2000–2004 STILL R60-20–R60-50 & R60-22i–R60-30i Electric Forklift Workshop Manual (P/N 164518)

The 2000–2004 STILL R60 workshop manual, Ident-Nr. 164518 (English edition), covers R60-20 through R60-50 electric forklifts and the R60-22i, R60-25i and R60-30i AC variants. It combines the base workshop material with later system-specific supplements.

• Steering and axles: Steer-axle removal, wheel-hub service, kingpin and track-rod work, steering-cylinder overhaul, and planetary reduction-gear disassembly.

• Service and parking brakes: Oil-bath multiple-disc brake removal and installation, brake-disc replacement, automatic-adjuster reset, and parking-brake adjustment.

• Electric motors: DC drive-motor armature removal and pump-motor disassembly, plus separate AC motor, speed-sensor and temperature-sensor sections.

• Hydraulic controls: Gear-pump replacement, directional-valve inspection, seal service and pressure-regulator checks for mechanical-lever and proportional-joystick systems.

• Electrical diagnosis: Pedal and motor-sensor tests, controller replacement, console parameterization and FleetManager card-reader checks, with separate AC-system documentation.

• Masts and carriage: Telescopic, Hi-Lo and triple-mast service, lift-chain adjustment, support-roller clearance checks, hoist-cylinder resealing and tilt-cylinder repair.

This manual suits forklift service technicians familiar with measuring adapters, insulation testers and the lifting equipment needed for axle and mast repair.

Axles, Brakes and Danfoss Steering

The power-axle chapter details the wheel reduction gears, bevel differential and integrated wet brake. Brake illustrations distinguish the disc arrangements for types 6022–6025 and 6026–6028, with actuator-reset information for disc replacement.

Danfoss steering-unit removal and leak-seal service sit alongside load-sensing priority-valve cleaning and steer-cylinder reassembly. Steering-unit repair is limited to oil-leak repairs; the manual specifies replacement of a failed steering unit rather than a full internal overhaul.

Torque and lubricant tables and battery-compartment dimension drawings provide supporting reference data.

DC Armature Service and AC Motor Limits

DC procedures include removing the drive-motor armature while the axle remains in the truck, inspecting brushes and reworking the commutator. The AC section covers removal and shaft-seal access for the AF 186-N1 asynchronous drive motor, but further motor disassembly is excluded because the rotor cannot be removed.

Motor temperature and speed-sensor checks are paired with wiring and connector diagrams. The AC insulation-test section warns that improper test preparation can damage the motor temperature sensors.

Hydraulic Valves and Mast Repair

Mechanical-lever and joystick valve blocks have different service procedures. For the joystick tilt and auxiliary valves, spool removal and internal spool-seal replacement are excluded because they would disturb factory-set travel.

Gear-pump troubleshooting links pump noise, foaming oil and delayed movement to possible suction-side leaks. This helps technicians plan leak checks before replacing the pump. The valve-seal instructions also flag sharp spool edges that can cut replacement seals.

Mast sections explain lift-stage sequencing, lowering valves and hose-failure safety devices. Exploded and sectional views accompany roller selection, lubrication, carriage-stop adjustment and cylinder seal work for telescopic, Hi-Lo and triple masts.

Controllers, Parameterization and Circuit Diagrams

A9 documentation distinguishes R60S20 and R60S60 controllers, including parameter transfer during replacement. AC supplements describe the A43 battery computer, A44 central computer and separate drive and pump converters.

The proportional joystick's 2A7 controller requires service-notebook parameterization; console hydraulic settings do not adjust that controller. FleetManager coverage adds card-reader testing and retrofit requirements.

Visual references include the controller block diagram, CAN bus connection layouts, converter pin assignments, standard and joystick hydraulic schematics, and mast oil-flow diagrams.

Observe the manual's precautions for battery isolation, converter discharge and secure support of raised masts during service.

A Sample of Steering and Pedal-Sender Specifications

These steering and pedal-sender values are a small selection of the workshop specifications in the manual.

The steer-axle data lists a wheel-lock angle of 80–82° and toe-in of 0 ± 1 mm.

For the single-pedal accelerator sender 1B1, the voltage-check section gives 4.7–5.3 V with the pedal released and 8.5–9.5 V with it operated, with a supply of approximately 10 V.

PDF Search, Diagram Detail and Page Count

Search and diagram detail: The PDF is only partly searchable; much of its embedded text does not match ordinary search terms, and some diagram labels are image-based. There are no embedded PDF bookmarks. Small schematic labels require zooming, and parts of the controller block-diagram legend remain pixelated.

Supplied as one 251-page printable PDF in English. The total includes one cover page, one model-applicability page and 249 technical pages, with the later supplements incorporated.