STILL RX20-15-20 & RX60-16-20 Electric Forklift Workshop Manual – PDF

Description

STILL RX20-15-20 & RX60-16-20 Electric Forklift Workshop Manual

This STILL RX20-15-20 & RX60-16-20 Electric Forklift Workshop Manual delivers complete service, repair and maintenance coverage for the RX20-15 through RX20-20 and RX60-16 through RX60-20 series of electric forklift trucks. Published as Edition 2017/10, Version 5 under document number 50638042201 EN, this workshop literature is the reference document for qualified service engineers and technicians maintaining these machines. Whether you are performing scheduled 1000-hour maintenance, diagnosing an electrical fault with DiaMon, overhauling the drive axle, or repairing the lift mast, this manual provides the procedures, specifications and system descriptions needed to complete the work correctly.

File Details

• Manual Type: Workshop Manual (Workshop Literature)
• Brand: STILL
• Models Covered: RX20-15, RX20-16, RX20-18, RX20-20, RX60-16, RX60-18, RX60-20
• Type Carriers: 6209, 6210, 6211, 6212, 6213, 6214, 6215, 6216, 6217, 6311, 6313, 6315
• Language: English
• Page Count: Approximately 318
• File Format: PDF
• Edition: 2017/10
• Version: 5
• Document Number: 50638042201 EN

Chapters Covered

• 00 Product Information – Product overview for RX20 and RX60-16-20, safety information, parking the truck for service work, working on the electrical system, jacking up front and rear, securing the fork carriage
• 01 Service Maintenance – Maintenance instructions, 1000 hours/annual maintenance, 3000 hours/every two years maintenance, tools, measuring instruments and testing equipment, harnesses and hoists, standardised tightening torques
• 02 Diagnostics – Introduction to DiaMon, STEDS-Navigator, diagnostics service box, diagnostics set-up, starting DiaMon, reading out access codes, reading out and clearing the error list, working using the ABE
• 11 Electric Motor – Traction motor general technical data, electrical connections, traction drive, sensors, pin sensor, temperature sensor KTY84
• 22 Mechanical Drive Axle – Drive axle AE18-05 (general technical data, removal and installation, wheel drive, drive wheel unit repair, traction motor, service brake), drive axle AE18-07 (general technical data, removing/refitting drive wheel unit, shaft seal, rotor removal/installation, bearing and shaft seal replacement, service brake, oil level checks)
• 30 Chassis, Bodywork and Fittings – Chassis, battery door, counterweight, overhead guard (removal and installation, front and rear bearings, gap adjustment)
• 42 Steering System – Hydraulic steering general technical data, steering system function, steering error detection, steering unit, 6S3 diaphragm pressure switch, priority valve, steering wheel with steering column, steering angle sensor 3B01, CSC steering angle-dependent handling performance, steering turntable (fifth wheel, curve switch, removal/installation), swing axle (general technical data, curve switch, removal/installation, wheel hub, steering angle, tie rod, axle stub)
• 50 Operating Devices – Drive and brake actuation, brake cable changes for AE18-05 and AE18-07, handbrake cable changer, actuating force of handbrake, parking brake switch 1S3, brake sensor, accelerator single-pedal and generation 2, electric parking brake (function, cause and effect, design, maintenance, brake check, calibration, cable change, limit position switch, drive unit), central lubrication device, dual pedal, operating devices (hand lever, Joystick 4Plus, generation 2 mini-lever, tip switch, joystick)
• 56 Display Elements – Operating console, direction indicator module (FABLI), turn indicator module for drive direction generation 2, drive direction turn indicator display, display, display operating unit (ABE 1 and ABE 2)
• 60 Electrics / Electronics – General technical data 48V and 80V, overview of controllers, electrical system, electrical components, switching on procedure, software compatibility, PAN process, parameter management, error ring buffer, intermediate circuit, insulation testing, temperature monitoring, driving behaviour, Blue-Q=IQ, wiring, CAN bus system, power cables, fuse box, fuses, contactor, sensor system, vertical lift mast position, tilt angle sensor 7B46, load measurement, additional electrical installations, CPP and RPP
• 64 Electronic Controls – Traction and working hydraulics control, Main Control Unit (MCU), MCU with servo hydraulics, MCU generation 2, Supply Unit (SU), converters (LAC, SAC), inverter removal and installation
• 69 Batteries and Accessories – Traction battery, battery, 2014 discharge indicator, discharge indicator, battery plug, maintenance guidelines for appliance plugs, repair of battery male connector contacts, working with reducer sleeves
• 70 Hydraulics – General technical data, depressurising the hydraulics, lifting/lowering/tilting operating speeds, safety checks, basic hydraulics, steering hydraulics, working hydraulics, hydraulic tank, hydraulic oil, return line filter, breather filter, suction filter
• 71 Working Hydraulics – Pump unit general technical data, pump unit, electrical connections, pump motor without rev sensor, pump motor speed sensor, pump motor temperature sensor, pump motor removal and installation, hydraulic pump removal and installation, tilt cylinder removal and installation, seal set change, auxiliary hydraulics, attachments, clamp locking mechanism, accumulator
• 76 Valves – Hand lever general technical data, hand lever valve block, emergency lowering, hydraulic transmitter, valve block dismantling and installation, directional control valves, discharge pressure governor, check valve, pressure relief valve, load holding valve, lowering brake, servo hydraulics (general technical data, valve block, manual lowering, directional control valve block)
• 80 Load Lift System – Mast bearings for 1.0t-2.0t
• 81 Lift Mast – General technical data, hose safety valve of triplex mast, support roller play, load chains checking and cleaning, run-out barrier, working on lift masts, lift mast removal and installation, telescopic lift mast, NiHo lift mast, triplex lift mast, support rollers, load chains and chain rollers, lift cylinder (outer, centre, end position damping)
• 84 Load Support – Fork carriage
• Annex X Circuit Diagrams – Hydraulics circuit diagrams for hand lever and servo hydraulics

This STILL workshop literature is structured to support the full range of service operations on RX20 and RX60 electric forklift trucks. Each chapter combines technical data, step-by-step procedures, exploded illustrations and specification tables so that a competent technician can carry out work safely and to the correct tolerances. The manual opens with product overviews and safety information, then moves through maintenance schedules, diagnostic tools and procedures, and finally into the major mechanical, hydraulic, electrical and electronic systems. Whether you are dealing with a routine oil change, a traction motor fault, a drive axle overhaul, a steering system repair or a lift mast rebuild, the relevant chapter provides the factory-derived procedures and values.

The drive axle chapters are particularly detailed, covering both AE18-05 and AE18-07 variants with removal and installation sequences, wheel unit repair, rotor extraction, bearing and shaft seal replacement, brake disc pack assembly and brake clearance setting. The hydraulics and working hydraulics chapters cover pump units, tilt cylinders, valves and accumulators, while the electrical and electronic sections explain the CAN bus architecture, controller layout, insulation testing, temperature monitoring and the DiaMon diagnostic system. The lift mast chapter provides comprehensive coverage of telescopic, NiHo and triplex mast designs, including load chain adjustment, support roller replacement and lift cylinder servicing.

What This Manual Enables

With this STILL RX20-15-20 & RX60-16-20 workshop manual to hand, a service engineer can confidently undertake scheduled maintenance, diagnose electrical and hydraulic faults, remove and refit major assemblies such as the drive axle and lift mast, overhaul traction motors, service brakes, replace shaft seals, calibrate sensors, adjust load chains and carry out safety checks. The manual provides the tightening torques, oil grades, pressure values, temperature thresholds and adjustment dimensions that are essential for correct and safe repair work. Having the correct specifications matters particularly on electric forklifts, where incorrect procedures can lead to insulation faults, brake malfunction, hydraulic failure or safety system errors.

IMAGES PREVIEW

This STILL RX20-15-20 & RX60-16-20 electric forklift workshop manual is delivered as an instant PDF download after payment. There is no shipping and no waiting for a physical book. The file can be viewed on any device that supports PDF, and relevant pages can be printed for use in the workshop. The document is searchable and can be kept on a laptop, tablet or smartphone for quick reference during service work.