BYD ECB16S-B User manual

ECB16S-B/ECB18S-B
OPERATOR MANUAL
< OM-ECB16/18S-B2019001-EN >

ECB16S-B/ECB18S-B
ECB16S-B/ECB18S-B
< OM-ECB16/18S-B2019001-EN >

TABLE OF CONTENTS
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TABLE OF CONTENTS
FOREWORD
Descriptions
Operation Notice 9
Forklift Delivery 9
OPERATOR NOTICE
Notice
Operator Qualification 11
Warning Decals and Signs 12
INTRODUCTION
Working Environment
Working Environment 19
Nameplate and Decals
Forklift Nameplate 20
Loading Capacity Chart 21
Battery Nameplate 22
Other Decals 22
OPERATING
Seat
Basic Seat (A type) 24
Basic Seat (B type) 26
Comfort Seat 28
Startup and Control
Using Area Overview 31
Key Switch 32
Emergency Disconnect Switch 32
Steering Wheel Tilt Adjusting 32
Gear 33
Travel, Steering and Braking 33
Low Speed Mode 35
Parking 35
Horn 36
Light 36
Mechanical Levers 37
Multi-function Armrest 37
Adjusting Spacing between Forks 39
Tow Pin 39
Display
Display Appearance 40
Display Using 40
Transporting Loads
Loading 43
Travel 44
Unloading 44
Exiting 44
Battery
Charging 45
TRANSPORTATION AND STORAGE
Transporting and Unloading
Loading 47
Transporting 47

TABLE OF CONTENTS
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Unloading 47
Decommissioning and Restoring
Decommissioning 48
Restoring 48
MAINTENANCE
Daily Maintenance
Period and Items 50
Content Description 50
Regular Maintenance
Period and Items 53
Content Description 53
Consumable Items
Type and Parameters of Consumable Items 55
Before Maintenance
Preparation before Maintenance 56
Dealing with the Faulty Forklift 56
Chassis System Maintenance
Steering Axle Lubrication 57
Braking Fluid Inspection 58
Braking System Bleeding 58
Braking Fluid Replacement 59
Gear Oil Replacement 60
Wheel Removal and Installation 62
Mast Maintenance
2-stage Standard Mast Chain Adjustment 63
3-stage Free Lift Mast Chain Adjustment 63
Mast Cleaning 65
Mast Clearance Adjustment 65
Mast Lubrication 66
Chains Lubrication 67
Hydraulic System Maintenance
Hydraulic Oil Level Inspection 68
Hydraulic Oil Replacement 69
Return Filter Replacement 70
Air Filter Replacement 71
Electric System Maintenance
Electrical Wiring Inspection 72
Main Controller Inspection 72
Fuse and Relay Inspection 72
Torque Inspection on Critical Fasteners
Drive Axle and Motor 73
Steering Axle 74
Wheel 74
Counterweight 75
Load Backrest 75
Tilt Cylinder 75
Mast 76
Schematics
Schematic of Braking System 77
Hydraulic Schematic 77
Schematic of Electrical System 79
OTHER INFORMATION
Contact Information 83

FOREWORD
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FOREWORD
Thank you for choosing BYD electric forklifts.
These operating instructions explain in detail how to correctly operate the BYD electric
forklifts, as well as the procedures that you should follow when conducting checks, maintenance
and repairs on the forklifts.
Read through every chapter in the manual before operation for the correct use and
maintenance of the forklifts. When the forklift is out for rental or transportation, keep this operation
instruction together with the forklift and make sure that operators can use the manual whenever
necessary.
Pay attention to the following signs:
Danger
(Indicates an imminent extremely hazardous situation. Failure to avoid it will cause severe
injuries, major property damage or even death)
Warning
(Indicates a potential extremely hazardous situation. Failure to avoid it might cause severe
injuries, major property damage or even death)
Caution
(Indicates a potential hazardous situation. Failure to avoid it might cause slight to medium
injuries, or property damage)
Note
(Note for detailed operation. Complying with the instructions will ensure a better operation of
the BYD forklift)
DESCRIPTIONS
Operation Notice
BYD industrial vehicles can only be operated in the designated areas in the factory or in other
specific environments, in compliance with Regulations on safety supervision of special equipment.
Inappropriate use of the BYD forklift might cause damages and losses, which the operators
or proprietor instead of BYD should be held liable for. If the forklift needs to be operated in the
environments other than those mentioned in this manual, contact with your local BYD dealer first
for confirmation.
Any modification to the forklift is not allowed unless BYD's written consent is granted. Contact
with BYD first before modifying the forklifts.
If you have ordered other auxiliary attachments besides forks, please handle the loads in
compliance with the loading capacity of the attachments. All the attachments are provided with
operation instructions. Read through the manuals before operation.
This manual is devised based on the standard forklifts. For other questions not covered in the
manual, please check with BYD after sales service. BYD forklift is subject to ongoing development
and optimizing the design of products. BYD Forklift reserves the right to alter the design,
equipment, technical features,
and technical specifications and so on. No guarantee of particular features of the forklift
should therefore be assumed from the present operator manual.
Forklift Delivery
Every BYD forklift has passed through thorough performance tests before shipment. Although
proper protection has also been adopted during transportation, it is advised to conduct a thorough
inspection when the forklift arrives. Before delivering the forklift to end customers, to guarantee
that the forklift is in perfect condition, the followings checks should be conducted at BYD dealers:：
(1) Check if the wheel nuts are securely fastened
(2) Check the hydraulic oil level
(3) Check the braking function
(4) Check the travelling function
(5) Check the steering function
(6) Check the operation of mast and attachments
(7) Check the high voltage connectors (transportation might have loosened the connectors)
To avoid inconveniences in future warranty claims, please check the functions of the forklift
and check if the forklift is complete.

OPERATOR NOTICE
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OPERATOR NOTICE
This chapter instructs on safety operation procedures that should followed during the use of
the BYD forklift.
The operator of the forklift should have obtained the driving permit in accordance with local
regulations.
Before operating the forklift, check the nameplate and capacity chart to know the loading
capacity of the forklift and avoid the overloading during operation.
Warning signs and decals are pasted on the forklift. Get familiar with the decals and its
contents.
NOTICE
Operator Qualification
Industrial vehicle can only be allowed to be operated by people with the qualification regulated
by local laws. The operators should be those who have been specially trained and have experience
in operating the vehicles. The user or other entrusting part must confirm the qualification of the
operators and make use of the tests before authorizing the person to operate the forklift.
The operating company must make sure that the operators understand all the safety
messages on the forklifts.
For the proprietor, make sure following safety instruction on your industrial vehicles are
observed.
Please abide by relevant regulations and guide-principles, such as：
(1) Operation of industrial vehicle
(2) Lane and operative area regulation
(3) Diver’s right, responsibility and standard of behavior
(4) Special operation area
(5) Daily maintenance and repair
(6) Regular maintenance and repair
Danger
(1) Unauthorized persons are not allowed to operate the forklift.
(2) Safety devices and features (such as OPS system) will provide extra safety. Do not
deactivate these safety device and features.
(3) Make sure that the load is well palletized and trimmed to avoid its protruding the loading
surface of forklift and thus slipping, collapsing and falling over.
(4) Any modification on the forklift is not allowed. Contact with BYD before making any
modification.
(5) Do not overload. Before operation, please check the rated loading capacity and loading
center on the capacity chart. When an attachment has been installed, abide by the rated
loading capacity given on the attachment.
(6) Do not operate the forklift after drinking. It might cause severe human injuries.

OPERATOR NOTICE
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Caution
(1) Read through the operation instructions before operating the forklift.
(2) Operators should wear working boots and working clothes.
(3) Do not operate the forklift with wet or greased hands.
(4) Conduct the daily checking 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.
Warning Decals and Signs
The BYD forklifts have warning decals and signs to remind the operators of potential risks, as
well as safety notices. Find and read all these decals and signs.
If the warning decals and signs are missing or difficult to read, please contact your local BYD
dealer for immediate replacement.
INTRODUCTION
This chapter instructs on the general view and technical specifications of the forklift.
BYD electric counterweight forklifts are purely powered by batteries. These forklifts are
characterized by high power, rapid charge, zero emission, and zero pollution. They may be used
for picking up, depositing, handling, or stacking loads in harbors, stock yards, plants, warehouses,
logistics centers, and marine shipment containers. They are notable for great convenience and
high efficiency, gaining the reputation “master-hand for handling loads in plants and workshops”.

INTRODUCTION
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INTRODUCTION, TECHNICAL SPECIFICATIONS AND
WORKING ENVIRONMENT
1、Introduction of 1.6-1.8t
ECB16S-B/ECB18S-B battery counterweight forklifts are purely powered by 80V voltage
platform. The drive axle is driven by three-phase AC motor. These forklifts are characterized by
high power and adopt standard charging port of the car with rapid charge, zero emission and
zero pollution. ECB16S-B/ECB18S-B mainly consists of body system, chassis system, hydraulic
system, electrical system, accessory system, working device system and battery pack. They
may be used for picking up, depositing, handling, or stacking loads in harbors, stock yards,
plants, warehouses, logistics centers, and marine shipment containers. They are notable for
great convenience and high efficiency. During working, the ECB16S-B/ECB18S-B can load
the maximum cargo of 1.6t/1.8t, and the gradeability with full load can reach 15%, gaining the
reputation “master-hand for handling loads in plants and workshops”.
4
3
2
11
5
6
7
13
14
1
8
12
10
9
No. Name No. Name No. Name
1 Charging Door 6 Mast 11 Using Area
2 Front Wheel 7 Front Lamp 12 Counterweight
3 Carriage 8 Overhead Guard 13 Tow Pin
4 Fork 9 Rear Lamp 14 Rear Wheel
5 Load Backrest 10 Rear Handle
2.Technical Drawing (Single Drive)
α
β

INTRODUCTION
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2.Technical Specifications (Single Drive)
Identification
1.1 Manufacturer BYD BYD
1.2 Model ECB16S-B ECB18S-B
1.3 Drive Electric Electric
1.4 Operator type Seat Seat
1.5 Loading capacity Q kg 1600 1800
1.6 Load center c mm 500 500
1.7 Axle centre to fork face x mm 420 420
1.8 Wheelbase y mm 1400 1400
Weight
2.1 Service weight kg 3340 3490
2.2 Axle load, with load, front/rear kg 4206/734 4553/737
2.3 Axle load, without load, front/rear kg 1555/1785 1570/1920
Wheel
3.1 Service weight kg SE SE
3.2 Axle load, with load, front/rear kg 6.00-9 6.00-9
3.3 Axle load, without load, front/rear kg 16x6-8 16x6-8
3.4 Wheels, number front/rear (X=driven wheels) 2x/2 2x/2
3.5 Track width, front b10 890 890
3.6 Track width, rear b11 870 870
Basic
Dimensions
4.1 Tilt of mast/fork carriage forward/backward α/βdeg 5/8 5/8
4.2 Height, mast lowered h1 mm 2020 2020
4.3 Free lift h2 mm 120 120
4.4 Lift height h3 mm 3000 3000
4.5 Height, mast extended h4 mm 4040 4040
4.6 Height of overhead guard h6 mm 2050 2050
4.7 Seat height h7 mm 1005 1005
4.8 Coupling height h10 mm 270 270
4.9 Overall length l1 mm 3195 3195
4.10 Length to face of forks l2 mm 2125 2125
4.11 Overall width b1 mm 1050 1050
4.12 Fork dimensions s/e/l mm 40/100/1000 40/100/1000
4.13 ISO2328, frame/type A, B 2A 2A
4.14 Fork carriage width b3 mm 1044 1044
4.15 Ground clearance, below mast m1 mm 85/90 85/90
4.16 Ground clearance, center of wheelbase m2 mm 85/90 85/90
4.17 Aisle width for pallets 1000x1200 crossways Ast mm 3480 3480
4.18 Aisle width for pallets 800x1200 lengthways Ast mm 3680 3680
4.19 Turning radius Wa mm 1860 1860
4.20 Inward turning radius b13 mm 537 537
Performance
Data
5.1 Travel speed, with/without load Km/h 16/16 16/16
5.2 Lift speed, with/without load mm/s 420/450 420/450
5.3 Lowering speed, with/without load mm/s 520/480 520/480
5.4 Max.drawbar pull, S2=5min, with/without load KN 10.0/9.5 10.0/9.5
5.5 Max.gradeability, S2=5min, with/without load % 20/20 20/20
5.6 Service brake 6.0/5.0 6.0/5.0
5.7 Service brake Mech./Hydr. Mech./Hydr.
Drive
6.1 Drive motor rating, S2=60min kW 8.5 8.5
6.2 Lift motor rating at S3=15%ED kW 16 16
6.3 Battery voltage, nominal capacity 80/270 80/270
6.4 Battery weight Mpa 650 650
Others
7.1 Type of drive control AC AC
7.2 Operating pressure for hydraulic system MPb ≤16 ≤18
7.3 Sound level at the driver's ear dB(A) ≤75 ≤75
7.4 Towing coupling, type PIN PIN
3.Technical Drawing (Dual Drive)

INTRODUCTION
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3Technical Specifications (Dual Drive)
Identification
1.1 Manufacturer BYD BYD
1.2 Model ECB16S-B ECB18S-B
1.3 Drive Electric Electric
1.4 Operator type Seat Seat
1.5 Loading capacity Q kg 1600 1800
1.6 Load center c mm 500 500
1.7 Axle centre to fork face x mm 370 370
1.8 Wheelbase y mm 1400 1400
Weight
2.1 Service weight kg 3150 3150
2.2 Axle load, with load, front/rear kg 3985/765 4312/788
2.3 Axle load, without load, front/rear kg 1390/1760 1393/1907
Wheel
3.1 Service weight kg SE SE
3.2 Axle load, with load, front/rear kg 18x7-8 18x7-8
3.3 Axle load, without load, front/rear kg 15x4.5-8 140/55-9
3.4 Wheels, number front/rear (X=driven wheels) 2x/2 2x/2
3.5 Track width, front b10 900 900
3.6 Track width, rear b11 900 900
Basic
Dimensions
4.1 Tilt of mast/fork carriage forward/backward α/βdeg 5/7 5/7
4.2 Height, mast lowered h1 mm 2020 2020
4.3 Free lift h2 mm 120 120
4.4 Lift height h3 mm 3000 3000
4.5 Height, mast extended h4 mm 4040 4040
4.6 Height of overhead guard h6 mm 2050 2050
4.7 Seat height h7 mm 990 990
4.8 Coupling height h10 mm 250 250
4.9 Overall length l1 mm 3145 3145
4.10 Length to face of forks l2 mm 2075 2075
4.11 Overall width b1 mm 1060 1060
4.12 Fork dimensions s/e/l mm 40/100/1000 40/100/1000
4.13 ISO2328, frame/type A, B 2A 2A
4.14 Fork carriage width b3 mm 1040 1040
4.15 Ground clearance, below mast m1 mm 95/100 95/100
4.16 Ground clearance, center of wheelbase m2 mm 85/90 85/90
4.17 Aisle width for pallets 1000x1200 crossways Ast mm 3400 3400
4.18 Aisle width for pallets 800x1200 lengthways Ast mm 3590 3590
4.19 Turning radius Wa mm 1820 1820
4.20 Inward turning radius b13 mm 433 433
Performance
Data
5.1 Travel speed, with/without load Km/h 16/16 16/16
5.2 Lift speed, with/without load mm/s 420/480 420/480
5.3 Lowering speed, with/without load mm/s 480/460 480/460
5.4 Max.drawbar pull, S2=5min, with/without load KN 9/8 9/8
5.5 Max.gradeability, S2=5min, with/without load % 20/20 20/20
5.6 Service brake 4.5/4 4.5/4
5.7 Service brake Mech./Hydr. Mech./Hydr.
Drive
6.1 Drive motor rating, S2=60min kW 5Kwx2 5Kwx2
6.2 Lift motor rating at S3=15%ED kW 16 16
6.3 Battery voltage, nominal capacity 80/270 80/270
6.4 Battery weight Mpa 650 650
7.1 Type of drive control AC AC
7.2 Operating pressure for hydraulic system MPb ≤16 ≤18
7.3 Sound level at the driver's ear dB(A) ≤75 ≤75
7.4 Towing coupling, type PIN PIN
1. Mast Specifications (Single Drive)
2-Stage Standard Mast 2-Stage Free Lift Mast 3-Stage Free Lift Mast
Lift height h3 3000 3500 4000 4500 3000 3500 4000 4500 4800 5000 5500 6000 6500
Fork height h23 3040 3540 4040 4540 3040 3540 4040 4540 4840 5040 5540 6040 6540
Height, mast lowered h1 2020 2270 2570 2820 2027 2277 2577 2102 2202 2252 2402 2672 2872
Load backrest height h8 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Height, mast extended
(without load backrest) h4 3610 4110 4610 5110 3670 4170 4670 5160 5460 5660 6160 6660 7160
Height, mast extended
(with load backrest) h4 4040 4540 5040 5540 4040 4540 5040 5540 5840 6040 6540 7040 7540
Free lift (without load
backrest) h2 125 125 125 125 1431 1681 1981 1506 1606 1656 1806 2076 2256
Free lift (with load
backrest) h2 125 125 125 125 835 1085 1385 1062 1162 1212 1362 1632 1812
Mast/fork carriage tilt,
forward/rearward α/β5/8 5/8 5/8 5/5 5/8 5/8 5/8 5/5 5/5 5/5 5/3 5/3 5/3
Axle centre to fork face x 420 420 420 420 420 420 420 431 431 431 431 431 431
2.Mast Specifications (Dual Drive)
2-Stage Standard Mast 2-Stage Free Lift Mast 3-Stage Free Lift Mast
Lift height h3 3000 3500 4000 4500 3000 3500 4000 4500 4800 5000 5500 6000 6500
Fork height h23 3040 3540 4040 4540 3040 3540 4040 4540 4840 5040 5540 6040 6540
Height, mast lowered h1 2020 2260 2510 2809 2027 2320 2570 2045 2153 2245 2445 2645 2845
Load backrest height h8 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Height, mast extended
(without load backrest) h4 3625 4125 4625 5125 3605 4105 4605 5130 5430 5630 6130 6630 7130
Height, mast extended
(with load backrest) h4 4040 4540 5040 5540 4040 4540 5040 5540 5840 6040 6540 7040 7540
Free lift (without load
backrest) h2 120 120 120 120 1415 1715 1965 1415 1606 1615 1815 2015 2215
Free lift (with load
backrest) h2 120 120 120 120 970 1270 1520 1995 1162 1195 1395 1595 1795
Mast/fork carriage tilt,
forward/rearward α/β5/7 5/7 5/7 5/5 5/7 5/7 5/7 5/5 5/5 5/5 5/3 5/3 5/3
Axle centre to fork face x 365 365 365 365 365 365 365 385 385 385 385 385 385
2. Battery Specifications
1.6t/1.8t
Battery voltage, nominal
capacity V/Ah 80/270
Battery weight kg 650
Working Environment
Temperature：-10 ~ 40℃
Gradeability：≤20%
Others: no flammable gas, no flammable dust and no volatile flammable liquid