🏷️ Basic Information Identification Make: STILL Product Type: Workshop Manual Vehicle Type: Diesel Forklift Truck Codes Model Codes: DFG R7087, DFG R7088, DFG R7089 👋 Introduction Market Position Market Position: Specialized industrial equipment manual for a reputable European manufacturer of material handling equipment. Targets service technicians, maintenance departments, and forklift owner-operators. Key Features Key Features: Original factory documentation, detailed illustrations, circuit diagrams, comprehensive coverage of mechanical, electrical, and hydraulic systems. Technical Data Availability: Contains 'Technical service data' for major systems (Steering Axle, Wheels/Tyres, Motor, Hydraulic System, DEUTZ engine/Generator), providing critical specifications for maintenance and repair. Competitive Analysis Competitive Analysis: Essential for maintaining STILL forklifts, which compete with other major industrial truck manufacturers like Linde, Toyota, Hyster, and Clark. This manual provides the factory-specific data needed for optimal repair and upkeep, ensuring performance and longevity comparable to competitors. 📋 Manual Details Coverage Models Covered: R70-60, R70-70, R70-80 Series (DFG R7087, DFG R7088, DFG R7089) Pages Page Count: 204 Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems: Chassis, Counterweight, Steering Axle, Wheels & Tyres, Service Brake, Electrical Installation, Relay Box, Hydraulic System, Motor, Pressure Regulators, DEUTZ Diesel Engine/Generator, Mast (Groups 20, 22, 25), Measuring and Test Equipment Electrical System Coverage: Extensive coverage of electrical installation, including general overview, instrument panel, consoles, lock switch, travel sensors, two-pedal control, parking brake switch, brake senders, horn button, hydraulic pressure sensor, tacho-alternator, alternator, batteries, DEUTZ engine sensors and switches (EMR), relay rack, diode assembly, current sensor, contactors, retarder, fuse bases, and controllers for travel and fan. Hydraulic System Coverage: Detailed coverage of the hydraulic system, including technical service data, functional description of lift and tilt hydraulics, control valve block design and actuation, wiring diagrams, connection blocks, plate/retarder, way valves, lift/lower, tilt/additional hydraulics, hydraulic pump, hydraulic tank, return flow filter, oil cooler, hydraulic unions, and hydraulic diagrams (circuit and functional). Engine And Generator Coverage: Comprehensive details on the DEUTZ diesel engine, including technical service data, general engine design, cylinder head, valve adjustment, injection pumps, glow plugs, compression pressure, V-belt, turbocharger, cooling system, coolant pump, thermostat, oil filter, fuel pump, fuel system, and engine mounting. It also covers the generator design, circuit diagrams, carbon brush replacement, and related components. Steering System Coverage: Detailed coverage of the steering axle, including technical data, design, removal/installation of axle and hubs, stub axle service, steering cylinder service, tie rod replacement, and steering angle adjustments. Also covers steering column, steering unit, priority valve, and steering cylinder functional descriptions. Mast And Lift System Coverage: Comprehensive coverage for mast systems, including technical data, mast removal/fitting, lift cylinder service, support roller maintenance, chain adjustment, fork carriage servicing, and tilt cylinder repair. This is critical for the core function of the forklift. Frame And Ancillary Systems: Covers chassis, counterweight, and steering axle, as well as wheels and tires, providing a complete picture of the forklift's structural and mobile components. Procedures Procedures: Removal, Installation, Adjustment, Checking, Greasing, Disassembly, Assembly, Troubleshooting, Repair, Maintenance, Parameterization, Insulation Test, Functional Description, Circuit Diagrams, Exploded Drawings Technical Depth Depth: Comprehensive workshop-level repairs and maintenance, including detailed technical data, schematics, and component-level diagnostics. Diagnostic Capability: High. Includes detailed electrical troubleshooting, circuit diagrams, component testing (e.g., sensor function, pressure regulator tests), and engine diagnostics (e.g., injection pump checks, compression tests). Wiring Diagrams: Includes dedicated wiring diagrams for functional descriptions of the hydraulic system and comprehensive electrical installation schematics, crucial for troubleshooting and repairs. Component Level Detail: Offers component-level detail with exploded drawings for the motor and generator, and cross-sections for the motor and generator, allowing for in-depth understanding of internal workings. Procedures Included Steering Procedures: Steering axle design, removing/fitting steering axle, removing/fitting wheel hub, adjusting/checking steering angle, removing/fitting stub axle, greasing running axle, removing/fitting tie rods, removing/fitting steering cylinder. Brake Procedures: Service brake system coverage, likely including inspection, adjustment, and component replacement. The electrical section details brake senders and parking brake switches. Electrical Procedures: Insulation testing, electrical installation schematics, component replacement for instrument panel, consoles, switches, sensors, alternator, batteries, EMR components, relays, fuses, contactors, and controllers. Includes parameterization of electrical equipment via the console. Hydraulic Procedures: Hydraulic system troubleshooting, pump removal/fitting, hydraulic tank maintenance (oil change, breather filter), return flow filter maintenance, oil cooler installation, union replacement, hydraulic pump speeds, sender function/adjustment, pressure regulator function and service, and lowering brake function. Engine Maintenance Procedures: Valve adjustment, injection pump timing/delivery checks, glow plug replacement, compression testing, V-belt tensioning, turbocharger inspection, cooling system bleeding, thermostat replacement, oil and fuel filter changes, fuel pump maintenance, and EMR system diagnostics. Mast Procedures: Mast removal/fitting, lift cylinder removal/installation, chain adjustment, fork carriage removal, support roller bearing replacement, tilt cylinder removal/installation, and mast tilt adjustments. Electrical Component Replacement: Detailed step-by-step instructions for replacing key electrical components such as the alternator, starter relay, pre-heating relay, contactors, fuses, and various sensors and switches. Hydraulic Component Service: Includes procedures for...