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ECB16 ECB18

103

OM-ECB162015006-EN-US

Restoring the Forklift to Service

Procedures to Restore the Forklift to Service

Remove and clean the dust on the forklift components and complete the following procedures:

Lubricate all the components.

Lubricate the inside of the hydraulic cylinders by completely lifting/lowering the forks,
tilting masts and handling attachment several times.

Check the status of charge of the traction battery.

Check the gear oil. Replace it if it contains too much water inside.

Check the hydraulic oil. Replace it if it contains too much water inside.

Conduct the inspections before daily operation.

Operate the forklift.

CAUTION

The operator should repeatedly check the performance of the forklift brake when operating it

for the first time after the forklift has been restored to service.

https://www.forkliftpdfmanuals.com/

Summary of Contents for ECB16

Page 1: ...OPERATOR MANUAL ECB16 ECB18 OM ECB162015006 EN US Lift truck must be inspected at the beginning of each shift ATTENTION https www forkliftpdfmanuals com...

Page 2: ...https www forkliftpdfmanuals com...

Page 3: ...OPERATOR MANUAL OM ECB162015006 EN US ECB16 ECB18 https www forkliftpdfmanuals com...

Page 4: ...Relocating Powered Industrial Trucks 7 Operator Training 8 Testing Retraining and Enforcement 10 Operating Safety Rules and Practices Operator Responsibility 11 General 11 Traveling 13 Loading 15 Ope...

Page 5: ...Adjustment of lateral position of seat 41 Backrest adjustment 41 Weight adjustment 42 Seat belt 42 Comfort Seat Adjustment of lateral position of seat 43 Backrest adjustment 43 Weight adjustment 44 S...

Page 6: ...nsporting the Forklift Crane lifting the Forklift 64 Driving into the Transport Truck 65 Transporting and Unloading the Forklift 65 Transporting Loads Loading 66 Travelling 66 Unloading 67 Exiting fro...

Page 7: ...ication 80 Adjusting the Chains 81 Changing and Replacing Chains 81 Electric Electric System Inspection 82 Hydraulic System Before Inspection and Maintenance 84 Hydraulic Oil Level 85 Return Filter El...

Page 8: ...g Axle Fasteners 95 Wheel Fasteners 96 Counterweight Fasteners 96 Mast Fasteners 97 DECOMMISSIONING AND RESTORING Decommissioning the Forklift Decommissioning the forklift for long term Storage 102 St...

Page 9: ...ECB16 ECB18 9 OM ECB162015006 EN US https www forkliftpdfmanuals com...

Page 10: ...https www forkliftpdfmanuals com...

Page 11: ...out for rental or transportation keep this operation instruction together with the forklift and make sure that operators can use the manual whenever necessary Upon receiving the forklift use the shipp...

Page 12: ...questions not covered in the manual please check with BYD after sales service Every BYD forklift has passed through thorough performance tests before shipment Although proper protection has also been...

Page 13: ...Gradeability 20 Others no flammable gas no flammable dust and no volatile flammable liquid Contact with your BYD local dealer if the forklift is intended to be used in the following environments 1 in...

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Page 15: ...5 SAFETY STANDARD This Standard defines the safety requirements relating to the elements of operation and maintenance https www forkliftpdfmanuals com...

Page 16: ...and operation and maintenance manuals 4 affixes a permanent and readily visible label on the truck stating the manner in which the truck has been modified or altered together with the date of the modi...

Page 17: ...range could result in truck instability Lighting for Operating Areas Controlled lighting of adequate intensity should be provided in operating areas in conformance with ANSI IES RP7 Trucks and Railroa...

Page 18: ...or serious injury to the operator or others 2 damage to the powered industrial truck or other property The training program shall emphasize safe and proper operation to avoid injury to the operator a...

Page 19: ...piping and other areas of limited clearance 7 areas where the truck may be operated near other powered industrial trucks other vehicles or pedestrians 8 use and capacity of elevators 9 operation near...

Page 20: ...During training performance and oral and or written tests shall be given by the employer to measure the skill and knowledge of the operator in meeting the requirements of the Standard Employers may d...

Page 21: ...in contact with one hand and two feet or two hands and one foot at all times Keep hands free of items i e food beverage tools Before starting to operate the truck 1 be in operating position 2 place di...

Page 22: ...to the railroad car with the force applied in a direction parallel with the door travel Care should be exercised when engaging the door opening device with the railroad car door in order to prevent da...

Page 23: ...locations Slow down and sound the audible warning device s at cross aisles and other locations where vision is obstructed Cross railroad tracks at an angle wherever possible Do not park closer than 2...

Page 24: ...the elevator neutralize the controls shut off power and set brakes It is advisable that all other personnel leave the elevator before truck is allowed to enter or leave Avoid running over loose objec...

Page 25: ...truck capacity with extra caution Stability and maneuverability may be adversely affected 4 Handle loads only with the load engaging means and do not transport loads or miscellaneous items within the...

Page 26: ...of tires 2 if pneumatic tires check inflation pressure 3 warning and safety devices 4 lights 5 battery 6 controls 7 lift and tilt systems 8 load engaging means 9 chains and cables 10 limit switches 1...

Page 27: ...all not be on the truck while refueling Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced before restarting engine Do not use open flames when...

Page 28: ...ons When lifting trucks for repair or inspection trucks shall be lifted in safe secure stable manner Removal of components such as counterweights or uprights will change the center of gravity and may...

Page 29: ...anisms warning devices lights governors lift overload devices guards and safety devices lift and tilt mechanisms attachments articulating axle stops and frame members shall be carefully and regularly...

Page 30: ...that the positioning lock is in good repair and correct working order If any fault is found the fork shall be withdrawn from service until satisfactory repairs have been effected 6 Wear 1 Fork Blade a...

Page 31: ...to minimize fire hazards and facilitate detection of loose or defective parts Modifications and additions that affect capacity and safe truck operation shall not be performed without manufacturer s pr...

Page 32: ...on the slope without block the wheels Preferred recommended actions to be taken in the event of tip over or off dock accidents 1 Always fasten the seat belt 2 Hold the steering wheel and brace the fo...

Page 33: ...ECB16 ECB18 23 OM ECB162015006 EN US https www forkliftpdfmanuals com...

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Page 35: ...ould have obtained the driving permit in accordance with local regulations Before operating the forklift check the data plate and capacity chart to know the loading capacity of the forklift and avoid...

Page 36: ...al operation area 6 Maintenance and repair message 7 Regular check up For the proprietor make sure following safety instruction on your forklifts are observed DANGER 1 Unauthorized persons are not all...

Page 37: ...ng and regular maintenance on the forklift 5 Stop operating the forklift when the abnormalities and damages are found on the forklift Do not use the forklift until the forklift is fully repaired Warni...

Page 38: ...ina No 1 BYD Road Zhenjiang Industrial Park Shaoguan Guangdong China 1800 South Figueroa Street Los Angeles CA 90015 CAUTION 1 Every forklift might have different specification Check the data plate be...

Page 39: ...which is the permissible maximum lifting load Following the same reasoning you can calculate the loading capacity in the case of other load center and lifting height CAUTION 1 Forklift specification v...

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Page 41: ...31 TRUCK VIEW AND TECHNICAL SPECIFICATIONS This chapter explains the overview of the forklift and its relevant technical specifications https www forkliftpdfmanuals com...

Page 42: ...TRUCK VIEW AND TECHNICAL SPECIFICATIONS OPERATOR MANUAL 32 View General View 1 2 3 4 6 7 5 https www forkliftpdfmanuals com...

Page 43: ...9 11 12 No Name No Name No Name 1 Overhead Guard 6 Carriage 11 Counterweight 2 Mast 7 Fork 12 Tow Pin 3 Using Area 8 Rear Lamp 13 Front Wheel 4 Front Lamp 9 Rear Handle 14 Rear Wheel 5 Load Backrest 1...

Page 44: ...CK VIEW AND TECHNICAL SPECIFICATIONS OPERATOR MANUAL 34 Specifications Technical Drawing y x l l2 l1 h1 h8 h2 m1 m2 h3 h23 s h4 h10 h7 h6 Wa b11 b10 b3 b1 e ECB16B ECB16C https www forkliftpdfmanuals...

Page 45: ...ECB16 ECB18 35 OM ECB162015006 EN US y x m1 l l2 l1 s h8 h1 h2 h3 h23 h4 h10 h7 h6 m2 Wa b11 b10 b3 b1 e ECB18B ECB18C https www forkliftpdfmanuals com...

Page 46: ...ng height h10 in 18 9 18 9 4 9 Overall length l1 in 115 55 118 31 4 10 Length to face of forks l2 in 76 18 78 94 4 11 Overall width b1 in 41 34 41 34 4 12 Fork dimensions s e l in 1 38 3 94 39 37 1 38...

Page 47: ...1 201 8 141 9 161 6 181 3 202 221 7 241 3 261 Height mast extended with load backrest h4 in 158 9 178 5 198 2 217 9 158 9 178 5 198 2 217 9 237 6 257 3 277 Free lift without load backrest h2 in 5 9 5...

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Page 49: ...fer to Instruction in Safe Operation for the information of forklift data plate capacity chart and safety warning and decals During the delivery of the forklift make sure the red emergency disconnect...

Page 50: ...f seats the basic seat and the comfort seat BASIC means the forklift is equipped with the manual valve the basic seat and the manual lever COMFORT means the forklift is equipped with the E Valve the c...

Page 51: ...d and or backward to find the right seat position for easier handling of levers steering and pedals Return the lever to its folded position and the seat has been adjusted Backrest adjustment Turning t...

Page 52: ...Press the lever for seat weight adjustment up or down The lever position indicates the adjusted user s weight by means of the symbols Seat belt Pull out the seat belt slowly from the retractor Put th...

Page 53: ...pedals Return the lever to its folded position and the seat has been adjusted Backrest adjustment Pull up the locking lever to release the backrest catch When releasing the backrest catch do not apply...

Page 54: ...ards 10 movements from minimum to maximum Before every new movement bring the lever back to the starting position audible locking sound The driver s weight has been set correctly when the arrow is in...

Page 55: ...ECB16 ECB18 45 OM ECB162015006 EN US Document box There is a document box on the rear side of seat which could store documents work gloves and other flat goods https www forkliftpdfmanuals com...

Page 56: ...OPERATING THE FORKLIFT OPERATOR MANUAL 46 Drive Control System Drive control system overall view 1 3 4 5 2 https www forkliftpdfmanuals com...

Page 57: ...N US 6 7 8 No Name No Name No Name 1 Steering Wheel 4 TFT Display 7 Parking Brake 2 Ignition Switch 5 Travel Direction Control Switch 8 Brake Oil Cover 3 Adjustment Lever 6 Combination Lights Control...

Page 58: ...stop lever in position After adjustment try moving the steering wheel to check if it is secured Ignition Switch OFF position indicates that the power is cut off and allows entering and removing the ke...

Page 59: ...B162015006 EN US Horn Press down the horn to send audible warning when approaching crossings or when the visibility is limited Note When the key is in OFF position the horn will not work https www for...

Page 60: ...types of braking fluids 2 Adding unauthorized braking fluids might cause irreparable damage to the braking system Use only authorized braking fluid 3 Authorized braking fluid type DOT4 4 Seek the con...

Page 61: ...hand brake lever and pull it towards your body 2 To release the hand brake press down the unlock button on the top of the hand brake lever and push it back CAUTION To park the forklift on a slope dep...

Page 62: ...orward 2 Stop 3 Reverse pull the lever backward after pulling it backward the reversing lights will be lit and the beeper will be sound F N R 1 2 3 Note 1 The display unit in the instrument panel will...

Page 63: ...stop 3 High beam turn the switch clockwise to the second stop 4 Right turning light pull the switch backward OFF 1 2 3 4 Note 1 When the key is in the OFF position the turning indicators could still w...

Page 64: ...warning indicator only available in comfort model Speed mode on indicator Parking brake indicator Traction battery system error warning indicator Motor overheating warning indicator Total working hou...

Page 65: ...d Mode Switch Button OK indicator When the forklift is powered on this indicator gets lit Power mode Standard When the forklift is powered on the default power mode is Standard MPH Total working hours...

Page 66: ...ding indicator will get lit and the buzzer will sound when the actual load is below the rated loading capacity this message will disappear and buzzer will stop Charge the battery at once When the batt...

Page 67: ...ing P Setting Time Unit Working hours Background light Language Factory setting Exit Total working hours 253h Traction battery voltage 79V Functions of the 3 buttons Moving the cursor up Increasing th...

Page 68: ...cators Indicator related to the battery which appears in the case of low battery and battery failure Indicator related to the temperature which appears when some components are overheated It appears w...

Page 69: ...three If load exceeds the rated capacity stop lifting otherwise restart the forklift Lifting motor 3 phase fault Check the polarities on the lifting control for a short circuit If no restart the fork...

Page 70: ...to the specific attachment 5 Emergency Disconnect Switch Press down the emergency disconnect switch when there is an emergency press down the emergency disconnect switch to cut off the power Pull up...

Page 71: ...Disconnect Switch Press down the emergency disconnect switch when there is an emergency press down the emergency disconnect switch to cut off the power Pull up the emergency disconnect switch and it w...

Page 72: ...the Forks 1 Pull up the locking pin of the forks 2 Adjust the spread between the forks based on the dimension of the load CAUTION Adjust the forks so that both forks are equidistant from the outside e...

Page 73: ...Pin Use of the Towing Pin 1 Pull up the tow pin 2 Insert the tiller of the trailer 3 Insert the tow pin through the tiller CAUTION The tow pin can only be used for towing light duty trailers within t...

Page 74: ...ing the Forklift Crane lifting the Forklift When lifting the forklift with a crane secure the swings to the attachment points near the top of the mast and the rear parts of the overhead guard See the...

Page 75: ...nto the floor 3 The ramp should be able to withstand the weight of the forklift and be secured to the transport truck or the truck 4 During loading and unloading constantly check the rigidity and the...

Page 76: ...letely 5 Set the driving direction to reverse and release the brake 6 Reverse the forklift with caution at a low speed until the forklift leaves the stacking area 7 Lower the forks to above the floor...

Page 77: ...the forks are clear of the load 5 Slowly remove the forks from the bottom of the load The mast must keep in vertical or tilted forward position 6 After driving the forks out raise them and start the...

Page 78: ...epositing the loads lower the forks until they touch the floor 2 Apply the parking brake 3 Turn the key anticlockwise to OFF position and take it out 4 Press down the Emergency Disconnect Switch 5 Unb...

Page 79: ...ECB16 ECB18 69 OM ECB162015006 EN US https www forkliftpdfmanuals com...

Page 80: ...https www forkliftpdfmanuals com...

Page 81: ...nspections on BYD forklifts The time interval for the daily check tasks depends on the actual use of forklift Daily or every 8 hours or weekly or every 40 hours Based on actual use of the forklift the...

Page 82: ...ting Horn And Warning Equipments Lights combination horn reverse lights reverse beeper Braking System Braking fluid handbrake brake pedal Driving System And Controlling System Steering wheel mechanica...

Page 83: ...rovides protection to the operator Regular inspection can ensure its correct working in case of an emergency 1 Pull the seat belt fully out and check for fraying 2 Check the locking device belt buckle...

Page 84: ...ormality 2 Check if the parking brake works properly when it is applied Check the operating force needed to fully apply the parking brake by using an ergometer Check for abnormal wear on the parking b...

Page 85: ...e fuses box WARNING Disconnect the battery before checking the electric system Tires 1 Check on a daily basis every 8 hours if the wheel nuts are secured or loose Fasten them if they are loose 2 Take...

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Page 87: ...77 REGULAR INSPECTION AND MAINTENANCE This chapter explains how to conduct regular inspections and maintenance on the BYD forklift https www forkliftpdfmanuals com...

Page 88: ...months 12 months Interval Standard Two 250 hours 500 hours 1000 hours 2000 hours Conduct the regular inspection and maintenance in accordance with the abovementioned two interval standards whichever...

Page 89: ...Tilt Rotating Pin Lubrication Lubrication Gear Oil 1st Replacement Replacement Steering Axle Clean Torque On Critical Fasteners Check Note If the working environment is harsh the maintenance interval...

Page 90: ...that the inner chamber is clean flat and well lubricated 2 Check gaps between the inner and the outer mast and use the adjusting screw to ensure gaps being equal Tilt Rotating Pin Lubrication 1 Lift t...

Page 91: ...After the adjustment inspections on the chains should be conducted use ergometer to pull the chain when it is 39 4 in above the ground When the ergometer reads about 11 lb the chain should have moved...

Page 92: ...REGULAR INSPECTION AND MAINTENANCE OPERATOR MANUAL 82 Electric Electric System Inspection 1 Check connectors 2 check fuses and connect bars of the main controller https www forkliftpdfmanuals com...

Page 93: ...ECB16 ECB18 83 OM ECB162015006 EN US 3 check fuses and relays in the fuses box 5A 10A 15A 25A 25A WARNING Disconnect the battery before checking the electric system https www forkliftpdfmanuals com...

Page 94: ...and fully lower the mast and apply the parking brake Switch off the forklift take off the key and press down the emergency disconnect switch 1 To check the hydraulic oil level and the state of the ret...

Page 95: ...of the return filter cap and refill the oil Return Filter Element State Indicator The indicator of the return filter indicates the state of the filter element 1 Green area the element is in good condi...

Page 96: ...ring are in good condition replace them if necessary 4 Check if the spread and the o ring of the new element are in good condition replace them if necessary 5 Use clean hydraulic oil to lubricate the...

Page 97: ...and the o ring of the new element are in good condition replace them if necessary 5 Use clean hydraulic oil to lubricate the the o ring of the new element fit the new element carefully 6 Screw in the...

Page 98: ...ge occurs 5 Add hydraulic oil into the oil tank and measure the oil level with the dipstick 6 Remove and clean the residual oil spill on the oil tank and forklift bottom and working area CAUTION 1 Com...

Page 99: ...eople for inspection and repair CAUTION 1 After jacking up the forklift do not crawl under the forklift The slipping and removal of the jack might cause severe injuries 2 Do not loosen the wheel nuts...

Page 100: ...wheel nuts and wheels 4 When installing the wheels back on follow the reverse procedures Torque 147 6 ft lbs Rear Wheels Replacement 1 Park the forklift on the level floor apply the handbrake switch...

Page 101: ...drain plug back on and tighten it Torque 4 5ft lbs 5 Add the gear oil through oil filler hole until the gear oil overflows out of Oil dipstick plug 6 Tighten both Oil dipstick plug and Oil filler plug...

Page 102: ...REGULAR INSPECTION AND MAINTENANCE OPERATOR MANUAL 92 Braking Oil Replacement Braking Oil Reservoir Braking Oil Drain Plug https www forkliftpdfmanuals com...

Page 103: ...il drain plug and tighten it securely 5 Add some braking oil into the braking oil reservoir Slightly loosen the braking oil drains plug to let the air escape Repeat this procedure more than 3 three ti...

Page 104: ...R INSPECTION AND MAINTENANCE OPERATOR MANUAL 94 Steering Axle Clean Clean the steering axle with the compressed air CAUTION Do not damage the steering axle when cleaning it https www forkliftpdfmanual...

Page 105: ...Fasteners 1 Drive Axle and Motor Mounting Bolt 36 90 2 Drive Axle and Motor Mounting Bolt 36 90 3 Drive Axle Mounting Bolt 95 94 4 Drive Axle Mounting Bolt 95 94 1 1 2 3 4 4 Steering Axle Fasteners Ca...

Page 106: ...n Torque Ft lbs Wheel Fasteners 1 Front Wheel Nut 147 51 2 Rear Wheel Bolt 118 01 1 2 Counterweight Fasteners Category No Description Torque Ft lbs Counterweight Fasteners 1 Counterweight Mounting Bol...

Page 107: ...d Backrest Fasteners 1 Load Backrest Bolt 88 51 1 1 2 Tilt Cylinder Fasteners Category No Description Torque Ft lbs Tilt Cylinder Fasteners 1 Tilt Cylinder and Mast Mounting Bolt 44 25 2 Tilt Cylinder...

Page 108: ...INSPECTION AND MAINTENANCE OPERATOR MANUAL 98 3 Mast Mounting Fasteners Category No Description Torque Ft lbs Mast Mounting Fasteners 1 Mast and Frame Mounting Bolt 88 51 1 1 https www forkliftpdfmanu...

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Page 111: ...follow the instructions in this chapter to decommission and restore the forklift to service Even when the forklift is taken out of service for a long time several tasks need to be carried out on a mo...

Page 112: ...the battery power and press down the emergency disconnect switch Battery status of charge should be around 50 to avoid over discharge or full charge for long term storage Spray a layer of proper agent...

Page 113: ...orks tilting masts and handling attachment several times 3 Check the status of charge of the traction battery 4 Check the gear oil Replace it if it contains too much water inside 5 Check the hydraulic...

Page 114: ...rmodal de Cargas TIC CEP 13069 119 CAMPINAS SP Tel 55193514 2551 Importer BYD Japan company Limited Address The fifth Yasuda Bldg 5F 2 20 3 Tsuya cho Kanagawa ku Yokohama shi Kanagawa ken 221 0835 Jan...

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Page 116: ...OPERATOR MANUAL ECB16 ECB18 https www forkliftpdfmanuals com...

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