2008– STILL R20-14–R20-20 & R20-15i–R20-18i Electric Forklift Workshop Manual (P/N 164526)

The STILL workshop manual, Ident-Nr. 164526 (en), November 2003, covers R20-14 through R20-20 and R20-15i through R20-18i electric fork trucks, including turntable and swing-axle configurations.

• Drive units and motors: Wheel-drive removal and installation, brushed-motor service, asynchronous-motor disassembly, and speed-sensor bearing replacement.

• Steering and axles: Steering turntable bearing overhaul, axle-shaft end-play adjustment, stub-axle service, priority-valve repair, and steering-system bleeding.

• Brake service: Service and parking brake adjustment, brake-lining wear limits, and brake-pedal transmitter testing and calibration.

• Electrical diagnosis: Insulation testing, speed and temperature sensor checks, controller replacement, console parameterization, and CAN bus connection layouts.

• Hydraulic systems: Mechanically operated and joystick-controlled valve blocks, hydraulic pump replacement, suction-filter service, and anti-cavitation valve checks.

• Masts and cylinders: Telescopic, Hi-Lo, and triple-mast chain adjustment, support-roller clearances, fork-carriage removal, and hoist and tilt cylinder seal replacement.

Suited to forklift technicians familiar with electrical measuring equipment and notebook-based service diagnosis.

Drive Motors and Reduction Gears

The brushed-motor chapters cover brush-wear monitoring, motor disassembly, and commutator machining limits. The AC section describes squirrel-cage motors, rotor removal, and Hall-effect sensor bearings.

Reduction-gear cross-sections show the planetary drive arrangement. Complete gearbox repair requires special tools and a suitable tensioner; the manual separately identifies planetary-gear and sun-gear replacement that can be performed without those tools.

The AC motor removal instructions warn that withdrawing the rotor can damage the speed-sensor cable.

Steer Axles and Load-Sensing Steering

Axle procedures distinguish turntable bearing adjustment with shims from articulating-axle kingpin and track-rod service. Wheel-hub assembly instructions also distinguish the bearing and seal arrangements.

The steering chapter identifies the Danfoss OSPC 40 LS 150-8143 steering unit and OLS 40 152 B 8015 priority valve. It explains load-sensing operation, emergency steering, valve servicing, and the factory-preset steering relief and shock-cushioning valves.

Controllers, Pedal Calibration, and CAN Diagnosis

DC and AC controls: The DC electrical installation maps controller A9, main contactor 1K1, and fuse carrier A7. The type 2015 AC section instead describes battery computer A43, central computer A44, and individual motor converters.

Controller block diagrams, motor connection diagrams, and CAN bus configuration drawings support circuit tracing. Replacement procedures address parameter transfer between the console and controller.

Pedals and steering signals: Separate instructions cover two-pedal controls with individual potentiometers and the later double-potentiometer arrangement. Steering-angle transmitter testing explains Error 119 and the associated reduction in travel speed. FleetManager coverage includes card-reader checks and service-related configuration.

Joystick control: Hydraulic controller 2A7 is documented with both external safety relay 2K04 and the integrated safety function. The separate CAN bus layouts help technicians select the correct connection for hydraulic diagnosis. Joystick and hydraulic-controller parameter changes require the service notebook; console changes alone do not alter those settings.

Hydraulic Valves, Masts, and Cylinder Repair

Mechanically operated and joystick-controlled hydraulics have separate circuit diagrams and valve-section views. These explain hoisting, lowering, tilt, auxiliary functions, pressure balancing, and anti-cavitation protection.

For the joystick tilt and auxiliary valve sections, factory-set spool travel limits the repair scope: the manual prohibits internal spool and pressure-tube removal. It also distinguishes valve inserts that must be replaced rather than repaired internally.

Mast documentation follows the different oil paths through telescopic, Hi-Lo, and triple configurations. Cylinder sections address packing replacement, line-failure safety devices, and cushioning during mast-stage transitions. Frame data cover the welded steel chassis and bolt-on cast-iron counterweight.

Service work requires the manual’s precautions for battery isolation, supported raised components, and hydraulic pressure release.

A Preview of Chassis, Battery, and Steering Specifications

These values are a small selection of the chassis, battery, and steering data included in the manual.

The frame section specifies 660 Nm for the counterweight bolts. Battery servicing lists a specific gravity of 1.28 kg/l for the filled traction battery.

Steering-angle transmitter positioning specifies a 1 mm gap between the console and timing wheel. The steer-axle data contrast 80–82° of lock for the articulating design with 90° for the turntable design.

Text Search, Diagram Detail, and PDF Contents

Search and diagram access: Text search works in many narrative sections, but some pages and diagram labels are not searchable. There are no embedded PDF bookmarks. Small connector and circuit labels require zooming.

One printable, 253-page PDF, with English workshop text, a multilingual cover, and occasional German labels. The total includes one cover page, one model/type overview page, 239 pages of technical chapters, and the 12-page System-Diagnosis section. That final section contains diagnostic-equipment references and connector arrangements.