘compensator (balance) u21 compensates for this difference, ensuring that both batteries charge evenly: ~ Battery n1 is monitored - Battery n2 is discharged when necessary (this, procedure is never reversed). Operation: The electronic compensator compares the voltages of batteries n1 and n2. If current is drawn from nt (starting operation) thevoltage will drop: Voltage of n1 is inferior so that of n2. Discharge resistors immediately connected to battery n2, discharging is until the state of charge of both batteries is equal This operation is terminated the instant the voltage of 11 rises again (after starting) or if n2 has been sufficiently discharged. ‘The discharge current amounts to around 2.5 amps and is pulsated at a rate of a few cycles per second (ow frequency). Check: Connect voltmeter leads to terminals 1 and 2 of discharge resistor 121 (12 volts). Start engine, turing it off again immediately. The instrument dial now displays a pulsating voltage of around 9 to 12, voltswhich gradually fades until volts are reached, Resistor is noticeably heated. Inthe event of a malfunction 24 1 1) Check state of charge and voltage of ‘a2 u2 batteries, 2) Check battery connections for tightness, 3) inspect fuses on electornic card u2t (Ordering No. 510658) 4) Ifthe electronic compensator stil won't operate it should be replaced with a new one, WARNING: Never disconnect terminals of battery n1 alone, otherwise the electronic compensator will continue todischarge battery n2 untilits voltage has dropped tozero. refore: Aways asconned ihe negative terminal f both batteries before carrying out any repairs. 2 STILL GmbH Stand: 6/2003 ( Ersatz fur Stand: 8/1994} 34a Workshop Manual R 7031(R 7011, R 7001) 08 Instrument Panel 1 2 1413 9 1211 10 ‘Truck instruments and driving controls View of instrument panel 1 parking brake lever 8 water temperature - warning ight 2 Spinnerknob fitted steering wheel 9 brake fluid reservoir 3 engine ol pressure warning light 10 5-stage switch 4 air cleaner waming light 1 fuse box, RH side 5 low fuel waming light 12 work hour meter 8 charge waming ight 13 steering column locking lever = preheat 14 direction selector Bulbs for 12 V/2 W warning lights Fuse box = preheatiglow plug system d88/h88 preheat relay dee relays d3, 4 shut-off valve c20 fuel check h76 air cleaner check h78 = warning hom B&B BRERA \ Ly \| | 8/15 Atuse © STILL GmbH Stand: 6/2003 ( Ersatz fr Stand: 8/1994} 35 SrSrreeememtmeme ap meen Bale ea i u 200 required value integrator actual current value ‘motor field control circuit rpm regulator (current regulator) speed droop pulse width control circuit current supply circuit power unit control circuit monitoring circuit test points for connecting a diagnostic meter © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 36 DFG 7001-31 / 37 , 7041-43 Endstufe u36 mit Sicherheitsrelais, power unit with safty relay, bloc de puissance avec relais de sécurité, Blockschaltbild (10/94) Schematic diagram JSchéma de principeWorkshop Manual_R 7014(R 7031, R 7001) ‘ao 29 20 27 26 a5 26 ‘Truck instruments and driving controls = Parking brake lever Direction selector Spinner knob fitted steering wheel Direction indicators* Ignition swatch Brake fluid reservoir Hour meter Engine oil pressure warning light Air cleaner warning light ow fuel warning light 11 = S-stage switch 12 = Charge warning light 13 = Glow plug indicator light Water temperature warning light Pressure gauge for 3rd and 4th functions” © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) Setting, 3rd & 4th functions* Fuse box (RH side) Operating lever for attachment 2* Operating lever for attachment 1 Mast tit lever Hoist lever Accelerator pedal Steering column adjustment Hood lock release Brake pedal Hom button* Fuse box for lighting equipment* Light switch” Warning hom Pushipull “coldstart” knob * Optional equipment i- Workshop Manual_ R 7011(R 7031, R 7001) Hour meter (7) ‘The hour meteris a quartz controlled d. c. hour meter with digital display, ‘Supply voltage: 12 - 80 volts. Itdisplays the operating time of the machine in hours (Also see wiring diagram). Engine oil pressure warning light (8) ‘The 12-volt, 2 W, DIN 72601 warning light will light up when the key switch is tumed ‘ON’. It must go off after the engine is started, (Also see Functional Group 1 and wiring diagram). cleaner warning light (9) ‘The 12-volt, 2 W, DIN 72601 warning light will light up if the filter cartridge of the drytype air cleaner of the engine must be changed (Also see wiring diagram). Low fuel warning light (10) The 12-volt,2W, DIN 72601 warning light wil ight up when the amount of fuel in the fuel tank has dropped to a residual quantity of around 3.0 litres. (Also see wiring diagram). © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 02 5 -stage switch (11) 5 different stages can be selected with this switch to adapt electrical braking and acceleration characteristics to actual driving conditions. (For a detailed description refer to Functional Group 08). Charge warning light (12) ‘The 12-volt, 2 W, DIN 72601 warning light will ight up when the key switch is turned ‘ON’, It must go off as soon as the engine starts (Also see Functional Group 15 and wiring diagram). Glow plug indicator light (13) The 12-voll, 2 W, DIN 72601 indicator light will ight up when the key switch is tumed ‘ON’ and goes off after6-7 seconds have elapsed after which the diesel engine can be started. (Also see Functional Group 15). Water temperature warning light (14) The 12-volt, 2 W, DIN 72601 waming light will light up if the engine cooling water has reached a temperature of around 120°C, (Also see Functional Group 15 and wiring diagram). Pressure gauge for 3rd & 4th functions (15) ‘See Functional Group 13. iHydraulic system Hydraulic pump Capacity Direction of rotation Torque loading, mounting hex screws Control valve bank Pressure setting, pressure limiting valve Torque loading, bolts securing valve sections together Anti -cavitation valve Pre-set pilot pressure Return line filter Filtration Pressure of response, by-pass valve Torque loading, fixing screws Hydraulic tank Filling capacity Hydraulic oil (OZ) Speeds Hoist speed Tilt speed (forward tit) Lowering speed Engine rpm, hoisting © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) - Workshop Manual_R 7011(R 7031, R 7001) 1 0 Technical Data for Maintenance Service 16 om’ clockwise (arrow on pump) 50+ 10Nm 230 bar 23 Nm up to & inci, 5000 mm of rated lift = 90 bar above '5000 mm of rated lift = 125 bar 251 1.5 bar 85Nm max. 30 litres grade to DIN §1524, Part 2/HLP or ISO VG 46 HM. 0.42 misec (tolerance 12 %) up to & incl, 3500 mm of rated lift = 0. 15 sec!” upwards of 3500 mm of rated lift = 0.26 seo” up to & incl, 5000 mm of rated lift = 0.26 sec/” upwards of 5000 mm of rated lift = 0.43 sec!” (tolerance = # 20%) 0.45 - 0.60 msec 1800+ ""° rpm (against bypass pressure 230 bar) ot i© STILLGmH Workshop Manual Operation of Lift and Tilt Hydraulics Drawn from the tank (5) the hydraulic oilis supplied by the gear-type pump (6) to the spool-type hydraulic, control valve (3), connection - P -. With the spools in the neutral position, or with a small actuation of a lever, the oll flows through the control valve from Connection - R- almost unpressurised (low pressure fluid circulation) via the retum tne fiter (4) tothe tank. ‘With the lever actuated still further, an amount of oll dependent on the degree of ever actuation is directed ‘rom connection - B - to the hoist cylinders (7) and from C and D to the tit cylinders (1). Incorporated in the control valve biock, a flow control valve restricts the ol low tothe ttt cylinders to reduce the working speeds (stability). The amount of oil not needed for the hydraulic tit cylinders takes the return line to the tank R.7014(R 7031, R 7001 10 Hydraul System An integral pressure limiting valve in the control valve block protects the system against overloading. ‘The anti-cavitation valve (2) safeguards against mast rit The lowering valve (8) limits the lowering speed of the load. Fora description ofthe function of the lowering valves and pipemhose failure safety devices see Functional Group 20. Stand, 8/2004 ( Ersatz fur Stand: 1986 ) 0210 - Workshop Manual_ R 7011(R 7031, R 7001 Directional Control Valve Block Directional Control Valve Block complete with operating levers operating lever connection R (return line) levers ug for flow-rate control valve bearing bracket test plug M (pressure gauge,connect. R 1/8") 4= pivot pin 13 = fixing bolts - control valve block 5 = rubber silentblock 14 = connection D (backward tit) camshaft 15 = connection C (forward tlt) valve switch; eliminated on 7011 16 = connection B (hoisting) valve mounting bracket 17 = connection P (hyd. pump line) 9 = control valve bank 18 = pressure limiting valve 19 = dowel pin 20 = tie rod for controlling engine rpm for “hoisting” Control valve removal: ‘The valve mounting bracket (8) is bolted to the bulk- ~ Disconnect hydraulic lines. head via three rubber silent blocks (5) (noise sup- Disconnect tie rod (20) pression). Space has been provided for extending _~ Loosen fixing bolts of valve mounting bracket at the existing spool valve bank by adding two sec- 6) tions for hydraulic ancillary equipment complete = Remove complete valve mounting bracket with operating controls. Apertures in bulkhead and Drive out dowel pins (19) valve mounting bracket give access to the plug of __~ Loosen bolts (13) the flow-rate control valve, fi, for exchanging the restrictor. Note: Itis advisable to first grease the pivot pin (4) before inserting it into the levers (2). © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 03 ASWorkshop Manual R.7014(R 7031, R 7001 ) 10 Directional Control Valve Block Construction and Operation Operating unit (manual operation) End plate Auxiliary valve section for supplementary functions (hyd. ancillary equipment) 3 bolts securing the valve sections together Seals between valve sections (0' rings) ‘Spoof - hyd. ancillary equipment Spool - tilt function Operation With the valve spools in - neutral position, or with the spools shifted by a small degree, the oil entering connection “P” flows almost unpressurised via the tickover port through the return line to the oil tank. As the spools are further moved into the power posi- tion, the tickover port is closed and the oil whose quantity is dependant on the degree of lever actua- tion is directed to the services Moreover, the maximum quantity of oll for the tilting {function is restricted by a flow-rate control valve which incorporates a restrictor. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 04 ‘Spool - hoist function 9 = Bottom plate Pressure balance bores Valve bank - hoist & tit Tickover port RK = Return port CAUTION: Valve spools should be reassembled in the same order. Prior to disassembly mark spoof position or make sure that the pressure balance bores (10) in the spools point towards test plug M. When carrying out assembly operations on the con- trol valve bank extreme care should be taken that no dirt particles enter the system, otherwise this could lead to the destruction of the spool fits, resulting in malfunction, Torque loading of valve section assembly bolts (4) is 23 Nm. i- Workshop Manual_ R 7011(R 7031, R 7001) 1 0 Pressure limiting valve adjusting bolt lock nut with seal plug pring washer Pressure spring ring plate washer ball cushion plunger ressure spring ‘The pressure limiting valve protects the hydraulic system against overloads, If fi. the piston of an ac- tuating cylinder is extended up to its maximum stroke and the pressure is maintained (overpressure), the pressure limiting valve will open, allowing excessive oil to be by-passed to the tank. Pressure setting = 230 bar By screwing or unscrewing the setscrew (1) the pres- sure setting can be either increased or reduced. IMPORTANT! Do not remove pressure limiting valve with control valve bloc installed, otherwise ball (8) will drop into the return port. When ball seat contamination is suspected (reduced lifutit performance), loosen lock nut (2), unscrew adjusting bolt (1) until spring pressure is relieved, flush pressure limiting valve by operating a spool. After that screw in adjusting bolt up to its former po- sition, © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 05 AS10 - Workshop Manual_ R 7011(R 7031, R 7001 Directional Control Valve Block Flow - rate control valve m al eatictor piston ving tshion bush PI pump port Operation ‘When the tit valve spool is operated to a power posi- tion, the oil from the pump port flows via restrictor (3) to the tit cylinder. Depending on the degree of actuation of the tit valve spool, the piston (4) is move against the spring (5) allowing excess oil flow to return pressureless to the tank via return port (RK). Tilt speed is a function of restrictor hole diameter. Depending on the rated lift provided by the elevating mast, the restrictors shown in the table below are fitted Rated lift h, Restrictor dia (mm) (mm) upto 3500 4.0 over 3.500 24 upto 5000 24 over 5.000 2.0 Replacement control.valve banks are supplied with a 4.0 diameter restrictor. When exchanging the control valve bank or mast it may therefore be necessary to change the restrictor. Remarks on installation of flow-rate control valv Before screwing plug (1) in place in the flowrate con- trol valve, push in piston (4) by hand as far as it will go in order to centre the cushion bush (6) in relation to the cushion plunger (7). © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 06 ASWorkshop Manual_R 7011(R 7031, R 7001) 1 = end plate plug 0’ ring and Teflon back-up ring pump port check valve test plug (pressure gauge connection) pressure connection (pump) 2 3 4 5 M P= Plug ‘The pump pressure port (4) is sealed at its end with plug (2) which is maintained by the end plate (1). Note: ‘When adding accessory valve units for hyd. ancillary equipment pull out plug from valve bank using a screw 4 and push it in pump pressure port of the last valve additionally attached, Otherwise there will be no oil flow to the attachment. Check valve Check valves (5), provided between pump port (4) and operating spools for hoist function and attachment functions, prevent back flow from cylinder ports to pump pressure line. Hf when operating the hoist lever the load is lowered to some extent before itis raised this is an indication cof improper functioning of the check valve in which case the control valve bloc must be replaced with a new one since the check valve cannot be repaired, © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) o7 AS10 - Workshop Manual_ R 7011(R 7031, R 7001 Directional Control Valve Block Operating Unit jalve spool rod “Compact'seal spring washer pressure spring housing ‘ring 9 = shim ( only for tilt and attachment valve spools) Removal of operating unit with valve spool: Loosen screws on housing (5) and pull out valve spool with operating unit, To change the operating unit. remove valve spool (8) from valve spool rod (1) by driving out pin (7). If the valve spool rod shows signs of leaks change “Compact’ seal (2) or replace the complete operating unit with a new one. Oo NOOnh wn — Installation Pin (7) must be riveted, Watch for correct valve spool position (Pressure compensating holes in valve spool must point towards test plug (M). NOTE: Replacement operating units are supplied without shim (9), ‘The shim removed from the old operating unit must be reused for tilting and attachment functions since it limits the stroke of the valve spool © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 08 ASWorkshop Manual_R 7011(R 7031, R 7001) Anti - cavitat ‘Type: SVC 47 E Pre-set pilot pressure: depends on mast type Up to and incl. 5000mm of rated lit= 90bar above 500mm of rated lift= 125bar = strainer spring ball cushion spring ball pressure spring spring pin threaded shim setscrew 10 = valve seat housing eet SSMS Operation Fitted between control valve bank and tit cylindre, the ant-cavitaion valve prevents the mast from dhiting forward on its own with or without load, The anti-cavitation valve permits ting only when pump pressure is present. The anti-cavitation valve car- ties the designation ("P") and (-R’) on the con- nector sides. restricted, ‘Fitting position: See Figure on page 2 Checking anti-cavitation valve - Pick up rated load = Raise fork carriage about 150 mm = Apply full backward tit ~ Keyswitch to neutral (off) ~ Push til lever fully forward Note: ‘The mast should not move forward at this stage. If the mast drifts forward on its own, this is usually evidence that the ball seat (5) is contaminated, Removal = Remove anti-cavitation valve ~ Screw out valve seat housing (10) - Inspect valve seat and cushion piston cavity (4) for ditt; clean if necessary. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 09 ASWorkshop Manual_R 7011(R 7031, R 7001) Operation and Maintenance Filter assembly: consisting of paper element with by-pass valve, tank ventilation and oil separator. Paper element and ventilation filter: Filtration = 25 1 By -pass valve: Minimum pressure of response 1.5 bar cover (outer cap) gasket housing ‘0’ ring gasket 6 = oil separator filter bowt paper element gasket ventilation filter clamp hose clip extension hose y-passvalve The flow of oil rom the control valve or steering hy- draulcs passes through the fter before it takes the return line to the tank. The oil will in that case flow through paper fiter ele- ment (8) from outside to inside. The by-pass valve (14) opens at 1.5 bar back pressure (if paper element is clogged) and allows oil to run into the tank unfiltered The oil separator (6) prevents ol from arriving at the ventilation fier. Replacing paper element and ventilation fiter: - Re- move cover (1) from filter housing ~ Pull out paper element (8) with bow (7) and shaped extension hose (13) = While turing it, remove paper element from fiter bowi ~ Remove any dirt that may have deposited on the bow! bottom Release clamp (111) and pull out ventiation fiter (19) ~ Install new paper element (8) as well as new vent lation filter NOTE: Paper element and ventilation fiter cannotbe cleaned and should therefore be replaced with new parts, Periodic Maintenance: Replace paper element: after 50, 100 then every 800 hours Replace ventilation fer: ~ every 800 hours of operation Fitting instructior Housing (3) must be fastened to the tank, Torque loading of nuts (16) = 8.5 Nm. © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 1010 - Workshop Manual_ R 7011(R 7031, R 7001 Hydraulic Pump Type: gear pump Capacity: 16 cm/R Direction of rotation: clockwise (arrow on pump) Driven by: generator shaft via coupling 1 = hydraulic pump coupling ring radial seal ring generator shaft pump cartier of generator end plate 7 = mounting hex screws Pump removal: ~ Remove inspection cover from RH side of frame ~ Detach h. p. hose (8) from pump flange = Before detaching suction hose (9) squeeze it tight with a clamp to prevent the oil from running out of the hydraulic tank ~ Detach suction hose from suction tube (10) ‘ ~ Remove hex screws (7) and pull off pump from pump carrier Pump installation ~ Place coupling (2) on pump shaft journal. (The cou- pling should move slightly on journal) ~ Grease O-ring (3) before installing it in recess of pump housing ~ The pump should be so fitted intothe pump carrier that the generator shaft journal engages with the coupling ~ Secure pump with hex screws and torque to 0+ Nm ~ Attach h. p. and suction hoses ~ Remove clamp from suction hose i : 8 pump operation or foaming up of the oil in the tank inspect radial seal ring (4) and ‘O-rings (items 3 and 11), and check suction line fitings for leaks. SGA, ‘a 7 © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 1"Workshop Manual_R 7011(R 7031, R 7001) Radial seal removal - Remove inspection cover from RH side of truck frame = Remove pump (see page 12) in which case the suction hose need not be disconnected - Engage an anguler tool such as f. i. an Alien key ‘and an offset screw driver (arrow) from behind pump carrier (6) and press radial seal ring (4) from the carrier until it comes out from the front. CAUTION: Inthis operation be careful not to damage the sealing surface of the shaft Radial seal installation = Provide new radial seal ring with a grease filing between sealing and dust lip, = Using a seltmade tool (see drawing), tap radial seal ring into pump carrier (6) until fully home. (The self-made tool must be made from tube or round steel) ~ Install pump. NOTE: Inthe event of leakage at the radial seal ring inspect sealing surface of generator shaft for damage or score marks. Ifnecessary, a shaft protecting sleeve (1) ID.No. 142017 can be placed overthe sealing surface. 1 = shaft protecting sleeve iting tool (sleeve) (contained in repair kit) 3=generator shaft 4= radial seal ring Fitting the shaft protecting sleeve = Thoroughly clean sealing surface = Compensate for signs of wear (Scoring) by applying ‘a sealing compound which does not age -harden = Grease selaing surface of shaft and grease shaft protecting sleeve (1) fromthe inside = Using the fitting tool, tap shaft protecting sleeve onto the shaft until the scored sealing surface is completely covered and the radial seal ring, after being fitted, rests with its dust and sealing lip on the protecting sleeve. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 12 AS10 - Workshop Manual_ R 7011(R 7031, R 7001 Hydraulic tank Description, Capacity Arranged crosswise under the floor plate, the hydraulic tank forms an integral part of the frame. The suction pipes for hoist and steering hydraulics are welded to the tank, ‘The oil drain plug is located on the underside of the frame, on the LH side as seen from the driving posi- tion, facing towards the forks. ‘Tank filing capacity isafunction of theoverall lowered height of the mast. Oil level is checked with oil filter ‘cap and paper element removed, masttilted fully back and forks lowered completely: from filter top to oil level = dimension X. ‘The oil capacities indicated in the table below corre- spond to the total filing capacity of the hydraulic sys- tem mast Dimension] Approx capacity Overliheightim)| (rm) (ites) Telescopic upto & incl 2230, 200 2 Upto inet 3230, 235 24 Hilo upto & incl 2230 250 2m Upto &inel 3230, 20 2 [Triple stage upto incl 2230 ~~ 28 Upto inet 2730 210 20 Upto inet 3230 405 32 Hydraulic oil change: after 50 hours of operation every 3000 hours of opera- tion Tilt mast fully back ~ Lower forks completely = Remove oil fiter cap - Remove drain plug (arrow), catch hyd. oil in pan = Replace drain plug (renew seal ring) - Refill tank with fresh oil through filter opening Hydraulic oll (02) Grade to: DIN 51524, Part 2/HLP ISO VG 46 HM © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 13 ASWorkshop Manual_R 7011(R 7031, R 7001) Tilt cylinder fittings ‘The fittings are provided with plastic-coated threads (arrow) for better sealing in cylinder tube. ‘The sealing is preserved only provided the fitting is not loosened by more than 15° or by 90° at the maxi- mum and retightened. Should the fitting be loosened in excess of this limit, either a new fitting will have to be used or the thread of the fiting provided with a thread sealing tape. (The same applies regarding the steering cylinder fit- tings). Unions 1 = tube union nut 3 = steel sealing ring 4 = screwed union Assembly: = Using @ saw, cut tube (1) to length required and remove burrs from inside and outside Place screwed union (4) in a soft jawed vise Lubricate thread and cone of screwed union (4), steel sealing ring (3) and thread of union nut (2) with oil Slide the union nut (2) and the steel sealing ring (3) over the tube (1) and insert the tube into the inside cone of the screwed union (4) as far as it will go ~ Screw on union nut (2) by hand until home Using a spanner, tighten union nut (2) by around 11/2 tums (tube must not turn) = Loosen union nut (2) and check whether the bulge that had thus been formed (arrow) fils the cavity of the front cutting edge. If not, retighten slightly. © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 14Workshop Manual Operation speeds ‘The trucks in this range are supplied with the follow- ing operating speeds, measured with the rated load fon the forks: Hoist speed: 0.42 m/sec Tolerance 12 % Note: On Hi-Lo and Triple stage masts the average value of the speeds measured in lift | and lift I! ap- plies. Lowering speed: 0.45 - 0.60 m/sec IMPORTANT! 0.60 misec are not allowed to be exceeded Tilt speed (forward tilt) up to & incl. 3500 mm of rated lft = 0. 15 sec! of tit angle onwards of 3500 mm of rated lift up to & incl. 5000 mm of rated lif = 0.26 sec!” of tlt angle ‘onwards of 5000 mm of rated lift = 0.43 sec!” of tlt angle Tolerance = + 20% (For mast tit angle see Functional Group 25) ‘The measurement must be carried out over the entire titing range! Not! ‘The above values may differ where the truck is fitted with optional equipment. Rpm setting - hoisting tied rod cam rod - hoist spool bell crank bowden cable to injection pump 5 = linkage to accelerator pedal Carry out basic adjustment of accelerator control (see rpm setting Functional Group 15) Next, operate hoist spool to power position until mast extends fully against bypass pressure (230 bar) and adjust tie rod (1) until engine 1pm amounts to 1800+ © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R.7014(R 7031, R 7001 ) 10 Speed settingsCircuit Diagram © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 16 tS.Drive motor Type Maker Construction Voltage rating (V) (Current rating (A) Excitation Rpm Power (kW) Service rating Protection Insulation Class Fuse protection Motor brushes a) Grade b) Dimension ©) Limit of wear ) Qty Currentdraw (See Functional Group 08) © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) - Workshop Manual_R 7011(R 7031, R 7001) 1 1 Technical Data for Maintenance Service applying to 7011 (1.5 tonnes) GF 184 -24/2.5 STILL shunt-wound electric 4-pole motor 125 150 24V, 21 2100 165 continuous duty operation P23 BIF KKA 12.5 x25 x32 replace if worn down to a length of 15 mm. 8 400 A at the maximum, depending on driving conditions ot iGenerator Type Maker Construction Voltage rating (V) Current rating (A) Excitation Rpm Power (M Service rating Protection Insulation Class Fuse protection Carbon brushes a) Grade. b) Dimension c) Limit of wear ) Qty Current draw (See Functional Group 08) a Workshop Manual R 7011(R 7031, R 7001) 1 1 Technical Data for Maintenance Service applying to 7011 (1.5 tonnes) GS 194 - 24/22 STILL shunt-wound 4-pole generator 127 150 24V, 146A 2600 19.0 continuous duty operation IP23 BIF EG 340 12.8 x 25 x 32 replace if worn down to a length of 15 mm 8 400 A at the maximum, depending on driving conditions © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 02 ASDrive motor, type ‘The self -ventilated, shunt-wound electric 4-pole mo- tor (1) is flange mounted to the gearbox. Wiring diagram: AJB = armature UK = shunt field (separately excited) ‘The direction of rotation is reversed by reversing the current flow in the armature. Neutral plane: Not adjustable. Connections: AJB = main current terminal J/K = shunt terminal | ne Leet t clockwise anti -clockwise rotation rotation © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 03Removal of drive motor ‘The drive motor cannot be removed unless the mast assembly is removed first. (See Functional Group 20 = Removal of mast) 1. Disconnect battery plug 2. Disconnect motor cables 3. Fasten motor to canopy guard with cable and pulley block (if no crane available). 4, Unscrew the six screws securing the motor to the gearbox. Turning the motor to the side pull out and lay aside, Installing the drive motor Install the drive motor in reverse order of removal. © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 04Drive motor disassembly Disconnect two armature cables (A/B) from brush ring, Pull commutator end bracket (8) with armature (4) from housing (stator) (2) by removing the four fixing screws (1) Remove fan (3) by removing screws. 4, Remove retaining ting (5) from armature shaft 5, Using a suitable puller, pull fan hub (9) from armature shaft. 6. Using puller, pull armature from comm, end bracket ‘Once the retaining ring (6) has been removed, bear- ing (7) can also be forced out of the comm. end bracket. © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 05a Workshop Manual R 7011(R 7031, R 7001) 1 1 ‘Changing and inspecting the brushes 15 mm at the min, Can best be done from a pit. If this is not available, the following procedure is necessary: 1. Lift out floor plate 2, Remove the strap from around the bearing plate. 3, Screw out the four commutator end bracket bolts (with ratchet and socket). Prior to this mark location of comm. end bracket in relation to housing 4, Unscrew armature cable from brush gear (ring) 5. The comm. end bracket with brush gear can now be rotated into any position desired 6. Check condition of brushes and replace ifbrushes are worn to 15 mm or less -(Also refer to TECHNICAL DATA FOR MAINTENANCE SER- VICE). 7. Rotate comm. end bracket back to its original position and tighten bracket screws. Neutral plane Not adjustable. 15 mm at the min. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 06 ASWorkshop Manual R 7014(R 7031, R 7001) 11 Insulation resistance ‘The insulation resistance of all windings against hous~ ing must have a minimum value of 200 000 Ohms - measured with 500 V d. ¢, voltage. (Usingthe Isolavi 2termed meter, for instance). ‘Turning down (skimming) the commutator on a lathe Permissible untrueness up to a rated armature speed of 3000 rpm 0.02 mm Permissible untrueness in case rated armature speed exceeds 3000 rpm 0.01 mm If the commutator is out-of -round turndown thearmature on a lathe. Abetter surface finish will be produced at high cutting speed combined with a fine feed, Important! ‘The commutator is allowed to be turned down up to a minimum diameter only, Drive motor Generator 128 mm dia 128 mm dia Undercutting the mica Carefully undercut the mica with the aid of an appro- priate saw blade or a milling machine. Make sure the {ull width of the mica is completely removed also at the sides of the laminations. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) General hints ‘Mica baaly out back — high Mica sill exists on the sides ofthe ‘yes IA | y y ‘Mica undereut properly i_ Workshop Manual_ R 7041(R 7031, R 7001) Generator, type ‘The seff-ventilated, shunt-wound 4-pole generator (1) Is flange -connected to the engine. Wiring diagram: AIB= armature main circuit GM = interpoles JIK = shunt field (separately excited) Reversal of polarity in main circuit occurs through reversal of current flow in shunt field. Connections: AJH = main current terminal JIK = shunt terminal Neutral plane Not adjustable. © STILL GmbH, Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 08 Generator ‘At B2 F2 F1 A1 B2 F2 F1 to- +t -+4- A HK J ae ‘STi"Workshop Manual_R 7014(R 7031, R 7001) 1 1 Generator Generator removal 1. Removing only the generator: Depending on local conditions and on whether a suit Requirement: Hydraulic lif, inspection pit, or the able equipment such as a hydraulic lift or an inspec- truck must securely be chocked up unti side of truck tion pitis availabe, it will have to be decided whether is around 30 cm off floor. (Place a block beneath the complete generator unit will have to be removed frame) ‘or whether itis possible to remove the generator alone. ‘The generator (1) cannot be separated from the en- - Pump carrier with power steering pump (3) gine (2) unless the below listed parts are removed - Pump (4) - see Functional Group 10: Pump removal first ~ Radiator (5) Muffler bracket ~ Clip retainer (fat bar) for cables on generator © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 09 a"Workshop Manual_R 7014(R 7031, R 7001) 1 1 Generator \ce the preceding operations have been car- ried out, the generator can be removal from the truck: - Rotate flange-face coupling (1) to a position al- Next, remove the five bolts (4) securing the genera- lowing the three bolts (2) which secure the tor housing othe housing 6) ofthe flange-face cou- flange-face coupling (1) to the starting motor ring pling to the generator housing (5) - the generator can gear (3) to be removed from below with the ald of now readily be lifted out of ruck by fastening gen: an Allen key. erator to canopy guard with cable and pulley block (ifm crane is available), © STILLGmbH_ Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 10 tS.a Workshop Manual R 7011(R 7031, R 7001) 1 1 Generator 2. Removing generator unit after which generator must be separated from engine Provided neither a hydraulic lift nor an inspection pit are available, and there is no possibilty to securely chock up the truck. First remove generator unit - see Functional Group 18: Engine removal and installation After that remove generator from engine as described in preceding section. Generator installation Install the generator in the reverse order of removal. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 1 ASWorkshop Manual R 7014(R 7031, R 7001) 11 Generator disassembly: 1. Disconnect two armature cables (A/B) from brush ring Pull comm. end bracket (8) with armature (4) from housing (stator) (2) by removing the four ffxing screws (1). Using a small puller, pull V-belt pulley (9) from armature shaft only to the extent that the flange of the pump cartier is not touched by the V-bett pulley, otherwise the flange could break. Using a big mechanical puller, pullthe comm. end bracket (8) unt itnearty contacts the V-belt pulley that had just been pulled from the armature shaft toa certain degree. Continue pulling V-belt pulley and comm, end bracket alternately until the armature is disengaged Note: Any attempt to pull off the comm. end bracket and the V-belt pulley in one operation may cause the bracket to break, ‘Once the retaining ring or circip (6) has been removed. bearing (7) can be forced out of the comm, end bracket If necessary, the radial seal ring (10) can also be pressed out. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) Generator Einzetheit 2 iImportant! During the pulling operation the driving dog of the ar- mature shaft must be protected with a bush (see drawing) against the pressing spindle of the puller. Otherwise the driving dog could get damaged. ‘The bush must be self made. Material: Too! steel, hardened. Note: ‘The coupling flange (11) is forced on the armature shaft with 18 kN, Pulling it from the shaft cannot be recommended. In the event that the armature must be changed this operation would in any case not be necessary since the armature is always supplied complete with cou- pling flange. © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 13Generator reassembly Place the generator (armature (8) with stator as- sembly (7) and coupling flange (9) on end with the commutator uppermost. Two blocks of wood (10) of suitable size should be placed under the gen- erator to give armature clearance. Install ball bearing (1) in comm, end bracket (3) and secure with circlip (2). Using a welding torch heat up V-belt pulley (4) to a temperature of 2000 C (or heat up in an annealing furnace if available), Place guide sleeve (6) on shaft, commutator end Place heated V-belt pulley (4) between pump car- rier and comm. end bracket and position it together with the comm. end bracket on the armature. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) Workshop Manual R 7011(R 7031, R 7001) “4 11 Generator = Using a hollow punch (6) tap V-belt pulley and comm. end bracket into generator shaft = Bolt comm, end bracket (3) to generator stator (7), Screw armature cables onto brush gear = Remove guide sleeve from shaft end = Install shaft sealing ring (11) in pump cartier. (See Functional Group 10). NOTE: ‘To prevent the V-belt pulley from cooling off too soon the assembly operation with the heated pulley should be carried out speedily ‘The guide sleeve (5) as well as the hollow punch (6) as per assembly drawing must be made by your- selves. iR7001) 1 1 Generator Workshop Manual_ R 7011(R 7031 © STILLGmbH_ Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 15 tS."Workshop Manual_R 7011(R 7031, R 7001) 1 1 Changing and inspecting the brushes After removal of cover band (strap) the four upper brushes can be inspected and changed if necessary. Regarding the lower four brushes this operation can best be done from a pit. If this is not available access to the brushes can be gained by jacking up the RH side of the truck. Note: ‘Suitable chocks must be placed under the truck frame to safeguard the truck against accidental lowering. Brushes must be replaced if worn down to 15 mm. (Also refer to Technical Data for Maintenance Serv- ice), © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 16 Mime.© STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) Workshop Manual R 7011(R 7031, R 7001) 13 Pressure Regulator Unit | and Il Operation Operation Pressure limiting valve Pressure gauge seal 4/= Pressure gauge connection Fitting, pressure gauge To protect the product being handled and also the attachment, a pressure regulator unit with an adjust able pressure limiting valve (1) is (f. i. when using a clamp) installed in the instrument panel shroud, on the RH side. ‘The pressure gauge (2) displays the pressure set- ting, o1 6 = Pressure line to pressure gauge Return hose 8 = Retum line from steering 9 = Hyd. line to attachment ‘The pressure regulator unit is connected to the up- per connection port of the control valve block for the function--Clampclosing on to the load-—. ‘The pressure regulator unit 1 for the 3rd function is connected to the quick disconnect couplings on the RH side of the fork cartiage, whereas the pressure regulator unit Il for the 4th function is connected to the quick disconnect couplings on the LH side of the fork carriage, i© STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) Workshop Manual R 7011(R 7031, R 7001) 13 Pressure limiting valve Type MV 53 ER Adjusting range: 0 - 160 bar ~ Manually adjustable rotating knob winged lock nut shims housing spring washer with screw pressure spring washer 8 = ball 9 = cushion piston 10 uushion spring Oil flow is from P —> R. By screwing or unscrewing the knob (1) pressure setting can either be increased or reduced ‘The adjusting range and therefore the maximum pres- sure is limited by shims (3) to a setting of 160 bar. IMPORTANT! Regarding the maximum pressure to which the at- tachment can be subjected, follow the instructions of the attachment maker. (Identification plate on attachment), Pressure gauge Located on the RH side of the instrument panel 1 graduation = around 25 bar Note: A drop in the pressure display with valve spool in the neutral position is caused by overflow oil at the spool and does not mean that there is a drop in pressure on the attachment. To assure its holding function the attachment is fitted with a check valve 02 Pressure Regulator Unit | and Il Graduations for clamp pressure Display only with valve open i~ Workshop Manual R7011(R 7031, R 7001). 13 Pressure Limitation for Sideshift Clamp Operation 1. Anti-cavitation valve, type SVC 47 E, pre-set pilot pressure 125 bar 2, Pressure line to attachment (via RH hose line on mast) 3. Pipe joint When using clamps with integral sideshift, the pres- sure for the sideshift motion must be limited to a maximum setting of 125 bar in order to prevent the clamp arms from opening automatically when the sideshift motion is against the stop. When the clamp has moved up to its stop right or left the anti-catitation valves will open at a pressure of 125 bar, allowing the oil to take the return line to the tank. Operation of Anti-cavitation valve R—> P= free oil flow P—> R= restricted For Construction see Functional Group © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 03 ‘The pressure limitation is built in due to safety rea- sons when using 3rd und 4th functions. Should an attachment be used on which the pre-set pilot pres- sure is not sufficient for assuring the function, either the pre-set pilot pressure can by screwing the threaded shim item 8 (see Functional Group 10, page 9) be increased up to a maximum of 160 bar, or the function of the anti-cavitation valves can be neutral- ized by disconnecting/plugging the pipe joint (3). CAUTION: When using a Sideshift Clamp with builtin sideshift the original function must be restored. i15 Technical Data for Maintenance Service - Workshop Manual_ R 7011(R 7031, R 7001 Diesel engine Make/Type WW Industrial Engine 068.5 Capacity 1588 c. c. Output 26.4 KW Rated speed 2600 mpm Torque (max) 93.6 Nmat 1600 1pm Bore 76.5mm Stroke 864mm, Firing order 1-3-4-2 Cooling system capacity 65 litres Oil system capacity sata or range acres vantercronge 38 ies tion pup dinbutorpunp Mate bosch Sta otaever 0900.02 mmbetoreT 0. ¢.of4 © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) on ASWorkshop Manual R.7014(R 7031, R 7001 15 Technical Data for Maintenance Service Injectors, Make Injection pressure (breaking pressure) Tickover speed High ickover Fuel Electrical system Glow Plug System Starter Altemator *Cetane number, indicates the ignitability of diesel © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) Bosch 120-138 bar 900 rpm 2800 rpm diesel fuel DIN 51 601 with a CN* not lower than 45 24avst2Vv 12V 12 V Bosch 24 V Bosch 7 i| Workshop Manual_R7011(R 7031, R 7001) VW Diesel engine Description Diesel engine. Make: WW Industrial Engine Type: 068.5, The diesel unit is resiliently mounted at three points, There is no solid connection to frame or transmission. ‘The Advantages: ~ Low noise level = no transmission of noise = no transmission of vibration - easier removal of the whole compact unit. (Engine, generator, radiator) Construction features: 4 stroke diesel engine -swirl chamber 4 insine cylinders Block is grey iron casting Sheet steel sump Light metal head 5 bearing crankshaft Valve control via toothed belt through upper cam shaft and cup tappets. Water cooling - pressurised closed system with seperate expansion tank. Drive for radiator fan from generator shaft Engine lubrication - pressure circuit with oil pump and replaceable filter. Mechanical fuel injection with distributor injection pump. Dry air fiter with paper element. STILL GmbH_ Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 03 =e.Workshop Manual Engine Starting General hints Before starting check the oil level, coolant and fuel supply. The engine can only be started if the direc- tion switch is in neutral. As soon as the engine fires, loose the key or starter button right away, the starter must not run with the engine. If the engine has to be restarted whilst locked out by the restart cut-out or if the engine remains at rest, this can only be done if the key is turned fully back ‘The restart cut out in the start switch prevents the starter motor coming in with the engine running, and thus being damaged, As far as possible 60 not allow the motor to run hot whilst standing, Avoid high r.p.m. & full throttle until the engine has reached normal operating tempera- ture oan 9 a cold engine Direction switch is neutral The engine is equipped with a pre heat installation and a cold start accelerator device. The required preheat time is indicated by a preheat warning lamp controlled by the coolant temperature, Regardless of the outside temperature pull out the knob of the cold start accelerator device fully. Turn the starter key until the preheat waming lamp lights (duration around 7 seconds). Immediately the warning lamp goes out start the engine. When starting at outside tempera- tures below 0° C do not operate it, Do not at any time operate the starter for longer than halfa minute. Ifthe engine does not fre, preheat after another half minute and re-start. If irregular fring oc- curs, re-start until the engine runs under its own power. Alter the engine fires push the cold start accelerator device knob fully back in © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 04 VW Diesel engine Starting an engine which is operationally warm For engines which are warm, regardless of outside temperature, do not either preheat or pull out the cold start accelerator device knob. Start the engine immediately. Do not operate accelerator pedal dur- ing starting, ‘Stopping the engine Release the accelerator pedal to tickover position and let the engine cool down at tickover for a few minutes. ‘Tum the key back. The fuel flow will be interrupted by the electromagnetic cut-out and the engine will stop. ‘Towing the vehicle Not possible. Do not try. Fuel Diesel fuel to DIN §1 601 CZ" not lower than 45, * Z-Cetane value - a measure for the ignition proper- ties of the fuel ST"Workshop Manual Warning lamp for three phase alternator ‘The warning lamp lights up when truck is switched into operational condition, It should go outafter the engine fires. If warning light for the generator lights up during op- eration: = Stop the engine immediately and check the vee belt. If the belt is torn or inadequately tensioned, put the fault right. Ifthe vee belt is 0. k., the trouble probably lies in the generator or regulating switch IMPORTANT! The entine must not be run with the battery discon- nected, as the alternator wi || be damaged Warning lamp for coolant temperature ‘This lamp lights up when the coolant reaches around 120 °C or more. In this case immediately stop the engine and check whether: thete is enough coolant present. Fan is operational Vee belt is 0. k Vee belt for coolant pump is 0. k. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R7014(R 7031, R701 05 15 VW Diesel engine Warning lamp for air filter This lights up when the filter element has to be changed. Warning lamp for oil pressure This lights up when truck is switched into opera- tional condition. It should go out after the engine fires. I the oil pressure warning lamp lights or flickers in operation: = Stop the engine - because in this event engine lubrication can be interrupted Check engine oil level. Occasional flickering of the oil pressure lamp with a hot engine at tickover is unimportant if the lamp goes out again when the revs pick up. ST| Workshop Manual_R7011(R 7031, R 7001) Topping up engine oil Remove the cap in the cylinder head cover and add ol ‘Check level with dipstick. The oil should not be above the ‘max’, mark. Put cap on again, Engine: Changing oil, checking for leaks Drain oil when warm and catch in a suitable container. ‘The washer under the drain plug (arrow) should always be renewed. ‘Torque drain plug to 30. Nm. Putting oil in amount required with fiter change 3.5 litres, without fiterchange = 3.0 litres Check level with dipstick. The oil should not be above the “max” mark Use only good quality HD oils. The container must be marked according to the API System with "CC" or ‘cD Since the temperature ranges of neighbouring SAE grades overlap each other, the oil does not need changing ifthe temperature varies for short periods. Do not run engine at full throttle for long periods when using single-grade SAE 10 W oil if temperature is above the range shown, ‘When engine is working continuously in very dusty conditions orin areas where the average temperature is below about - 20° C, the engine oil should be changed at shorter intervals. No additives of any kind should be mixed with HD oils. ‘octets Meter STILLGmoH Stand, 8/2004 ( Ersatz fur Stand: 1986 ) 06Workshop Manual Cooling system: The cooling system must be filled with a mixture of water and our G 10* additive. G 10 prevents frost and corrosion damage, furring, and also raises the boiling point of the water. For these reasons the cooling system must always be filed with additive all the year round, Especially in countries with tropical climates the coolant, with its higher boiling point, aids operational safety at high loadings. The cooling system contains around 6.5 litres of coolant (11 1/2 pints) Checking coolant level: ‘The coolant level in the expansion bottle should be checked at regular intervals. ‘With a cold engine the fluid level in the expansion bottle should be seen between the min. and max, marks; with a hot engine the level should stand out above this. For checking the coolant level the cap on the expansion bottle need not be removed as the bottle is translucent, Topping up the coolant: CAUTION! Do not if possible remove the cap with a hot engine - Risk of scalding. The cooling system is pressurised! “Anti freeze with @ Glycol base and anti-corrosion additives. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R7014(R 7031, R 7001) 15 VW Diesel engine So that the protection against corrosion is maintained, and so that the cooling system does ‘not fur up, the proportions of the coolant mixture should not be altered by topping up with just water even in the warm period of the year. For topping up use a 60/40 water/antifreeze mixture. Fill with cold mixture only when engine is cold to avoid engine damage. Do not fill above the max. mark. Excess coolant will be forced out of the relief valve in the cap when it warms up. ‘Screw down the cap tightly. NOTE: In the closed cooling system there is seldom any coolant loss so normally it does not have to be topped up. Noticeable loss of coolant means leakages must be sealed. In this case the cooling system should be checked without delay. STVW Diesel engine Diesel engine - electrical system This consists of = 12.yolt glow plug system = 12-volt engine oil pressure warning light -12-volt water temperature warning light ~12-volt shut-off valve for injection pump =1 2volt starter - 24-volt three-phase alternator ~12-volt low fuel warning light ~12-volt ar cleaner warning light = two 12-volt/44 Ah batteries All warning lights are mounted on the quick-check strument panel. Any malfunctions can thus be recognised immediately. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 08 ee.- Workshop Manual_R 7014(R 7034, R. 7001 1 5 VW Diesel engine Operation of the automatic pre-heat ‘There is available for the diesel engine a relay with built in pre-heat automatic control. This relay d88, ‘can be used in conjunction with a normal ignition switch, as on spark ignition engines. Starting is only possible with direction switch in neutral - Safety feature, Immediately on turning on the ignition, the preheat process begins. The time is controlled in relation to the engine temperature. At switch on, the L terminal of the relay d88 receives a voltage. This starts the automatic preheat cycle, indicator lamp h8é lights up and the relay contacts are closed (terminal 30, with 87) (94-188) ‘The period of preheat and hence the time the indica- tor is lit is determined from the engine temperature via temperature sender e88 (connection G on e88) When the light goes out, the engine can be started As the light ces out, reheat phase of about 15 seconds comes in. Also during the starting procedure terminal 50 of the relay receives a voltage, Because of this, through internal connections, not shown in the circuit diagram, the relay remains closed, so that the glowplugs receive voltage during the start- ing procedure, even if the 15 seconds reheat have run out, If the engine fires before the 15 seconds reheat runs out, the terminal 50 loses its voltage and the whole preheat cycle is broken off, © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 09 ee.Workshop Manual 15 R.7014(R 7031, R 7001 VW Diesel engine CHECKING GLOW PLUG SYSTEM Note: Identification of quick glow/normal glow systems - see Fig. 1 Test conditions: Battery OK. [checking current supply + Connecttest lamp between glow plug for No. 4 cylinder and earth (Fig. 2) + — Pullwire off engine temperature sensor. + Turn ignition key to heating position for max, 18 seconds. Test lamp should light up. | __Connect wire to engine temperature sensor again, restamp Test lamp joes not light up lights up v v See Page 12 Check glow plug current supply with V.A.G 13154 With test lamp or V.A.G 2000 + loder V.A.G 2000 priifen (Fig. 3) clamp. sensor. lnot more than 15 sec. |-_ Read off current draw. [Stromzufuhr mit V.A.G 1315 A + Connect power supply for tester. | Place glow plug lead in current clamp | Press button for current test with current | Disconnect lead from engine temperature |} Tum ignition key to heating position for Checking glow plugs + Remove lead and bus bar for glow plugs + Connect test lamp to battery positive and apply probe to each glow plug in tum (Fig. 4) + Lamp lights up: glow plug is OK + Lamp does not light up: glow plug is defective, renew (tightening torque 40 Nm), If glow plug electrodes are burnt, see notes on page 11 lapprox. 48 A quick glow system | below 48A lapprox. 36 Anormal glow system] or 364 v Istow plugs Ok. {fault is in fuel system) v ‘Current draw should stabilize at about 12 amps with quick glow or 9 amps with normal glow per glow plug. If glows plugs give a current draw of about Quick glow system Normal glow system 36A-one glow plug.defective 27 A- one glow plug defective 24A-two glow plugs defective 18 A- two glow plugs defective 12A-three glow plugs defective 9 - three glow plugs defective 0A-allglow plugs defective 0 A- all glow plugs defective ‘These values can only be obtaines with a battery voltage of not less than 1.5V. AT? COMETS PagO TZ © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 10 ASFig. 1 Identification of glow system Quick glow Normal glow 1 - Brass nut 1- Aluminium nut 2- Red lettering 2 - White lettering Fig. 4 Checking glow plugs Glow plugs with bumt electrodes Burt electrodes in glow plugs are frequently caused by faulty injectors. Damage of this nature is not due to faults in or on the glow plugs. Fig. 3 Placing glow plugs supply wire in current clamp STILLGmbH Stand: 8/2004 ( Ersatz fur Stand: 1986 ) When damage of this nature is found - arrow - itis not sufficient merely to renew the glow plug. The injectors must also be tested for condition of nee- dle tip, breaking pressure and leakage - see page 64, a i- Workshop Manual_R 7014(R 7034, R. 7001 1 5 VW Diesel engine Continued from page 10 Glow plug fuse defective Check glow plug fuse. Fuse OK. _Fuse not Dk. jo voltage at terminal 30 on glow plug relay Connect test lamp to terminal 30 on relay. [Test lamp Test lamp lights up does not light up Break in connection from terminal 30 Glow plug relay not working on relay to battery. Connect test lamp to terminal 86 on relay, Tum ignition key to heating position. [Test lamp Test lamp ights up Jdoes not | ight up Repair connection Repair connection. between terminal 85 from terminal 86 n relay and earth or on relay to terminal lay terminal 87 to 15, Juse or renew relay. Note: If the engine is difficult to start at any time, the operation of the automatic after-glow and the operation of the glow plug while starting up should also be checked. At the end of the pre-glow period, which depends ‘on temperature (indicator light goes out), there should be voltage at the glow plugs for another 6 to 7 seconds on the quick glow system or 10 to 15 seconds on normal glow system, Do not operate starter motor for this test. If there is no voltage at the glow plugs, renew the relay. 2 When the starter motor is operating there must be voltage at the glow plugs. If there is no voltage at the glow plugs, repair the wire from terminal 50 on the glow plug relay to terminal 50 on starter switch’ starter, orrenew glow plug relay. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 2 ee.- Workshop Manual_R 7014(R 7034, R. 7001 1 5 VW Diesel engine GLOW PLUG WARNING LAMP DOES NOT COME ON Pefective waming lamp Phecking warning lamp Check warning lamp Disconnect glow plug relay. Connect test lead between terminal Glow plug waming Glow plug waming in relay socket and earth lamp comes on lamp does not come on Tum ignition key, Renew waming lamp or check wire from. relay terminal Lto warning lamp Tow plug relay or sender unit tor engine hecking operation of relay perature defective (see notes on page 72) Check operation of delay. Disconnect glow plug lead Disconnect lead from engine temperature jaming lamp comes ] Waring lamp does sender and leave it hanging loose. nas described not come on as ‘Switch on ignition: warning lamp must come on described for about 25 - 30 seconds on quick glow system or max. 120 seconds on normal glow system and| then go out. ‘Switch ignition briefly off and on. Connect lead for engine temperature sender to jenew Sender unit Renew glow plug relay earth, engine temperature) Warning lamp must go out. END © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 13 Mime.a Workshop Manual R 7011(R 7031, R 7001) 1 5 VW Diesel engine ‘Speed setting (design with bowden cable) 1 Basic adjustment of throttle linkage a) Pump lever does not reach the full stop: in that Position bell crank on bulkhead so that it points case the ball head in the slotted hole of the pump. down vertically, atthe same time moving the slotted lever must be shifted towards the fulcrum of the hole of the accelerator pedal tie rod untilitis against ump lever. the rear end b) Accelerator pedal fails to reach full stroke due 2 The bowden cable linked to the injection pump tothe pump lever being against the full throttle should be so adjusted that the bushing with both of stop: in that case the ball head in the slotted its threaded ends seats properly into its respective hole ofthe pump lever must be moved away from, locations and the bowden cable in idling position is the fulerum. virtually free from play. ‘When the pedal is in the full throttle position there 3 When checking engine rpm_ must be approx. 0.2 mm play between pump lever and stop screw (full throttle stop is on the 900+ 50 spmmust be read in idling postion, and accelerator pedal) ‘Shouldthe pump levernotfollowthe corresponding 2750 & 50 rpm in fullthrottle postion pedal travel proceed as follows: 4 With control valve spool forthe *hoistfunction moved to the power position set engine rpm by means of tie rod to 1800 + 100 rpm against bypass pressure 230 bar. peahiebes. i /” pump lever oatie making contact © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 14| Workshop Manual_R 7011(R 7031, R 7001) 1 5 Rpm setting Throttle linkage 7 = Angle joint Washer intermediate shaft Bearing support Hex hd bolt 12 = Spring washer gle joint Hex hd bolt M 6 x 20 Hex nut M6 21 = Bowden cable Hex nut M8 © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 15 AS- Workshop Manual_R 7014(R 7034, R. 7001 20-25 Technical Data for Maintenance Service Elevating mast Mast mounting bolts Torque loading 295 Nm or 275 Nm ‘Support lier bol Torque loading 60 + 6 Nm Lowering valve Torque loading 20 2 Nm Chain max. permissible stretch = 3% to the checked to UW Lowering speed max. permissible = 0.6 msec © STILLGmbH_ Stand: 8/2004 ( Ersatz fur Stand: 1986 ) a1 tS.Workshop Manual_R 7014(R 7031, R 7001) Mast types All mast types are clear-view masts. The section of the mast is an | beam. Fork carriage and mast. sections are guided by support rollers which also take up side loadings -the previous side thrust rollers are thus not fitted Telescope Fullfree-titt Triple tullfreesitt ren the mast is raised, the During the lifting operation, the Hes similar features to full free-lft inner section will extend beyond ‘extending mast section wi 11 mast, but with an extended lift the height of the load. When not exceed the height of the height for the same overal closed ‘operating in areas of limited load. When operating in areas height. When operating in areas headroom, the it night of he, of limited headroom, the lit of vith limited headroom, the it of inner section must be taken info the inner section need not be te inner section need not be taken into account taken into account without increasing the overall ‘losed height of the mast) Removal of mast 1.Secure the truck so that all mast removal ‘work can be done. 2.With mast vertical, secure above with wire rope or chain. 3.Take off forks or attachment. 4.Loosen hoist cylinder hoses. 5.Pull out tlt cylinder pins from fixings ‘on mast 6.Screw out mast support fixing bolts. 7.Pull out mast from the front. Installing the mast This is done in reverse order. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 02 IMPORTANT! Torque requirement for mast mounting bolts: 1) Boltwithout aftertreatment (black bolts) =295Nm 2) Electroplated bolts (bright bolts) = 275 Nm Note: ‘To reduce wear the running tracks on which the rollers roll must be greased at regular intervals. BSWorkshop Manual_R 7011(R 7031, R 7001) Description of Operation ‘The two external cylinders lie in the profile of the | Beam outer mast. ‘They are connected hydraulically by one tube. Both piston rods are connected at the top to the crossmember of the inner mast. ‘When the cylinders are pressurised both piston rods, go out and lift the inner mast. Travelis limited by cylinder stroke. The lft chains are fixed to the outer mast, run over chain sheaves on the inner mast and are fixed at the other end to the fork carriage. Thus the ratio of inner mast to fork carriage travel is 1:2 A lowering valve built into the pipework provides for a maximum lowering speed of 0.6 misec. ‘The rh. outer cylinder has a line failure safety device A stop prevents the fork carriage coming out and tipping forward. 1=Chain tensioner 2 = Outer cylinder. h. 3= Line failure safety device 4= Lowering valve 5 = Outer cylinder I. h 6 = Carriage stop © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 03 AS- Workshop Manual_R 7014(R 7034, R. 7001 20-25 Telescopic Mast il flow in mast The oil enters at the lowering valve (2) from where it goes via a tee piece to the 1. h. andr. h. cylinders. The line failure safety device (1) in the r. h. cylinder prevents the load dropping too quickly if a pipe fractures, 1 = Hose failure safety device (for assembly see page 18) 2= Lowering valve © STILLGmbH_ Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 04 tS.20-25 Telescopic Mast - Workshop Manual_ R 7011(R 7031, R 7001 Chain adjustment ‘The lift chains are tensioned equally by the adjusters co) ‘The centre of the upper fork carriage rollers must re- main 35 mm inside the inner mast section when pis- ton is fully extended (to cylinder stops). Under no circumstances must tyre wear be compen- sated for by adjusting the lift chain tension! Caution: Also consider the necessity for the carriage stops page 13, Important! ‘The chains must be inspected for wear, damage and Undue stretch (3 % at the maximum) in compliance with the regulations of UW (German Society for the Prevention of Accidents). © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 05 ASWorkshop Manual Description of operation ‘The mast has three eylinders. ‘The short centre cylinder mounts in the inner mast. One end of the centre chain is fixed on the inner mast behind the chain sheave, and the other end to the fork carriage, This centre cylinder provides the high free lift, ex- tending within the inner mast but not exceeding the overall height of the mast, ‘The two outer cylinders are tucked into the 1 beam section of the outer mast. ‘The piston rods of these cylinders are firmly secured to the inner mast, When the cylinders are pressurised the centre oyli der first goes out to its stop because of its greater piston area ‘Then the two outer cylinders go out and lift the inner mast. A lowering valve mounted in the pipework and in the centre cylinder provides a max. lowering speed of 0.6 misec. ‘The outer cylinders are fitted top and bottom with a line failure safety device. A stop prevents the fork carriage coring out of the mast when maximum lift is reached. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R.7014(R 7031, R 7001 06 ) Line failure safety device in adaptor R. H. Outer oylinder Line failure safety device in cylinder base = Lowering valve Line failure safety device in cylinder base LH. Outer cylinder Centre cylinder Chain tensioner = Carriage stop 7 8 9 iil flow in mast ‘The oil enters at the lowering valve. From there via a tee piece through the two outer cylinders. The oil then flows through hose connections from these two cyl inders into the bottom of the centre cylinder. Because of differential piston areas the centre cylin der goes out first and when it reaches full stroke the two outer cylinders go out simultaneously. Lift! only moves the carriage for Free Lift LiftII__ moves the mast section out. ‘The safety devices built into the outer cylinders pre. vent the load dropping too quickiy if a pipe fractures. Safety device - (assembly see page 18) Lowering valve, Note: (On Hi-Lo masts featuring an overall lowered height of up to and incl. 2330 mm, a line failure safety device is fitted in the RH outer cylinder only. From overall lowered heights of 2390 mm a line failure safety de- vice is fitted also in the LH outer cylinder. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) - Workshop Manual_ R 7011(R 7031, R 7001 ) iWorkshop Manual Chain adjustment With lft cylinder fully extended, turn the adjuster (2) Unti the centre ofthe upper fork carriage roller remains ‘35 mm inside the inner mast section. The piston must extend to its full stroke always inside the cylinder. Min. clearance between carriage stops and stop blocks at inner mast = 2 mm. Under no circumstances must tyre wear be ‘compensated for by adjusting the lift chain tension! Caution: Also consider the necessity for the carriage stops page 13, Important: ‘The chains must be inspected for wear, damage and undue stretch (3 % at the maximum) in compliance with the regulations of UV (German Society for the Prevention of Accidents). © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R.7014(R 7031, R 7001 08 ) iWorkshop Manual Description of operation ‘The mast has three cylinders. ‘The short centre cylinder is in the inner mast, One end of the central chain is fixed to the inner mast behind the chain sheave and the other end to the carriage. This centre cylinder provides the high free lift, ex- tending within the inner mast but not exceeding the ‘overall height of the mast. The two outer cylinders are tucked into the | Beam section of the outer mast. ‘The piston rods of these cylinders are firmly secured to the middle mast. ‘The chains are arranged on the rear side. ‘These chains are secured at the top of the outer mast, and at the bottom of the inner mast. When the cylinders are pressurised the centre efi der first goes out to full stoke because of its greater piston area, ‘Then the two outer cylinders go out and lift the mi die mast. This lifts the inner mast in the ratio of t via the chain connections. Alowering valve (4) installed in the pipework provides. ‘a max. lowering speed of 0.6 m/sec. The r. h. outer cylinder is fitted with a failure safety device A stop prevents the carriage coming out, © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R.7014(R 7031, R 7001 09 ) 1= RH, Outer oylinder 2= Chain tensioner Line failure safety device in cylinder base 4= Lowering valve 5 = Line failure safety device in cylinder base 6 = Centre cylinder 7 = Chain tensioner 8 = L. H, Outer cylinder 9 = Carriage stop iWorkshop Manual Oil flow in mast il enters at the lowering valve; from there via a tee piece to the I. h. and r, h. cylinders ‘The r. h. cylinder has a closed end, on the 1. h. side the oil is fed through the cylinder and via a hose down into the centre cylinder. Because of differential piston areas the centre cyl der goes out first. When this has reached full stroke, the two outer cylinders go out simultaneously. = Lift! moves only the fork carriage for free lift Lift moves the mast section out, The line failure safety device fitted in the r. h. outer cylinder prevents the load dropping too quickly if a pipe bursts, 1 = Line failure safety device (assembly see pages 17 & 18) 2= Lowering valve © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R.7014(R 7031, R 7001 ) 10 20-25 Triple mast iWorkshop Manual Chain adjustment Outer chains: ‘The outer chains are adjusted equally by the adjust- cers (3) until the three mast sections are flush. Centre chain: The chain is tensioned by the tensioner (2) on the centre cylinder, The centre of the upper fork carriage roller must re- main 35 mm inside the mast section when the piston (Lift 1) is fully extended (to cylinder stops). At least 2 mm clearance must be present between the two stop blocks, Under no circumstances must tyre wear be compen- sated for by adjusting the lift chain tension! Caution: Also consider the necessity for the carriage stops page 12 Important: Wear, damage and elongation (max. 3 %) are to be checked to UW. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R7014(R 7031, R 7001) 20-25 Triple mast ) iWorkshop Manual Carriage stops When adjusting the chains, care should be taken that, with mast lifted to maximum height, the piston ex- tends to its full stroke always inside the hoist cyl der. Important! At least 2 mm clearance should be maintained be- tween block on carriage (4) and stop (5) on inner mast. Fork carriage 2 = Inner mast section 3 = Support roller 4 = Block (on carriage) 5 = Stop (on inner mast cross member) © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R.7014(R 7031, R 7001 ) ae iWorkshop Manual_ R 7014(R 7031, R 7001 Assembly of support roller Roller Dimension “A” @ over up to 75.2 759 787 759 | 764 76.2 76.4 | 769 76.7 7e9 | - 1= Support roller (see Parts catalogue) 2= Shim (see Parts catalogue) 3= Countersunk screw secured with liquid plas- tic compound 519 899 (loctite 242) Torque loading: MA=60t 6 Nm Permissible lateral clearance: Carriage assy - inner mast min. 0.2 mm, max. 0.5 mm at the tightmost spot, otherwise 1.3 mm at the max. Inner mast - central mast - outer mast Upper roller: min. 0.5 mm, max, 0.8 mm (in as- sembled position) at the tightmost spot, otherwise 1.3 mm at the max. Lower roller: min. 0.2 mm, max. 0.5 mm at the tightmost spot, otherwise 1.3 mm Note: ‘The support or guide rollers are sealed and lubricated for life with lime soap based grease. Subsequent lu- brication is therefore not necessary, Never disassemble the support rollers, otherwise the spring rings in the thrust washers are liable to get damaged. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 13 ) iCheck (See figures on the right) Raise fork carriage = Place a square piece of wood under the forks Lower carriage, The fork carriage will it back- wards, whereas the upper rollers will come to rest against the rear running surface, Using a feeler gauge measure gap between support roller and running surface. Max. permissible gap'X’= 0.5 mm, Note: Before carrying out.this operation check the lateral clearance of the carriage. © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 14Workshop Manual Description ‘The cylinders are single acting plungercylinders (plunger pistons), Cylinder tube and base are welded together. ‘The oylinder head is screwed onto the tube and secured with Loctite 242, ‘The sealing between tube and head is by "rng. ‘The sealing between head and piston is by V seal. ‘A piston basescrewed into the piston and fixed with Loctite 242 acts asa lit stop. ‘The safety valve screwed into the cylinder base may be a lowering valve ora line failure safety device, Dismantiing the central cylinder Detach the swivel coupling and catch the oi Remove chain protector, itup the carriage, remove the chains, lower the carriage, ‘Take off the clamp from cylinder. Lif out the hoist cylinder. Grip cyinder body firmly in a vice- at the base- otherwise tube may distort. ‘Screw offcyl. head with ‘C’ spanner B6875 DIN 1810. Ifeyi. head will not move, preheat with a flame. Remove piston from cylinder with a strong pull ‘Take offchain sheave. Grip the sheave fork in the vice, unscrew piston base with °C’ spanner B 58-62, DIN 1810, Fortis a bind hole 5 mm ia, must be dled in the circumference of the piston base. Otherwise use a different spanner on the face. Pull the cylinder head off the piston. Fit a new seal kit, ‘Check guide bush for wear. Reassemble in reverse order. Note: Fix piston base, cyi, head and bearing fork wirk Loctite 242--three spots around cirumference. © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R.7014(R 7031, R 7001 ) 15 punch mark setvng as stop Wiper “U' seal collar Cylinderhead = Bleedsorew ‘O'ring (Guide bush Piston = Cylindertube Piston base owering safety brake valve (Triple mast) (torque loading = 20+ 2 Nm) Where the trucks fitedwith a Hi-Lo mast a pipe failure safety device has been installed, i20-25 - Workshop Manual_ R 7011(R 7031, R 7001 Hoist cylinders Dismantling the outer cylinders Raise mast and prop securely. Remove securing ring from upper piston fixing (cross. member), Detach rear hydraulic connection. Screw out the threaded coupling. Remove the fixing clamp. Open the hoist valve - piston drops down, if necessary assist with a screw driver. Lift out the hoist cylinder. Grip the cylinder body firmly in a vice -at the base, otherwise the tube may distort. Unscrew the cylinder head with ‘C’ spanner B 52-55 DIN 1810. Ieyl. head will not move, preheat with a flame. ~ Remove the piston from the cylinder with a strong pull Pull cylinder head off piston. Fit a new seal kit Check guide bush for wear. Forremoving the piston base use'C’spannerA40-42 DIN 1810 or drill a 4 mm blind hole in the outer diameter and use 'C' spanner 8 40-42 DIN 1810. Reassemble in reverse order. Note: Fix piston base and cylinder head with Loctite 242, three spots on circumference. Wiper ‘U’seal collar Cylinder head Bleed screw ‘o'ring Guide bush Piston Piston base ‘Spacer limiting lift height (on application) Cylinder tube Hose failure safety device Durch Kernen Anschlag fur Rohrbruchsicherung punch mark serving as stop for hose failure safty device © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 16 ASWorkshop Manual Lowering valve ‘The lowering valve provides a constant lowering speed, whatever the load - even if pipe bursts. Operation: As the load is lowered, the sliding orifice, due to the medium flowing through it, is moved to the metering position thus forming an annular restrictor inside the control piston, whose resistance against flow in conjunction with the pre-loading of the piston control spring (adjustable) determines the amount of flow. Note: Max. permissible lowering speed (with rated load): 0.6 misec. Hoisting, direction of flow F —> B Free unrestricted flow with low resistance is made possible by the sliding orifice at this stage retreating from the metering position (orifice effect inoperative in this direction) Lowering, direction of flow B —> F Flow is constant over a wide range as a result of the self adjusting balance between the intemal pressure differential and the pre-load position on the piston control spring, © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) R.7014(R 7031, R 7001 ) Shing orice (restrictor in Unrestrictes flow direction Piston spring Control piston Slicing orice in metering S position Control edges- Workshop Manual__R 7014(R 7034, R.7001 20-25 Line failure safety device B The illustration shows the position of the hose failure safety device at the lower end of the outside cylinder p ite pled pt agent te Sop 2. H oe 4 pao 3 Y U4 3 = Hose failure safety device Operation: ‘The safety device for hose failure, a safety restrictor, prevents uncontrolled and abrupt dropping of the load in the event of hose or pipe failure. The hose failure safety device is a plate valve whose valve disc is raised off the valve seat by spring action in the neutral state, thereby maintaining an open through-flow cross section of variable width. ‘The through-flow resistance and the backpressure action at the valve disc in the through -flow direction BF (operating or actuating direction) generate a force which during normal operation does not exceed the spring counterforce: the valve remains open. Ifin the event of a burst in the hydraulic feed pipe or hose the through-flow increases due to the driving load, the flow forces will exceed the spring force and the valve will close immediately. The valve plate contains an ‘orifice hole through which oil c an flow from B to F, imespective of the magnitude of the load, thereby gradually lowering the load to the ground. LLL S The figure nthe mide show the poston ofthe tne 4 | ihre ately saves tn he ater cre athe to mest | fem tightened \ agate the sop Valve dise © STILLGmbH_ Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 18 tS.20-25 Dismantling r - Workshop Manual_ R 7011(R 7031, R 7001 Grip the cylinder body in a vice. Remove upper screw union (hydraulic connection, item 7) - thread protrudes into the bore. Knock down cylinder head (8) a bit with plastic punch, Press in the spring ring (10) with a probe through the small hole in the cylinder and lever out with a screw driver. With a strong pull on the cylinder rod pull the head (8) out of the body. Grip piston rod in vice (with protective jaws). Remove eyebolt (12). IMPORTANT! Note the thread depth and retain this when re-assembling, otherwise the tilt angle will change. Pull off the cylinder head and remove seal material Remove grooved seal (1) from piston (2). 8 ; 3 -< 3 t sorwarner | u | Spring ring 1 = grooved seat 2= piston | 3= piston rod 11 = wiper seal | 4=oylindertube 12= tilt cylinder | 5 = circlip eyebolt | Gagwovedsea! 43 eee ae Sojinternens I © STILL GmbH , Stand: 8/2004 ( Ersatz fur Stand: 1986 ) 1920-25 - Workshop Manual_ R 7011(R 7031, R 7001 Assembling Check all parts for wear and clean as a matter of Note: Piston (2) and hex. nut (14) are secured with loctite 242. Torque for nut MA = 130+ 10 Nm. Fit grooved seals (1) onto piston (2) and lightly grease. Insert piston and piston rod into cylinder. Provide cylinder head (8) with new sealing material and lightly grease. Insert cylinder head (8) into body. Note: Cut out in cyl. head must point towards connection hole. Fit spring ring (10). Screw on eyebolt and secure. IMPORTANT! Ensure thread depth is as marked on dismantting ‘Screw in hydraulic connections (sealed with thread sealing tape) When assembling pay attention to measure y = 22 28. grooved seal 2 = piston 10 = spring ring piston rod 11 = wiper seal 4-= cylinder tube 12 = tilt cylinder 5 = circlip eyebolt 6 = grooved seal 13 = bolt ‘screw union 14 = hex. nut = cylinder head 15 = ball joint = 0 ring © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 20, ASWorkshop Manual_R 7014(R 7031, R 7001 Mast tilt angle When carrying out repairs on the tilt cylinders be careful not to modify the tit angle as set at the factory, as this would otherwise impair stability. 8 = backward tit a= forward tit Standard tilt for truck fitted with pneumatic or superelastic tyres Mast type Telescopic Fu ree tm (i - Loy Trple Jom to ftom to | from to | fom to trom to_| from to from to Height of 1mm | 2680-2780 2830-4430] 4530-5454 2700-2600) 2900-4100 [3600-4700] 4840-7850 Height, mast lowered hinm_|1830-1880]1830-2730|27e0-3234 1830-1880) 1930-2530 [1830-193C] 1960-3230 Heian, mast extended humm |3269-3360]3469-5069 5169.606d 3339.5430) 3539.4739 544.4044) 4904.8544 Free It hana 150 2n-1261f13-1911] 1211-1319 1961-2611 Titangle “8 lefep feiss Bf [se 3 |e © STILL GmbH Stand: 8/2004 ( Ersatz for Stand: 1986 ) 20 MT.Workshop Manual_R 7034(R 7014, R 7001) Diagnostic instructions IMPORTANT TESTING HINTS for checking the electrical power transmission Pages 1 to 23 ® STILLGmbH_ Stand: 8/1990 ( Ersatz far Stand: ) ST/ Workshop Manual_R 7034(R 7011, R 7001) S-D Diagnostic meter with digital display 1 Diagnostic device 2 Data card set ‘The diagniostic meter or device Part No. 147587 is __If a value is not reached, systematic fault finding used for simple and speedy pin-pointing of faults in _and elimitation must be carried out in compliance the electrical installation of trucks inthe R70 range _with the test step concerned. Detailed information 7031), can be found in the system diagnostic sheets of ‘workshop manual 7031 Anderungen , dle dem technischen Fortsohritt Design and specifications are subject to La conception et les spécifications sont dienen, bleiben vorbehalten change without notice modifiable sans préavis. © STILLGmbH_ Stand, 8/1990 ( Ersatz fur Stand: ) " Ct —600000000 6 Anderungen , dle dem technischen Fortsohritt Design and specifications are subject to La conception et les spécifications sont dienen, bleiben vorbehalten change without notice modifiable sans préavis. © STILL GmbH Stand, 8/1990 ( Ersatz fur Stand: ) 0Anderungen , dle dem technischen Fortschr dienen, bleiben vorbehalten Workshop Manual Mechanical configuration of diagnostic device 1 7 Indication of the 20 test steps via LED's, 2 ON-OFF switch 3. LCD display, digital 4 Indication of voltage checks via LED 5 Indication of resistance measurement via LED (continuity checks) 6 Datacard A 7 Datacard B 8 Slit for truck data cards A and B 2 9 Selector switch A for ,V", ,ohms* and test steps 1 - 10 10 Selector switch B for test steps 11 - 20 3 ‘11 Socket for connecting current clamp (tong tester) 12 Sockets for connecting leads for voltage measurement 13. Connection cable (32-wire) with 48 position DIN plug, integrated into the diagnostic meter 14 Sockets for connecting leads for resistan ce measurement and continuity checks 15 Fuse (315 mA) in supply lead connected to adapter connection B22 16 2-piece sheet-metal housing 9-volt rect, battery, installed in instrument, absolutely necessary as power supply for LCD display! change without notice © STILL GmbH Stand, 8/1990 ( Ersatz fur Stand: ) R.7034(R 7011, R 7001) Design and speciications are subject to Diagnostic meter with digital display Operation instructions Diagnostic test sequence Insert data cards A and B all the way into sits of diagnostic meter Connect diagnostic meter to adapter 351476 Connect adapter in place of p.c.b. 1 A1 Follow SAFETY INSTRUCTIONS! (ON-OFF switch ON Select individual test steps in sequence by means of selector switches A and B located on front of diagnostic meter: A= 1-10, V, ohms B= 11-20 during test steps 1 -10 using selector switch A selector switch B must be switched to position 10. During test steps 11-20 using selector switch B, selector switch A must remain in position 10 Once a test step has been carried out, no risk is involved in repeating it - just turn back the selector switch Before carrying out each test step select first the test step and then operate the truck function to be tested ‘Compare displayed value with data card (make a note of deviating values) After completion of tests, turn ON-OFF switch to OFF (battery consumption) La conception et les spécificatons sont ‘modifables eans préavis, iM AST"Workshop Manual_R 7031(R 7011, R 7001) S-D Multimeter - funktion Disconnect adapter cable from adapter Current measurement using curfent clamp (tong tester) Connect clamp to socket ner and socket LOW Selector swith A to poston V, selector ewtch to © wed socket = HIGH (postive) postion 2m Measurement connections: © siacksocket = LOW (negative) Switch on clamp and eal calibrate with display: Voltage measurement up to 20 volts: Socket 20 V against socket LOW Close clamp around lead and take reading of Selector switch A position V, selector switch B current directly positon 10 gure oS 430 A = display: Pah | LED V lights Resistance mesurement / continuity check Example: Selector switen Ato positon V, selector switch B to position 10 ees 3) 12.8 V display esl LED Ohm lights Voltage measurement up to 00 V: Measurement range 0 ... 2 kilohms Socket 500 V against socket LOW ‘Switch A position V, selector switch B position 10 Example = open lead 1 open circuit / value <2 kilohms LED V lights . Numbers flash or display: 56 V = display: i y Te] ~ full continuity . display: oGt © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) v AST Example: 187"Workshop Manual_R 7031(R 7011, R 7001) S-D Measurement of resistance: Example: 685 ohms play: 4.5 kilohms = display: CO | Replacement of g-volt rect. battery a) Loosen housing cover by removing 4 screws, then pull up carefully b) Disconnect coloured, flat cable from printed circuit board, pull out housing ©) Push battery out of bracket in upper part of housing d) Replace battery, then reconnect flat cable to printed circuit board Replace cover and screws ) Check function ON-OFF switch to OFF after completion of all the tests. © STILLGmbH _ Stand: 02/2003 | Ersatz far Stand: 8/1994 ) uw STWorkshop Manual R.7034(R 7011, R 7001) Read these instructions thoroughly ! Foreword ‘Trucks DFG 70-16 in the 7031 range display basically the same features as the trucks in the 7001/11 range. Workshop Manual 7031 Id.-No. 145807(GB) ‘The instructions contained therein will assist you in diagnosing the fault ‘The test stages already contained in the above manual are not repeated in the present Workshop manual. Fault analysis Always carry out these tests with truck jacked uy engine tured off, p.c.b. ‘traction circuit control’ removed and diagnostic meter connected © STILLGmbH_ Stand: 02/2003 ( Ersatz fur Stand: 8/1994 ) wi For your fault diagnosis use diagnostic device with digital display Part No. 147587 For instructions on use of diagnostic meter refer to ‘Workshop manual 7031(7011/7001) Since the sequence of the test stages to be observed differs according to the type of diagnostic meter used (with digital display or ‘redi/green’ display), you will find on the following pages a comparative table of the test stages. Inthe left column figure the test stages to be carried ut using the diagnostic meter with digital display with indication of the connections tested. In the right column figures the comparative test stage carried out with the diagnostic meter with ‘red/green’ display, ‘The boxes identified by a grey colour indicate that a different meter connection is to be used for the diagnostic meter with digital display compared to diagnostic meter with ‘redigreen’ display. This permits you to immediately pinpoint the ‘correct test point’ in Workshop manual 7012 CeWorkshop Manual__R 7034(R 7011, R 7001 S-D Diagnostic device DIAGNOSTIC DEVICE ‘The diagnostic device is a semi-automatic instrument. Itis used for simple and speedy pin-pointing of faults in the electrical installation, The diagnostic instrument is maintenance free and does not requirea powersource of its own as itis fed by the vehicle batteries (24 volts) 1 Stemmemiaon Read the instructions IMPORTANT! Chock up front of truck Handbrake on, engine off Handbrake off, engine runing © 1 Battery votage © 11 Relay controtler © 2 Keyswitch on © 12 Fuse exctation © 8 Direction switch forwara © 13 Motor excitation zero © 4 Direction switch neutral 14 Motor excitation max © 5 Direction switch backwards 15 Gen, excitation backwards 6 Current actuel value sender 7 Drive sender O-posiion 18 Gen, excitation forwards 17 Gon. voltage Fwd. tckover 8 Drive sender fully operated 18 Gen, voltage Fwd. full revs, 9 Direction switch neutral 19 Frequ, Dynamo neutral full evs. © 10 ster engine © 20 Tachogenerator Fud. full revs nofaut @ @ fault STILLR70 DIAGNOSTIC METER © STILL GmbH _ Stand: 02/2003 ( Ersatz fur Stand: 8/1994 ) vil Ct —_ Workshop Manual_R 7031(R 7011, R 7001) S-D Diagnostic device Diagnostic device yellowLED 1-10 yellow LED 11-20 48-position plug f / Diagnostic meter ‘Ordering No, 301 723, Adapter plug A ‘Adapter cable Ordering No. 301 724 © STILL GmbH_ Stand: 02/2003 ( Ersatz far Stand: 8/1994 ) x Ct —© STILLGmbH_ Stand: 02/2003 ( Ersatz fur Stand: 8/1994 ) x "Workshop Manual_R 7031(R 7011, R 7001) S-D Diagnostic device Diagnostic device Explanation of abbreviations Handbr. angez. V.- Motor steht Pscsosesnwetoues beech = Handbrake on, engine off Achtung! Fanrceug vorn autbockan Gen. Erregung riickw. = Generator excitation backwards Frequ. Lichtmasch. neutral, Vollgas = Frequency Dynamo neutral full revolutions sesvesees| 2 Pty een cau har Tachogenerator vorw. Vollgas = Tachogenerator forward, full revolutions 4 \ \ \ \ LED1-10 LED LED LED 11-20 Button FRONT PANEL yellow green red yellow Fixing screws If fuse is blown check motor-generator circuit for earthing.Diagnostic device Comparison between test stages performed with digital diagnostic meter and diagnostic meter with red-green display ——— Fault analysis with digital 5 digital diagnostic meter Pin ed/green| Pin intemal supply voltage 1 +10 volts 22B — Sich.e3— P/n2 22B Internal supply voltage 1 “10 volts 282 — 2/u36 —Nint 282 ‘Recelerator controlu2s 7 un-operated 24Z-21L.25 24Z 48D-4/25 _ 28D-3/L.25 Keyswitch b1 2 20B 8Z- 15-30/b1-22- Pin2 20B-Pin2 Direction switch b2 neutral 46D - Nint = 0Volt (9) 24D - Nint = 0 Volt 16B Direction switch b2 forwards 46D - 4/U1/b2 3 16D 48Z - 1/U1/b2 Direction switch b2 backwards 24D - 4/U2/b2 418Z - 1/U1/b2 5 24D Direction switch b2 neutral 16B - Nin1 = 24 volts 16B 16B - Ninfi=24volts Accelerator u25 fully operated (full throttle) 8 24Z 242-2125 48D-1/.25 _28D-3/L25 Start engine 10 | Parking brake off 10 Ground —18D,30D,2Z,282 _ +10Volt— 28B,28D,18Z,30Z - 10Volt — 322, © STILLGmbH_ Stand: 02/2003 ( Ersatz fur Stand: 8/1994 ) 4 rareDiagnostic device Comparison between test stages performed with digital diagnostic meter and diagnostic meter with red-green display digital Fault analysis with digital diagnostic meter Release parking brake 148 - 1B/c26 Rom sensor, frequency 42D-Wiutl Fuse, generator excitation only at power unit 315105 12B - 7/u36 Pin red/ Pin 14B 12D 12 12B Drive motor excitation blocked 10B 410B - 1/436 13 Drive motor excitation max. 102 - 1/u36 14 102 Generator excitation forwards/backwards Idlespeed 15 8B 6B-6/u36 8B-3/u36 6B Current sensor n 35 16 32D - 2/135 30Z(+) - 3/L35,, 20Z(-) - 1/135 6 32D Generator voltage AZ forwards Idlespeed 35 AD - 4Z = voltage ‘Tachogenerator m10 Voltage FULL REVS. 22Z 20 22Z 19 | 22Z- 30D = voltage Tachogenerator m10 Synchronous operation FULL REVS.| 997 20 207 20 22Z - 30D = voltage Ground —18D,30D,22,28z © STILLGmbH_ Stand: 02/2003 ( Ersatz fur Stand: 8/1994 ) xi +40Volt — 28B,28D,18Z,30Z = 10Volt — 32Z STWorkshop Manual_R 7031(R 7011, R 7001) Measuring and test The following test equipment and tools are required to carry out the test. Item Description 1 Diagnostic meter with digital display 2 Data card for diagnostic meter 3 Analog-Digitalmultimeter METRAHIt 16L. including insulation test 4 Current clamp C7233 5 Continuity tester Insulation resistance tester METRISO 500D soe 7 Extraction tool for multiple-pin plugs 8 — Replacementtube 9 Crimp tool 10 Test prods for 30. (pair) 11 Test prods , Kleps 30 (pait) 12 Alligator clips (pair) 13. Instrument leads (pair) 14 Hand pliers for SKT-connectors 15 Extraction tool for SKT-connections 16 Universal measuring adaptor for SKT PartNo, 147587 145530 161117 156300 120644 161117 120600 144023, 144087 143426 143424 143427 143425 146354 143432 147358 g instruments Manufacturer STILL STILL Metrawatt Metrawatt Testofon Metrawatt AMP. AMP. AMP. AMP. AMP. STILL Itis assumed that the tester is familiar with the proper use of the test equipment and tools. Please follow manufacturer's instructions in each case, Always check the power supply batteries of the measuring instruments before each test and recharge them, ifnecessary. © STILLGmbH_ Stand: 02/2003 ( Ersatz fur Stand: 8/1994 ) xa CeDiagnostic meter with digital display Part No, 147 587 Fuse 315 mA for diagnostic meter Part No, 146 341 Data card set Part No, 145 530 Universal measuring adaptor for SKT Part No. 147 358 © STILLGmbH_ Stand: 04/2003 ( Ersatz for Stand: 8/1994) xv"Workshop Manual_R 7034(R 7014, R 7001) S-D Analog-Digitalmultimeter METRAHIt 16L inclusding insulation test Part-Nr. 161117 Current clamp Z13B Part-Nr. 156 300 Testofon Part-No, 120644 red rot! schwarz black Test lead Part-No. 301 958 Test lead Part-No. 301 957 Test lamp 24 volts /18 or 21 W (Sel-made) Bridges , 3altogether (Seltmade) © STILLGmbH_ Stand: 02/2003 ( Ersatz fur Stand: 8/1994 ) xvInstrument leads, pair Part No, 143.425 Alligator clips, pair Part No. 143.427 Test prods, pair Part No, 143.426 Test prods, pair (Kleps 30) Part No, 143.424 Jumper lead (orrelay) © STILLGmbH_ Stand: 04/2003 ( Ersatz for Stand: 8/1994) vl & back sctware GRD red rot oS tack schware Qh lea 0 WA~ Workshop Manual_R 7034(R 7011, R 7001 S-D Hand pliers for insulation displacement technology Part No, 146 354 Crimp tool Part No, 144 087 Extraction tool Part No, 143.432 Extraction tool for insulation displacement technology Part No. 120600 Replacement tube Part No, 120601 Revolution counter, digital Part No, 146 665 © STILL GmbH _ Stand: 04/2003 ( Ersatz fur Stand: 8/1994) vi Ct —" Workshop Manual Deumo In these diagnostic instructions, revs.between 900 and 3000 rpm are measured with the Deumo revolution counter at the camshaft Remove cap screw Please pay attention: Fault diagnosis from test steps 1 - 10 is carried out with engine off and parking brake applied, and from test steps 17 - 20 with engine running and parking brake released, R.7034(R 7011, R 7001) CAUTION when operating the engine indoors or in confined spaces: Poisonous fumes! ‘Adequate ventilation should be provided to disper- se the exhaust gases into the air. Preparation SAFELY CHOCK UP TRUCK AT DRIVE WHEELS (FRONT) Both drive wheels must bé'tumned easily © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) AST‘The parking brake must be applied ‘The Keyswitch must be turned OFF. ‘The fuel tank must be filed Diesel: Fuel system must be bled wane 2 Batteries Batteries must be filed and charged 3. Controller © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) xTo remove p.c. b.: Raise rear hinged cover (remove r. h. section cover where truck is fitted with a bipartite hood in connection with an exhaust pipe of he upswept type), - Disconnect starter batteries. - Loosen setscrews of contactor control panel (electrical control gear) assembly, pull the latter upwards and secure in vertical position by tightening the upper setscrew. Remove screws which hold plastic cover and pull off the latter from control panel assembly. = After loosening the 6 screws, remove p.c. b. from Power unit u36, Unplug connector L200. © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: )Preparations Diagnostic device ~The connectors are of asymetrical style and halves join positively during mating only provided the - Connect diagnostic device with adapter cable, connection is engaged property; never employ force, -Plug diagnostic device-adapter cable into connector —_- Reconnect batteries. Stecker L200 Distance a is evidently larger compared to distance & A safeguard against twisting is therefore provided © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand:Workshop Manual_R 7034(R 7011, R 7001) Setup of the Diagnostic Instruction In the following diagnostic instructions the operational sequence is shown on the left page in the form of a flow chart and the corresponding figu- rative representation of the testing procedures on the right page. The sequence of the specific operations is represented by figures in a(_),, the operations displayed on both the left and the right page being identical ‘The correlated figure numbers appear in a box{_] on both left- and right-hand pages. The abbreviations stated in brackets are to be intempreted as follows: Bu = socket half, St= pin halt Preparations Regarding all test steps this applies: Before starting the operations listed below disconnect the negative terminals of batteries n1 and n2, after which they must be re-connected Checking wire connections, Removal and replacement of components. - Fitting and removal of bridges. Always disconnect diagnostic device before checking for ,earth faults" and proper insulation. © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) Ce_ Workshop Manual_ R 7034(R 7011, R 70( Connectors ‘The electrical functional groups and components are connected via different types of connectors to the wiring hamess. Below you will find a synopsis of all connectors used on the truck. Front cowl L19- Mate - N - Lok, 6 position Start interlock parking brake switch b21 L21- Mate-N-Lok,6 position (1) Directional selection switch b2 (steering column) L2- Mate-N-Lok, 15 position @ Instrument panel, various L20- Econoseal, 3 pole @ Directional selection switch b2 L4- Econoseal, 3 position ® S-stage switch L1- Positive Lok, 2 position 4 Starter relay c14 Beneath floor plate, front end L25- Econoseal, 3 position @ Accelerator pedal transmitter u25 L35- Econoseal, 3 position ® Current sensor n35 Lit - Econoseal, 3 position ® ‘Tachogenerator m 10 L10- Mate - N- Lok, 6 position a) ‘Switch, waming horn b89 Ls, L7- Positive Lok, 2 position 4 Motor fieldigenerator field L8- Positive Lok, 2 position 4 LO8 - Mate - N - Lok, 2 position 4) Rear truck compartment: L5- Positive Lok, 2 position 4 Glow plug/starter system LO5- Positive Lok, 2 position 4 Exciting current motor/generator L3- Mate-N-Lok, 15 position (2) Control panel! L21- Mate-N-Lok,6 position (5) Electronic compensator u21 L36- Mate-N-Lok,6 position (6) Control, power unit 1200- DIN connector, 2x24pin 6) Connection p. c. b. u200 11-7/u36 - Positive- Lok- Faston a © STILL.GmbH_ Stand: 8/1904 ( Ersatz fur Stand 01) XaWorkshop Manual ‘TEST CONDITIONS Engine turned off Parking brake applied Safely chock up truck! Drive wheels (front) must be turned easily Keyswitch turned to OFF Diagnostic device connected Batteries charged and file Fuelintank 8 test stage 1 indicated by LED 1? yes Which Indicator lights? green R 7034(R 7011, R 7001) Test stage 1 Teststauet (4 Battery voltage Unelip diagnostic device Remove fuses €3 and e4 and cheek for continuity cheek wire connections: 1) 282/L200- 1/136 2) 1036 21u36 3) 2u96 = Nint 44) 228/L200 61L3 (st) 5) 6iL3 (Bu) - 30103 8) 303 ale 7) bled = 1 Ale26 (426) 8) 1Aic26 ale (internal retay ©26) 9) bles Pina 10)7011 be3 -21L05 - Pina Remneer or renew fuses e2 and e cure faut Connect alagrowte Geviee, Retest test stage 1 again Are the wire connections OK? Check battery voltage: 11) 8 Pm2 (0) - Nint around 24 volts Charge, repair or renew batteries Replace fuse in diagnostic device (200 mAi250 V fast) Connect dagnostic device; retest tet stage 1 again © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 2 AST© STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 3 Ct —"Workshop Manual_R 7034(R 7011, R 7001) S-D Test stage 2 fon Teststage2 (4 Checking keyswitch for function Press button Test stage 2 Is indicated by LeD2 sham keyendich to 088 Tnelp diagnostic device Remove and check fuse e3 (fuse box R. H. 8. of truck) Check wire connections 1) 20/1200 — 2113 (s1) 2213 (8) — 212 (@y) red 3) DLS) —Sicn 3A/e 4)3 Sich 3B/e .— 15ibt 5/3001 —21L1 (SY) 6) 2IL1 (Bu) — Pint Reingert fuse €21 Cure faut Connect diagnostic device green Retest test stage 2 again Wich Indicator lights? are the wire connections. OK? Disconnect batteries (Check Keyswitch bt renew if necessary 6 Reinsert fuse 3e) Reconnect batterice Connect diagnostic device Retest test stage 2 again Cure faut Reinsert fuse ©2 Connect diagnostic device Retest test stage 2 again green © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 4 Ct —© STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: )R_7031(R 7011, R 7001) "Workshop Manual © STILLGmbH Press button ‘Test stage 3 is indicated by Les Direction sunitch into forwards" red Unclip diagnostic device whieh Indicator Ights? >] Switch Ut in switch assembly 62 must be closes: cheek for function: Ut against 41U1 =continulty green no yes Check wire connections: aur — 121 (St) 2) 10.21 (Bu) — 11.20 (Bu) 3) 120 (s4) — 182/200 sat — 21021 (s) 8) 21L21 (Bu) — 21.20 (Bu) 6) 21120 (st) — 1e0".200 Direction switch into Cure faut backwards" Connect diagnostic device Retest test stage 9 again green Sion UT Tr swith assembly BE an must be open: check for function indicator Ights? >] U1 against 4/U1 =no continuity adjust switch; replace if nec. red Direction switch into forwards" Indicator ,green* lights green Stand, 8/1994 ( Ersatz fur Stand Test stage 3 Tesanoes (6) Direction switch ,forward* ‘Adjust evitch U 1 /b2 or replace if Connect diagnostic device Retest test stage 3 again AST© STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) z Ct —Workshop Manual R 7034(R 7011, R 7001) Test stage 4 Tost stave 4g Direction switch ,,neutral" Checking start delay unit for function [Rajust satan USBZ, renew I nec. Iconnect diagnostic device Retest te Istage 4 again Cure faut Connect diagnostic device Retest test stage 4 again Renew etart delay uni w37 Connect diagnostic device Retest test stage 4 again 7 Indicator ,,gree nie Ted | must be closed; check for function: Indicator lights? ty vs . directly | 4) 173 — 4/121 (St) light has 6) 5/121 (Bu) — 3/L19 (Bu) elapsed 7) IL19 (St) — chassis ‘ 8) 4/U3 (+)—1/.37 (-) = © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) ASTWorkshop Manual_R 7034(R 7011, R 7001) S-D Test stage 4 © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 9 Ct —Workshop Manual green R 7034(R 7011, R 7001) ® Vatimeter check at (lug relay 64 Into socket) 1) 85144 1+)—Minus. = around 12 volts Pat direction ewitch into forward" or ,backward no ls voltage present? yes [check wire connections: 3) asiaa — 131L21st) Js) 131.2 (Bu) — ants (St) 5) Bridge: 11.19 — 21L19 (Bu) cure faut [Connect diagnostic device Retest test stage 4 again 4 Test stage 4 Teststaged (3 Direction switch qneutral Checking start delay unit for function Voltmeter check 2) B6id4 (+)}—chassis = around 12 volts no s voltage present? yes green whieh Ineator lights? > ‘Switch U3 in switch assembly b2 ‘must be open: check for function: | 103 against 4/U3 = no continuty adjust or renew switch as. necessary (Check relay dé or renew if nec. (Functional Group 08/Checking relays) Connect diagnostic device Retest test stage 4 again red ‘ut direction switeh into ,neutral ndicator green wil ight er around 2 secs have elapsed. Does Indeator green" light with avcelay? Renew Sar delay unk aT Retest test stage 4 again © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 10 (Check wire connection; cure ae lnecessary lssisa—sae |Connect diagnostic device Retest test stage 4 again ASTWorkshop Manual_R 7034(R 7011, R 7001) © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 1""Workshop Manual_R 7034(R 7011, R 7001) S-D Test stage 5 ‘green Test stage 5 (7) Press buton “Test stage 5 i indicated by Direction switch ,backwards* LEDS Dikection suiteh into backwards" Uncip agnostic device ‘Smich U2 in switch assembly red | b2 must be close: wien indicator ights? > Peek 0" function: 1102 gegen 4/02 = continuity green us Adjust switch U2Ie2; renew if Connect aiagnostc devioe Retest est stage 5 again yes Pat drecion soiteh ito ‘Check wire connections foruarss 4) 11u2-40u1 2yauz —3121 (8) 3) 31421 (Bu) — 3.20 (Bu) 4) 31120 (St) — 240/200 cure faut Connect diagnostic device Retest test stage § agsin we GFEEN Ts vitch U2 in witch assembly b2 ea must be open; check for funtion: ane U2 against 4/02 = no continuity adjust or renew switch as, red Put decton sui ite backwards" Indicator .green” lights green © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 12 Ct —Workshop Manual R 7034(R 7011, R 7001) © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 13 Ct —"Workshop Manual_R 7034(R 7011, R 7001) green Press button Test stage 6 i indicated by LEDS wich indicator lights? green green © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: Test stage 6 Tetshoet (47) Checking current sender Unclip diagnostic device Check wire connections 1) 1835 ~Bu) — 20211200 2) 21.96 (Bul — 320/L200 3) SIL35 (Bu) — 302/L200 10 Are the wite conections OK? Cure faut Connect diagnostic device Repeat tost stage & Renew current sender n35 Connect diagnostic device Repeat test stage 6 “4 AST© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand Test stage 6_ Workshop Manual_R 7031(R 7011, R 7001) S-D Test stage 7 ‘green Test stage 7 (3) Press button Checking travel sender st sioge 7 i indented by {accelerator pedal transmitter) |Acceierator peda in © positon red Inspect O-positon of travel sender: wien Disconnect thot inkage at Indiatorights? >> sccelerator pedel green een whieh 2 Eliminate fui at thot inkage: indeator ints? > see Functional Goup 15 under section .Speed setting, red Unclip diagnostic device Check wite connections: 4 41125 (S) — 1801-200 2) 20.25 (s%) — 242/1200 3) 3126 (St) — 2801200 0 Ate Cure faut wire connections oK? Connect diagnostic device Repeat test step 7 yes Renew accelerator pedal Connect diagnostic device Repeat tet step 7 green © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 16 Ct —© STILLGmbH_ Stand: 8/1994 ( Ersatz fur Stand: ) 7 Workshop Manual_R 7034(R 7011, R 7001) S-D Test stage 7green Press batar Test stage 8 is indicated by LEDs Accelerator pedal fully ‘operated (ful throtle) whieh indicator lights 2 green Workshop Manual_R 7034(R 7014, R 7001) S-D Test stage 8+9 Testsases (9) Checking travel sender (accelerator pedal Press button ‘Test stage 9 i indicated by LeDe Put direction switch ino neutral” Indicator green lights with @ delay whieh indicator lights? green ‘green © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: transmitter) testsiages (5) 1 Direction switch ,neutral* ees rai ci green fEiminate fuk atthrotle Inkagey See Functional Group 15 under section ‘Speedsetting® whieh Indiator lights? Retest test step 8 again red UUnelip diagnostic device Renew accelerator pedal Connect diagnostic device Retest test step 8 again 2 Put direction switch into neutral ‘cary on with test stage 10 ) oo ASTs-D Test stage 8 and 9 8 8 4 8 “ 8 2 a a g Z 5 = 2 8 2 é = 5 = Me ST 19 ) © STILLGmbH_ Stand: 8/1994 ( Ersatz fur Stand:"Workshop Manual_R 7031(R 7011, R 7001) green Praws billon Test sage 10= inated by LED 10 ‘Start engine Release parking brake no (Reyswiteh 10-0" does the lt starter: starter u 12 | en? ICheck earth (chassis) connection yes Cure faut Test stage 10 testsase0 (40) 10 Engine starting GENERAL HINTS. -see Functional Group 15 Retest test stage 10 again Check whee connection: 301ut2—Pin Cure as necessary or inspect battery n 1 (Functional Group 08) : @ © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: 20 0 6 ‘earth connection OK? yes Voltage measurement: 3) 301ut2 14) - 311012 () round 9 - 12 volts 0 is voltage present? yes Keyswitch to ,START* Voltage measurement 3) 11L08 (+) — chassis (engine) = around 9-12 volte yes is vo tage present? | 4) 11008 (Buy — sovut2 Engine will start with a delay} of around 2 secs Keyeniich to OFF Check wire connection: Repair or replace starter as necessary Retest test stage 10 again AST© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 24Keysuiteh to START: Voltage measurement 41) ALA (#}—chassis () = around 9-12 volts is voltage present? Workshop Manual R 7031(R 7011, R 7001) Test stage 10 Testsawe10 (4) Engine starting yes Keyswitch to START: Voltage measurement: 2) Sobt (+}-—chassie Hts = around 9-12 vol cheek wire connection 5) 41L4 (Bu) — 1/108 (St) Cure faut Connect diagnostic device Retest test stage 10 again is voltage present? yes Disconnect batteries Replace keyswitch b1 Reconnect batteries Retest test stage 10 again Keyswitch to OFF Check wire connections: 3) 3014 — S001 4) 144 (89 — 87104 Ate wire connections OK? no yes Renew relay dé Retest test stage 10 again Repair wire connections Retest test stage 10 again yes © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: 22 AST© STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 23. Ct —Workshop Manual R 7034(R 7011, R 7001) S-D Test stage 10 yes Test stage 10 vom (10) Check shut vave 20 no | 1) Pullout tre pug and spiean | Engine starting Does several mes against engine sar? ‘onnection the valve should ele audbiy yes yes Isa click” audbie? 0 Votmeter check at 2) Lead /e20 (+)—chassis, round 12 volts Keywiteh to ,OFF Renew shut-off valve ¢20 Repeat test from (2) Voltmeter check at 3) 4Ave... (+) —chassie = around 12 volts Keysuiltch to OFF no | cheek shutoff valve and supply _ lead for earthing voltage present? CCure faut, replace valve if necessary Replace fuse Ad Repeat test from (2) Keysuitch to OFF Check wire connections 4) ale20 — 3112 @u) 3) 3112 (S)- 4 Ale aa) Cure faut wire connections Repeat test trom ‘OK? ys ® © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 24 Ct —© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 25~ @ Keyswitch to ON! Voltage measurement 1) 11L5(+)— chassis, around 9-12 volts Workshop Manual R 7034(R 7011, R 7001) S-D Test stage 10 Testsage 9 (4) Engine starting Keysuiteh to OFF is voltage present? yes es te " Check we connection voltage present? 3) 15 (Bu) — ves no is wire connection ox yes ACheck glow pidge (see Funnel Group 15) B.Check shutoft valve for Vollage measurement mechanical operation, replace parts as necessary 2) 21.5 (+) ~ chaseie Pama Retest test stage 10 agoin round 9 - 12 volst ‘ure faut Retest test stage 10 again Keyswitch t OFF no ReysaTich 10 OFF check wire connections 4/218 (St) — 30188 5) 871488 — ale2 6) bier — 1115 (81) ~ @ © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: Check wire connection (7) 215 (Bu — Pint Cure faut Retest test stage 10 again a AST© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 2R 7034(R 7011, R 7001) "Workshop Manual ‘ce the wie connections (OK? 1) Check fuse 2 fuse 62 yes Remove relay 488 from socket; keyswiten to ,ON" Voltmeter check at: 2) 861488 (+) — 851488 () = around 12 volts yes is the voltage present? 0 ~ ® © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: Test stage 10 restense0(4.Q) Keyswitch to ,OFF Cure faut Retest test stage 10 again Engine starting Check glow plugs for short circu faut (ee Functional Group 15) Cure faut Replace fuse e2 Retest test stage 10 again —Tresting test stage 11 green green © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 30 Preheat check age—9113—121L2—2me8, 1 Mh@6—Sich, 1 /e AST© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand"Workshop Manual_R 7031(R 7011, R 7001) S-D Test stage 11 a Tensor (44) ress button Relay controller Test stage 11 is indicated by LED 11 means power unit (old type) without integrated relay red yes s Shut off engine indcater ght? >_< contactor 28 Unaip lagnotc devee pulleain? (Check wire connections 1) 1826 4036 2) 41u36 - 148/200 green 10 Are wire conections (OK? check contacts of 26 foxiclation?) * repair €26 if necessary Renew diagnostic device Repeat procedure from test step 10) Cure tau Connect diagnostic device Repeat procedure from test step 10 geen © © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 32 ASTTest stage 11 © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 33__ Workshop Manual R 7034(R 7011, R 7001) laren [4 Shut off engine Remove relays 1 - 63° Bridge relay contacts: Bridge safely switch b21 (1-421) on the parking brake (parking brake released) no Has: contactor 626 pullesin? yes Remove bridge on safety switch 21 on the parking brake >] 1) alc2s (+) - bic2s (9 Has contactor 626 pullesin? yes green ) © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: Te relays as por ions Functional Voltage measurement: ge round 24 volts Renew contactor ©26n ake Repeat procedure from test stage 10 * means different types of power unit “Adjust or change if necessary ‘safety switch b21 on parking brake Care ut Go on again with faut finding from (6) Test stage 11 Testsaset (44) Relay controller is the voltage present? nei diagnostic device Check wire connections: 2) bv026 3)6509 — 1313 6 * 4) 1903 (S1) — chassis () sya ——eraZ——— bridge 8716220142 6) 302 —aiL3 (@u) 7) ait (St) — SIL19 (St) 8) SiL19 (@u) — 4021 Re Pull off lead 421 from switeh = asda ae are wire connections (OK? ‘STi.Test stage 11 © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 35. Ct —" Workshop Manual_R 7031(R 7011, R 7001) S-D Test stage 11 loreen [4 ® Test stage 11 (1 1 ) Remove badge Yom relay soe Relay controller Plug relay 2 into socket d2 Unclip agnostic Caves ‘Chesk wire connections! 0 —_Jheck wire connections: is 4) as — 8.18 64) eee ese2 - 713 (oy syeni9(s) — 413 (89 2) 71.9 (St) - 60 /L:200 6) 4 (Bu) — 01d 7) 30181 —86ia2 bridge 20/61—87a/dt a) evaia) — 26st 9) sraiat — 7143 bridge 30/43—87143 Cure faut Reconnect ead 4/021 to b2 Repeat fault finding from (8) yes 2 Ramnave bilge Wom relay socket Plug relay d3 into socket &3 Keysuitch to .ON* yes | Keyeuten to OFF are Renew diagndstic device wie connections >———| Keysuiteh to ,ON’ (OK? Press button to test stage 11 Do net start engine Go on again with faut finding from (7) Cure faut connect diagnostic device Ikeysuitch to ,ON" Press button to test stage 11 loo not start engine [Go on again with faut fincing from (7) ins different types of power unit Keyswitch to OFF no | Repair wire connection: Has. 3) B61a3 — 203 (Bu) contactor 626 >—— 5 asus — 19.3 (Bu) pulledin? 4) 198.3 (S1) — chassis () Cure faut fee Press button to test stage 11 Do not start engine Go on again with fault finding from (7) ~ — |® STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 36 ASTeos ZC 001) eee _S-D Test stage 11 Workshop Manual R © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 37, Ct —Workshop Manual R.7034(R 7011, R 7001) Test stage 11 loreen [4 ® Test stage 14 (1 41 ) Teayerich 0 OFF Remove bridge from relay socket Relay controller u Pig relay 1 to sooket 1 Kayeutich to JON" Turn Keyswitch to OFF" Urcip ogres coves check ve conectone: no [Wma eemirement pian —1012(@) bees the syn) 278 ‘ eee pars.) aNB 2yrou2 pf tmz light? = around 24 vol (bridge, or Diode n25) 412 @u)— 1 yes 518 @4) — Dow 7 sins — e123) , 72.) — eras the volage 2) 118) — ana present? or 87a core tut yes Connect dgnoste device farm teyowten oO Prete buton toed ape 1 snot Sat engine eee eo ach akg Charge control lamp h73 will go Renew charge control lamp h73 from (8) ot SAG sae ReTTRyaT m0 [eheoraternstr a, cogs, Connect elegnoste deve Oa ‘V-belt, posttive line to battery; Repeat fault finding from test ‘charge control lamp h73 repair or renew as necessary. stage 10 go out? Repeat fault finding from test Sage 10 yes Sha age < mo [ct igus device oe Remove relay d1 from socket Are ccommactoniece) Check wire connections ‘wie connections puledin? anne 9) ro. Bs) 31 (8) 40) 863143 60) yes creat agnosie necator os aio Cornet dagnoste deve stage 11 lights .o Repeat fault finding from test Say 10 reen STILL GmoH, Stand: 91904 ( Ersatz tur Stand, 28 Ceshop Manual _R 7031(R 7011, R 7001) © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 390 Ct —- Workshop Manual_R 7031(R 7011, R 7001) S-D Test stage 11 green Testsaset (441) Engine r. p. m., idle 1 (tickover) Cheek. p.m, of engine: idle 7011 900 + 50 rpm. 7031 100050 rpm.or 7031 1250210 rpm i engine rpm Reciy speed setting: ‘See Functional Group 15 under eat? section ,Speedsetting” yes 2 [Check . p.m. of engine: Full, thvottie: 2750 50 rpm, no ‘6 Reclly speed setting: engine rpm ae correctly ‘See Functional Group 15 under set? section ,Speedsetting® yes yes © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 40, ASTTest stage 11 © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) at| Workshop Manual_R 7031(R 7011, R 7001) S-D Test stage 12 es Testsage 12 (43) Is 028 integrated in power unit 0367 Fuse excitation Continue at test stage 13 (generator field) (28 at contactor conrol panel! Press button Test stage 12 Is indicated by LeD12 Shut off engine 41) Check fuse in power unit u36 for continuity (ype 20/LCT) UUnlip diagnastic device Check connection: (inside on u36) 2) fuse /u36 - 7436 Check wire connection: yes 3) 736 - 128/200 Wich Indicator lights? Has: fuse continuity? 4 no UUnelip feld connectors 31436 and 16108 of generator Fela Replace fuse in u36 by test lamp green are wire connections (OK? Start engine Renew diagnostic device Retest test stage 12 again ro Does the test lamp light? 2 yes ‘Shutoff engine Pullout leads (only 1 + 41.36 remains connectea| Cure faut Retest test stage 12 again 203IL36 -) trom wi36 disconnected Si6iL36 -) Shut off engine teallamp Renew power un v6 tt? Connect 2815/6.98 Continue with the testing fo rocedure! 3 Reconnect 2/3/56/L96 to u36 Uneip leads Lead 1 Ut Lead4ui atb2 Lead 42 (Girection switeh 2) Start engine ®| ® © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 42 Ct — green© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 43green Workshop Manual [2] R 7031(R 7011 @ R 7001) yes Does the test lamp light? no a off engine heck wire connections at itch 82 for swapping: 1) ¥L20 (Bu) - 1/01 una 17U2 2) 21.20 (Bu) - ait 3) 81120 (Bu) - 42 ure far, e-connect plug L20 art engine, Direction switch b2 into backwards" Does the test amp ight? 3\|4 yes Direction suitch b2 into forward” Does the test amp light? 3||5 10 yes Sha of engine ‘Switch 2 into ,neutral* Remove test lamp Fit a new fuse info 26 ® © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) Test stage 12 Testsawe 2 (4 3) Fuse excitation (generator field) ‘Shut off engine Renew diagnostic device Connect plug L20 Start engine 5 ‘Shut off enaine Replace power unit u38 Carry on wifh the testing procedure @ Shut off engine Renew power unt u36 Carry on with the testing procedure aa ASTWorkshop Manual R 7034(R 7011, R 7001) © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 45" Workshop Manual_R 7031(R 7011, R 7001) S-D Test stage 12 areon ® Testeaoe 12 (43) Disconnect diagnostic device Fuse excitation (Check generator field and leads for (generator field) contioully and earthing ‘3496 - 61U36 =continuty 31436 - chassis = no continuity 161u36 - chassis © no continuy Cure faut if nec 1 FAS A fuse fo feet e8d 301 OST lengthen lead 3/496 with test lead 301 957 (+) and tead 6/u36 with test lead 301 956(-) Hold the free ends of test leads firmly onto the folowing connections (24 volts) 3036 Se Pin (+ batt) 6496 @ Nit batt) Is 15a yes fuse intect oad 301857 blown? 2 10 Tengthen lead 6106 withtest lead 301 957 (+) and 7031-7011 Tend Ss vith tox tad 901 86, At -A Hol hee ends ofthe tetas frmly ‘onto the following connections (24 volts): B2--H 6u36 ew eape Pind (Oat) A2--B M38 ge Nt (ba ree F1- -J F2- -K v Earthing or short-circuit fault in generator field! Cure fault necessary renew generator eld ca Is oF generator mot is 188 fuse in test lead 201 957 blown? yes v v Connect generator feld and leads to 31u36 and 61436 Connect diagnostic device Retest test stage 12 again green © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 46. Ct —© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) a7Workshop Manual R 7034(R 7011, R 7001) S-D Test stage 13 Test stage 13 green Motor excitation zero Press button Test stage 13, is indicated by LED 13, red which Voltage measurement indicator ights? >] 1) 1/496 (+) «chassis = around 27 vots ‘green Shut off engine is re Uncip diagnostic device the voltage ES _] check wite connection: present? 4) 1436 - 108/200 0 Shut off engine cm Check wire connections: 2) 436 - Flim? isthe 3) 1436 - F2im2 wie connection OK? Replace degnostc device Repeat test step 13 7031-7011 A1--A B2--H Repair or replace motor m2 as A2--B Connect diagnostic device; repeat F1--J fault finding fom test stage 1 F2--K no are Cure fault wire connections >) repeat test step 13, yes oven ® © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 48 ASTTest stage 13 © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 49Workshop Manual R 7031(R 7011, R 7001) green ® yes Connect dagrostic device Go on again with faut finding from test stage 13, Voltmeter check at: 1) 41.36 (+) = chassis Votage lower than 1 vol 0 -nn.vort) Is the voltage lower than 1 vol? yes ‘Shut off engine Start engine ‘Shut off engine Unclip ead at 138 2). Press the en test lamp ont connection 1 and 4 15s of the leads of fo power unt USB green © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: the test lamp Does light? no yes ‘Shut off engine Test stage 13 Teersuses? (4.4) Motor excitation zero Renew diagnostic device Retest test stage 13 again 1 Unclip diagnostic device Renew power unit u36 ASTTest stage 13 © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 51"Workshop Manual_R 7034(R 7011, R 7001) S-D Test stage 13 Tesitase's (4 4) Motor excitation zero green 1 ‘Shut off engine Unclip diagnostic device Equip test lead 301 957 with 40 amps fuse Lengthen the lead 4/u26 with test lead 201 957 and lead 1/u36 with test lead 301 958 Hola the free ends of test leads firmly tonto the following connections (24 volts 436 Se Pina (+ batt) 138 @————Nint Catt) yes 340 A use In test lead 301 957 blown? 2 Repeat teaing procedure wth Teveraed potaiyt Lengthen he toad Vu96 vith test lead 301 957 and lead 4/u36 with test lead 301 958 7031-7011 Hold the tre ends o tes leads fry onto A1--A the folowing connections (24 vols} ° B2--H 136 eS Pind (+ att) A2- -B 4436 @——=— Nin batt) F1--J F2--K v Earthing or short-circuit fault in motor field, Cure faut necessary renew motor field coils ‘ar motor m2 lead 301 957 blown? ‘onnect motor fed and leads to 1 1496 and 4/86 Connect diagnostic device Repeat test step 13. green © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 52 Ct —| Workshop Manual R 7031(R 7011, R 7001) S-D Test stage 13 © STILLGmbH, Stand: 8/1994 (Ersatz fur Stand) 53 MSTA"Workshop Manual R 7034(R 7011, R 7001) S-D Test stage 14 green 41 rest stage 14(15) Motor excitation max. Press bon Test stage 14 is indicated byLeD ts red wien Indicator lights? Votage measurement ees 1) 4it36 (+) ~ chassis () round $10 vote green Shut off engine Uncip yes | diagnoste device ts the vottage Renew power unit u36 resent? bs Connect eiagnosic device Retest test stage 14 again 0 Shut off engine Unc diagnostic device Check wire connection 2) 41.36 - 10271200 0 is Cure faut wire conection >——} Connect diagnostic device On Relea test stage 14 again yes Replace diagnostic device Retest fest stage 14 again green © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 54 ASTWorkshop Manual R 7034(R 7011, R 7001) Test stage 14 © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 55/ Workshop Manual R 7034(R 7011, R 7001) Test stage 15 = reeteage (16 ) Press bution WARNING: Tes stage 15 6 nsicates by . Generator excitation Direction switch into eee sbackwards* sbackwards" Keysnitch to .OFF Unelamp lead "at drive motor m2 yes and hold & clear ie Svatch b2 into snout the engine Start engine ‘alled? Diagnostic meter to test stage 15 ‘Sulton B2 nto zbackwards" ia 1 ‘hat off engine Uncip diagnostic device ' yes Check drive motor m2 for shorts in th rat armature circuit A1 - A2; cure fault me engine teplace drive motor m2 if necessary| stalled? Re-connect lead At/m2 Connect diagnostic device Retest est stage 16 again 3 0 Keyswitch to OFF Unclp lagrostic device ‘Check generator m0t for shorts in armature circuit At - 82: cure felt feplace generator mt necessary 7031-7011 Reconnect lead Atlm2 ‘Connect diagnostic device Al- -A Retest teat sage 15 again B2--H A2--B F1- -J F2--K red Volimeter check at Which indicator ights? 1) 31099 (+) chassis = around 20 volts green yes ‘Shut off engine 6 Uncip diagnostic device the votage Check wire connectors present? 2) 9611200 - 196 no green 5) © STILLGMbH Stand 8/1904( Ersatz fur Stand) 56 , 7Workshop Manual R 7034(R 7011, R 7001) S-D Test stage 15 © STILLGmbH, Stand: 8/1994 (Ersatz fur Stand) 57 eweWorkshop Manual_ R 7034(R 7011, R 7001) S-D Test stage 15 ‘green 5) Test stage 18 (1 6 ) Generator excitation backward: Voltmeter check at: are 1) 21.36 (4) -21u36 (-) wire connections: found 10 volts Ok? Renew diagnostic device Retest test stage 15 again yes is the voltage present? Shut off engine Renew power unit u36 Retest test stage 15 again no ‘Shut off engine (Cure faut Unelip diagnostic device Connect slagnostic device Check wire connection: Retest test stage 15 again 2) 21L36 - 122/L200 yes I Renew diagnostic device wite connection ->———— Retest test stage 15 again ‘OK? no ‘Cure feu Connect diagnostic device Retest test stage 15 again green © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 58 Ct —lorkehiop!Memualls i703 4(R12 01:1 Ft} 00/1) SeiaEeaaeeemetesee memes (Used 7 © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 59R 7001) /— Werkstatt-Handbuch _R-7031(R 7011 Test stage 15 ‘green Test stage 15 (1 6 ) 2 no Generator excitation -backwards" Does Votimeter check at the dive tun >} 1) 8136 (= 2498 6 ackwarcs? = around 10 vots| yes no : Shut off engine 5 Unelip ciagnostic device calusiagee reck wie connection present? Check “ 4) 6iL36 - 14011200 no Voltmeter check at 8 Wire connection 2) 3498 () = oK? ound 20 volts yes Renew diagnostic device Retest est sage 15 again Shut of engine Unclip diagnostic device Check for continuity (ead) 5) 51u36 chassis () es x no is continuity present? Shut off engine Renew power unt 36 Uncip agnostic device coe Cheek for continuity: (eae) anima 3) 81u96 ~ 61496 = continuity Cure faut Connect diagnostic device Retest est sage 15 again ce © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 60 AST© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 61__ Workshop Manual yes yes R 7034(R 7011, R 7001) @ 8 continuity present? [Connect diagnostic device [Connect lead 336 and 6196 Retest test stage 15 again Votage measurement at drive motor m2 (idling speed 900 rpm, IC engine) 1) Atim2 (+) = Azim2 () = around 50 volts ‘Shut off engine Unciamp lead-AI at drive motor ‘m2 and hold it clear Direction switch b2 into neutral" Start engine Press button of diagnostic meter to test stage 15 Direction switch 2 into ,backwards" Voltage measurement between: 2) Lead Avim2 (+) and lugboAz/m2 (-) = around 50 volts © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 62 Test stage 15 Tetsnse 18 (46 ) Generator excitation pbackwards" Ccheck wire connections and terminals: 3)8u38 = F2imo1 4)3u38 = Ftmo1 S)Fimot = F2imo1 Connect diagnostic device Retest lest stage 15 again 7031-7011 A1--A B2--H A2- -B Fl--J F2--K 1 kof engine Foheck drive motor m2: Motor rushes, connections, leads rmatureveld Cure faut Renew five mator if necessary Iretectioct stage tS-ageie AST© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 63"Workshop Manual_R 7034(R 7011, R 7001) yes 8 the voltage present? > check arive motor m2 for shorts in Test stage 15 Test stage 15 (16 ) Generator excitation ,backwards" ‘Shit off engine Uneiip diagnostic device armature circuit Cure faut replace ative motor m2 if necessary Re-connect lead Atim2 to m2 Connect diagnostic device Retest test stage 18 again Voltage measurement at generator mot 4) AlimO4(+) = B2imot(-) around 50 vots yes ‘Shut off engine Unclip diagnostic device (Check for continuity 2) Lead A1/m2 -Baimo1 3) Lead Atim2 -Atimo1 44) Lead A1m2 n35 IGen ) 5) Lead Aim2 n35 (Mot) 6) Lead At/m2 AZim2 (Bolzen) 7) Lead Atim2 Atim2 (Bolzen) cure faut Re-connect lead At to M2 Connect diagnostic device Retest test stage 15 again Shut off engine UncHp diagnostic device Check generator mot: Carbon brushes, connections, leads, armature ield Cure fault Renew (generator mOt if necessary Re-connect lead Alim2 to m2 Connect diagnostic device Retest test stage 15 again 7031-7011 A1--A B2--H A2--B F1- -J F2--K yes © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 64, ASTWorkshop Manual_R 7034(R 7011, R 7001) © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 65"Workshop Manual_R 7034(R 7011, R 7001) Test stage 16 wermnoets (46) Generator excitation forwards“ ‘Shut off engine Unelip diagnostic device Check wire connection: 2) 6B/L200 - B1u36 no 6 Wire connection 0K? Replace diagnostic device Retest test stage 16 again green Press BT Test stage 16 is indicated tae by LED 16. Becton switch into Drive wheels turnt forwards" wien Volage measurement ingeator lights? 4) 696 (6) - 238 = around 24 vols ‘green ts nes the vorage present? 0 7031-7011 AL. -A B2--H A2- -B F1- -J F2--K green © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 66 Cure faut Connect agnostic device Retest test stage 16 again AST© STILLGmbH_ Stand: 8/1994 ( Ersatz fur Stand: ) o7 ed Workshop Manual R 7031(R 7011, R 7001) S-D Test stage 16"Workshop Manual_R 7034(R 7011, R 7001) S-D Test stage 16 green Test stage 16 qa 6) Generator excitation forwards“ yes Voltage measurement 1) SIL36 (+) - 2136 () around 10 volts es 8 2 Shut off engine the voltage | Unolp ciagnostc device present? Renew power unit u36 Connect diagnostic sevice aa Rotest test stage 16 again Shut off engine UUnelip diagnostic device Checkwire connection 2) 31L36 - 142/L200 yes i Renew diagnostic device eee Retest test stage 16 again no Care aut Connect diagnostic device Retest test stage 16 again green © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 68. Ct —Yreacee © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 69"Workshop Manual R 7034(R 7011, R 7001) green Does ™ the crve turn forwards? yes yes Voltage measurement 1) SIL3B (+) - 2136 () around 10 vols the voltage present? yes Shut off engine Unclip diagnostic device (Check wire connection 2) S1L36 - 100/L200 8 wire connection ‘ok? no yes Care aut Connect diagnostic device Retest test stage 16 again © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) Test stage 16 (16) Generator excitation ,forwards* Test stage 16 1 ‘Shut off engine Uneip agnostic device Renew power unit u36 Connect diagnostic sevice Retest test stage 16 again Renew diagnostic device Retest test stage 16 again AST© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand Workshop Manual_ R 7031(R 7011, R 7001) Test stage 16- Workshop Manual_R 7031(R 7011, R 7001) S-D Test stage 17 Test stage 17 green 8 (1 8) Press button Test slage 17 is WARNING: Generator voltage indicated by LED 17 Direction Switch , forwards oop] red ‘Which 17011 / 31 (900 / 1000 1/min indicator ights? >| Increase engine rm to 1000 1 min ‘green Measure voltage at drive motor m2 oe ‘ed 4) Atima () -A2/m 24) Ineeator ight? around 57 vots green no ‘Shut of engine ® Unelip diagnostic deve the votage present? check generator mat renew ft nec Sha of engine Uncip diagnostic device Check wire connections 2) A2m2- az.200 3) Ati? - 401.200, yes Are Renew diagnostic device wire connections Retest test sage 17 again ps 7031-7011 oe A1--A Cure eu B2--H Connect diagnostic device Retest A2- -B test stage 17 again Fl- -J F2--K green © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 72 ASTs-D ~ Workshop Manual_R 7031(R 7011, R 7001) Test stage 17 [AL i © STILLGmbH_ Stand: 8/1994 ( Ersatz fur Stand: 73__ Workshop Manual_R 7031(R 7014, R 7001) S-D Test stage 18 and 19 Test stage 18 green Generator votage (18) Frees button Teal sage 18 ‘WARNING: indicated by LED 18 (12) Direction switch “forwards Drive wheels turnt Test stage 19 apply full throttles Frequency dynamo (alternator) red Moiage measurement a which lanve motor m2 Indicator ights?>>———| 1) A2Im2 (+) - Atim2 Nottage: around 180 volts ein 127 vos) ‘green Shutoff engine Press button Test stage 19 is Is the Uncip diagnostic device indicated by LED 19 corresponding voltage >"° —— Direction switch into .neutrat* apph present? CCheck generator mot Cure fault, full throu renew generator if nec (approx. 3 to 4 secs) yes Connect diagnostic device Retest test slage 18 again Shik of enone Renew diagnostic device 7031-7011 Retest loge 18 290 MOA B2--H which ed. [Volage measurement a dynamo 2- -B indicator lights? >> (aternator) utt F1- -J Swett) cass Ytaye atound 12 vote F2--K reen Shut off engine io Unelip diagnostic device s 12 volts check wire connections: present? 3) Wu 11 ~21L8 (St) 4) 21L8 (Bu) - 120.200, 0 Cure faut Ate Connect diagnostic device Retest wire connections test siage 19 again OK? 1 1 Gheck dynamo Vet ‘Check V ball tension tension; recension or renew Renew diagnostic device as necessary Retest test stage 19 again green © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 74, Bier© STILLGmbH_ Stand: 8/1994 ( Ersatz fur Stand: ) 75 Workshop Manual_R 7034(R 7011, R 7001) S-D Test stage 18 and 19_ Workshop Manual green Press bition Test sage 20 i indicated by LED 20 Direction switch ,forwards apply full throttle R 7034(R 7011, R 7001) S-D green wich indicator lights? Test stage 20 Test stage 20 (1 9+20) Tachogenerator Shut off engine Check the bearing seat of Green lights | generator (may not pull down) Fedilashes | Check tachogenerator for excessive axial play, renew if nec. inspect drive couping renew if nec. (See Functional Group 08) Retest test stage 20 again Votimeter check 4) VM (2-211 around 11 volts green © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: fe Ce© STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand )_ Workshop Manual_R 7031(R 7011, R 7001) S-D Function b36, b86 Functional check: 5-stage switch b36 green Functional check: brake switch b86 Shut off engine Keyswitch to ‘OFF Unelip diagnostic device ck S-stage switch 636 and brake switch bE6 for continuity and garth faut (body contact 86 operated 1) 268/200 - 308/200 = continuity 36m poslion 1 , BBS unoperated 2) 162/L.200 - 262/200 = no continuity 3) 16211200 - chassis 4) 162/1.200 - chassis b36 696 in position 5 '5) 162/L200 - 26211200 = continuity b26 in postion 4, 3, 2 = partial continuity only check when testing the brakes at the end of the fault finding procedure (see Test drive) yes Check wire connections [check wire connections Has ‘62/200 = a4 sie {6211200 - 26-1 4-090 2 fait been | 282/1200-11.4.0198 4 2ev1-200 1 ee - 9-4 - S36 found? 25011200 - 17005 30200 - 2887031 Joab. 701 alt 10 0 are ‘wire connections Cure faa OK Repeat testing procedure yes Check oll pressure etch B86 or S-tage owich 696, replace detective pat, any, repeat testing procedtre no STILLGmbH_ Stane: a/1994( Ersatz fur Stand.) 80 hare_ Workshop Manual_R 7034(R 7011, R 7001) S-D Functional check b36, b86 © STILLGmbH_ Stand: 8/1994 ( Ersatz fur Stand: ) 81__ Workshop Manual_R 7031(R 7011, R 7001) S-D Functional check green Functional check with p.c.b. u200 (Check wire connections 4) 113 (@u) - 513 (Bu) 2) SIL3 (St) - 62iL20 3) 53 = 28(u36) ‘nly power unt with integrated 26 Driving functions: (truck chocked up) 0 ne Accelerating wite connections > sforwards" ‘ox? Cure faut Decelerating 41 forwards- yes Accelerating nbackwards- Connect diagnostic device Repeat test stages t to 20 The Decelerating Wasa yes diagnostic indicator green” - faut nbackwards* taut recognised | ree = must ght up in each tes step. Plugging forwards! & cured in stages backwards backwards! forwards ren Drive cut-out by Ronee ana pig npeoTIoNS Shut of engine applying handbrake connect L200; start engine; perorm Keysuiteh to .OFF Saanarencoe Uneip diagnostic device Refit existing p.c,b. u200; connect 1200; stant engine; per orm unctonal checks no ‘A arving Shut off engine tutions with tuck 1 rapige pe. s200 oy start engine Perform functional checks yes Shutoff engine @ © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 82 Ct —Functional check p.c.b. u200 y BzA.200 L200 © STILL GmbH, Stand, 8/1994 ( Ersatz fur Stand ) 83"Workshop Manual_R 7031(R 7011, R 7001) Functional check Functional check: Monitor Unit (Failsafe circuit) CHECK MONITOR UNIT (Failsafe circuit) OF P.C.B.u200 Slant engine, direction switch in forwards’ or .backwards’, release handbrake; operate accelerator pedal, Lunplug plugs one after the other and re-plug again 1) Unplug plug L25 3) Unplug plug L35 1 Doss ut off engine contactor 626 aaa Goo leaty Renew p. ¢.b. u200 Repeat testing procedure yes Shut off engine 2) SRe-pug plug (25 a) Replug 135 Power unt u26 wit integrated 26 check wire connection ‘xe »" 12611200 Cure fut es AST © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: )shop /MenualRi703 URi7011) 7001) Eee Functional check Monitor Unit © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 85 Ct —" Workshop Manual_R 7031(R 7011, R 7001) S-D Functional check Functional check: @ Handbrake switch, warning horn Start engine Contactor £26 pulls in 1 Apply handbrake Cheek handbrake eviten Does Has it been omitted to remove test lead? contactor 626 f No: Check operation of swith; top out? core faut or renew suiten [shut off engine Keyswitch to .ON" Operate hom switch fseveral times in succession check fuse 6le .., suite no | warning hom N89 ‘and wire Does ‘connections: the ham sound? >——J 6Ne .. - 112 - iL 10- v8 - ‘VLIO - h89 - earthing bak. Cure fault repeat testing procedure yes Keyswitch to .OFF™ Remove chocks and restore truck to diving operation Test drive (see page 88) Remove from truck Al toots, measuring inetruments, iagnostic meters, measuring, leads as well as any loose'tems (@. g. shims * screws, batt nuts etc.) Check all plug and socket ‘connections for tightness ‘Test electrical Braking 128 per detalis page 88 END © STILLGmbH_ Stand, 8/1994 ( Ersatz fur Stand: ) 86 Ct —Jorkshop Manual_R 7034(R 7011, R 7001) S-D Functional check Handbrake, Horn © STILLGmbH_ Stand: 8/1994 ( Ersatz fur Stand: ) 87. eweWorkshop Manual Remove from truck Alltools, measuring instruments, diagnostic device, measuring leads etc. Check connectors for tightness. Remove chooks and restore the truck to proper operation. Test drive Carry out a TEST DRIVE during which electrical braking must be tested according to the different positions of the 5-stage switch: Performing the test: ‘Accelerate the truck without load to maximum speed (around 20 km/h), remove foot from the accelerator pedal and allow truck to coast (do not use the foot brake) SA, gaming R 7034(R 7011, R 7001) Test drive Controlled electrical braking now enables the truck to decelerate more or less smoothly according to the position of the 5-stage switch b36 ‘The distance thus covered by the truck is defined as coasting distance (see table below). Be pre-setting switch b36 to one of the § stages the electrical braking and acceleration can be adapted to the driving characteristics required ‘oasting distance Position 1 19m-23m lof 2 16 m-20m, Istepped 3 13m-17m switch 4 11m-13m b36 5 9m- tm END of Diagnostic Instructions © STILL GmbH Stand, 8/1994 ( Ersatz fur Stand: ) 88 Ce