Comprehensive STILL Electric Forklift Workshop Manual, Models R20-15, R20-16, R20-18, R20-20

STILL Electric Forklift Workshop Manual – R20-14 to R20-20 & R20-15i to R20-18i Series

This professional-grade workshop manual is the definitive technical resource for the STILL R20 series, covering both the standard DC and the advanced AC (i-series) electric fork trucks. Spanning over 1,000 pages of deep-dive technical documentation, this manual is designed for master mechanics and fleet managers who require factory-level precision for maintenance, diagnostics, and complex overhauls.

Comprehensive Model Coverage

This manual includes all documented configurations, including Turntable and Swing Axle designs across their respective production cycles:

• R20-15 (2008-2014)
• R20-16 (2008-2014)
• R20-18 (2008-2014)
• R20-20 (2008-2014)
• R20-14 Turntable (2017-2024 / 2037-2044)
• R20-15 Turntable, short (2008-2014 / 2018-2024 / 2038-2044)
• R20-15 Swing axle, short (2009-2014 / 2019-2024 / 2039-2044)
• R20-16 Turntable (2010-2014 / 2020-2024 / 2040-2044)
• R20-16 Swing axle (2013-2014 / 2023-2024 / 2043-2044)
• R20-18 Turntable (2011-2014 / 2021-2024 / 2041-2044)
• R20-18 Swing axle (2012-2014 / 2022-2024 / 2042-2044)
• R20-20 Turntable (2014 / 2024 / 2044)
• R20-15i Turntable, short AC (2015 / 2045)
• R20-15i Turntable AC (2046)
• R20-16i Swing axle AC (2047)
• R20-18i Turntable AC (2048)

Technical Excellence & Key Specifications

The R20 series is known for its dual-motor front drive and high maneuverability. This manual provides the specific data needed to maintain these high standards:

• Advanced Drive Systems: Detailed service for AE 18-02 wheel drive units, including reduction gear cross-sections and precise torque specs (e.g., slotted nut M60x2 at 650 + 20 Nm).
• Steer Axle Versatility: Full coverage for both the 90-degree Turntable steering and the 80-82 degree articulating Swing Axle variants.
• Hydraulic Precision: Complete schematics for the control valve blocks, featuring pressure relief valve settings (fixed at 250 bar) and auxiliary functions (3rd and 4th hydraulics).
• Digital Control & Electronics: Instructions for the A9 controller, including parameterization for drive programs 1–5 (VMAX, acceleration, and deceleration settings).
• Insulation & Safety: Essential testing procedures for electrical components, requiring a minimum insulation resistance of 48 kOhm (1000 Ohm/Volt).

Detailed Workshop Contents:

1. Chassis & Frame: Procedures for jacking up the truck, frame unit construction, and counterweight bolt torques (660 Nm).
2. Drive Units: Motor removal (FM1/FM2), transmission oil specs (SAW 80), and planetary gear repairs.
3. Brake System: Service and parking brake adjustments, including brake lining wear limits (2mm minimum thickness).
4. Steering System: Service for Danfoss OSPC control units and priority valves (pre-load pressure 7 bar).
5. Console & Interface: Full guide to the LCD display levels, password levels 1 and 2, and software version history.
6. Mast & Hydraulics: Chain adjustment for Telescopic, Hi-Lo, and Triple masts; lift/tilt speeds; and line failure safety device (LBS) operations.

Unique Reference Data

For exact part identification and system cross-referencing, this manual includes:

• Manual Ident-No: 164526 (en)
• Controller ID: 01601503
• General Series Ref: R50-00
• Lubricant Reference: STILL Ident No. 148659 (Stub axle grease)

Whether you are performing a routine battery computer reset or a full hydraulic pump overhaul, this manual delivers the specific voltages, torques, and circuit diagrams required for professional results. Keep your STILL fleet in factory-spec condition with the most informative technical guide available.