BYD ECB70 User manual

ECB70 | ECB80
SERVICE MANUAL
< SM-ECB70/802019001-EN >

This manual is used for authorized personnel to service BYD forklifts

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TABLE OF CONTENTS
INTERVAL, ITEM AND AUXILIARY MATERIAL
Daily Maintenance
Period and Items
Content Description
Regular Maintenance
Period and Items
Content Descriptions
Auxiliary Material
Type and Parameters of Auxiliary Material
CHASSIS SYSTEM MAINTENANCE
Steering Column
Descriptions
Steering Column Removal and Installation
Steering Column Overhaul
Steering Axle
Descriptions
Steering Axle Wheel Bearing Service
Drive Axle
Gear Oil Replacement
Wheel and Tire
Appearance Check
Wheel Removal and Mounting
Tire Replacement
MAST MAINTENANCE
Chain
2-Stage Standard Mast Chain Adjustment
3-Stage Free Lift Mast (4 Cylinders) Chain Adjustment
Lift Cylinder
Lift Cylinder Air-Exhausting
Lift Cylinder Rod Lubrication
Lift Cylinder Shimming Adjusting
Mast and Carriage
Description of Mast and Carriage Roller
Carriage and Mast Clearance Adjustment
Carriage Removal and Installation after Mast Removal
Mast and Carriage Roller Replacement
OTHER INFORMATION
Contact Information
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2.Tires
(1)Check if the wheel fasteners are secured or loose. Fasten them if they are loose
(2)Take out debris embedded in the tire.
(3)If the four tires are unevenly worn, or the tires are found damaged, or the rims are bent,
then replace the tires.
3.Mast
(1)Check the cylinders, oil pipes, and hoses on working equipment for oil leakage.
(2)Check the working equipment for deformation and damage. Check if the bolts are
securely fastened.
Note
If oil leakage occurs, confirm the location of oil leakage and contact the BYD after sales service.
4.Hydraulic System
(1)Check the hydraulic oil level in the oil tank.
(2)Check the state of the filter indicator.
5.Seat
(1)Pull the seat belt fully out and check for fraying.
(2)Check the locking device (belt buckle) of the seat belt, and check if the retractor
functions properly.
(3)Check if the seat can be adjusted forward and backward, and if the back rest angle and
seat suspension can be adjusted.
Danger
In the case of seat belt failure, stop operating the forklift and replace the seat belt.
6.Display
(1)Check if the battery voltage and status of charger displayed are correct.
(2)Check if any error/fault indicator appears on the display.
(3)Set the direction control switch to “forward”, “neutral” and “reverse” and check if
corresponding indicator appears
(4)Check if the turning indicator signs appear when the turning indicator is activated.
(5)Check if the 3 control buttons on the display functions properly.
Daily Maintenance
Period and Items
Daily (or every 8 hours) and weekly (or every 40 hours) for daily inspection items, whichever
comes first. For example, if daily working hours are less than 8 hours per day, conduct the inspection
and checks on a daily basis. If daily working hours exceed 8 hours, conduct the inspection and
checks every 8 hours.
Inspection checklist:
No. Items
1 day 1 week
8h 40h
1 Forklift Exterior Check
2 Tires Clean and tighten Clean and tighten
3 Mast Check
4 Hydraulic System Check
5 Seat Check
6 Display Check
7 Warning Equipment Check
8 Braking System Check Check
9 Driving, Steering and Controlling Check
10 Electric System Check
11 Counterweight Check
12 Clean Clean
13 Others Check
Note
(1)These inspections should be conducted before operating the forklift.
(2)Before conducting the daily inspection, recheck for any fault and error found earlier.
Content Description
1.Forklift Appearance
(1)Check the forklift body for damage and deformation.
(2)Check the floor where the forklift is parked for oil leakage.
(3)Check whether nameplate, loading capacity chart and warning decals and signs are complete.
Note
If oil leakage occurs, confirm the location of the oil leakage and contact the BYD after sales
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7.Warning Equipment
(1)Check if working lights work properly.
(2)Check if turning lights work properly.
(3)Set the gear to “Reverse” and check if reversing lights work and reversing beeper
sound
(4)Press horn to see if it works.
(5)Check if other warning equipment work properly.
8.Braking System
(1)Fully depress and then release the braking pedal and check if there is any abnormality.
(2)Check if the parking brake works properly when it is applied. Check the operating force
needed to fully apply the parking brake. Check for abnormal wear on the parking brake.
(3)Check the braking fluid level.
9.Driving, Steering and Operating
(1)Turn the steering wheel clockwise and anti-clockwise and check if the steering is
smooth.
(2)Operate the mechanical levers and check if lifting and tilting are smooth.
(3)Depress the acceleration pedal to see if the forklift can accelerate normally.
(4)Check for abnormal sounds during forklift operation.
10.Electric System
(1)Check the electrical wiring of the forklift.
(2)Check the fuse and relay.
(3)Check the main controller.
11.Counterweight
(1)Check the counterweight bolts.
(2)Check the tow pin.
12.Clean
(1)Clean the forklift.
13.Others
(1)Check if there are other problems.
Regular Maintenance
Period and Items
Period for regular inspection and maintenance, whichever comes first. For example, if the
vehicle works less than 250 hours in 6 weeks, conduct the following inspection and checks every
6 weeks, otherwise conduct the following inspection and checks every 250 hours. Perform the
maintenance service accordingly
Category Items 6 weeks 3 6 12 Months
250 500 1000 2000 Hours
Chassis System Steering Axle Lubrication
Braking Fluid Replacement
Gear Oil Replacement 1st replacement Replacement
Mast Chains Adjustment Check
Lift Chains Lubrication Lubrication
Mast Cleaning Clean
Mast Lubrication Lubrication
Hydraulic System Hydraulic Oil Replacement of Main
Oil Tank
Replacement
Hydraulic Oil Replacement of Tilt
Mechanism
Replacement
Return Filter Element Replacement 1st replacement Replacement
High Pressure Filter Element
Replacement
1st replacement Replacement
Return Filter's Air Filter
Replacement
Replacement
Electric System Electric System Check
Others Torque on Critical Fasteners Check Check
Note
If the working environment is harsh, the maintenance interval should be reduced, and advice
from BYD after sales personnel should be sought.
Content Descriptions
1.Chassis System
(1)Lubricate the drive axle.
(2)Replace the brake fluid.
(3)Replace the gear oil.
2.Mast
(1)Check the tightness of the chain and adjust if necessary.
(2)Lubricate the chains.
(3)Clean the mast.
3.Hydraulic System
(1)Replace hydraulic oil regularly.
(2)Replace return filter element
(3)Replace high pressure filter element
(4)Replace air filter
4.Electric System
(1)Check the electrical wiring of the forklift.
(2)Check fuse and relay.
(3)Check the main controller.
5.Others
Check torque on critical fasteners

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AUXILIARY MATERIAL
Type and Parameters of AUXILIARY MATERIAL
Items Category Volume Needed Type
Gear Oil Replacement Gear Oil As Needed Mobil Fluid 424
Hydraulic Oil Replacement Of Main
Oil Tank
Hydraulic Oil 130L ISOVG46( ≤ 46 ° C),
ISOVG68( ≤ 68° C)
Hydraulic Oil Replacement Of Tilt
Mechanism
Hydraulic Oil Used For Planes As Needed 10#
Braking System Braking Fluid As Needed DOT4
Mast Lubrication Lithium Lubrication Grease As Needed EP2
Steering Axle Lithium Lubrication Grease As Needed EP3
Lift Chains Lubrication Machine Oil As Needed 20#(Winter), 40#(Other seasons)
Note
The given quantities are maximum values and take the actual quantities as the standard.
CHASSIS SYSTEM MAINTENANCE
This chapter explains how to maintain chassis system.
Steering Column
Descriptions
The switch assy (basic or comfort) is fixed between the steering shaft assembly and the
steering wheel
Connected to the bottom of the steering shaft assembly, the steering control unit is
operated by the steering wheel, which is supplied with oil pressure from the main hydraulic pump
and directs oil flow to the steering cylinder in the steering axle.
The cover and the entire column can be removed for service or replacement.
CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
11 STEERING WHEEL 1 13 FRONT STEERING COLUMN
COVER
1
12 SWITCH ASSY (BASIC) 1 14 REAR STEERING COLUMN
COVER
1
12 SWITCH ASSY (COMFORT) 1 15 STEERING SHAFT ASSEMBLY 1
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Steering Column Removal and Installation
1.Cover, Steering Wheel and Switch Assembly Removal
(1)Loosen 4 screws in the Rear Steering Column Cover and remove them.
Loosen 4 bolts to remove the Front Steering Column Cover (4 clip nuts don’t need
to be removed).
(2)Open the cover of the steering wheel, loosen the nut, and remove them.
(3)Loosen 4 screws to remove the switch assembly.
2.Steering Column Removal
(1)Loosen nuts on the steering column.
(2)Loosen the insert nut
(3)Remove them
3.Steering Column, Cover, Steering Wheel and Switch Assembly Installation
Follow the steps in reverse to install Steering Column, Cover, Steering Wheel and Switch
Assembly.
Steering Column Overhaul
Use the picture of the explosive view as the guide to overhaul the steering column.
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
11 FRONT STEERING COLUMN
COVER
1 16 HEXAGON FLANGE NUT
M12
1
12 REAR STEERING COLUMN
COVER
1 17 STEERING WHEEL 1
13 CLIP NUT M6 4 18 SCREW M5×14 4
14 BOLT M6×30 4 19 SWITCH ASSY (BASIC) 1
15 SCREW M6×20 4
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
11 FLAT WASHER 4 14 FLAT NUT 2
12 FLAT ROUND BOLT 2 15 NUT 1
13 SPRING WASHER 2

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Steering Axle
Descriptions
The steering axle has the steering cylinder, knuckles, and links mounted on it. All these
components can be removed, serviced, and replaced.
The steering control unit at the base of the steering column directs hydraulic oil to one end or
the other of the steer cylinder to pivot the steer wheels.
The steer axle is bolted to the truck frame. The steer cylinder is connected to the steering
knuckles by links.
All bearings used in the steer axle linkage have lubrication fittings and are serviceable.
Steering Axle Wheel Bearing Service
1.Bearing Disassembly
(1)Remove the Wheel.
(2)Open the dust cap, remove the split pin, the castle nut and washer.
(3)Pull off the hub from the knuckle. Support the hub to avoid dragging the grease seal at the
back side across the thread on spindle end.
(4)Clean the old grease out of center of the hub.
(5)Lay the hub down with outer edge up (support hub on blocking), and then remove the inner
bearing cone and grease seal.
(6)Clean and inspect the bearing cups and cones for wear or other damage. Replace them as a
set if necessary.
(7)Inspect grease seal for wear and damage. Replace as necessary. It is recommended to install
a new grease seal whenever old ones are removed.
(8)Use a standard puller to remove bearing cups from hub if bearings require replacement.
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
11 STEERING BRACKET 1 82 BALL BEARING 1
12 CARDAN SHAFT ASSY 1 83 CIRCLIP 2
13 TOP FLANGE 1 84 HEXAGON FLANGE BOLT
M10×16
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14 BOTTOM FLANGE 1 85 SCREW M10×35 4
15 INSERT 4 86 BOLT M8×35 2
16 RUBBER 4 87 SPRING WASHER M8 2
17 SUPPORT PLATE 1 88 CIRCLIP 1
18 WASHER 1 89 CIRCLIP 1
19 INNER SHAFT 1 90 FLAT WASHER 4
21 WASHER 1 91 FLAT ROUND BOLT 2
22 SUPPORT PLATE 1 92 SPRING WASHER 2
23 JOINT 2 93 FLAT NUT 2
24 SPLINE ROD 1 94 BALL BEARING 1
25 SPLINE COLUMN 1 95 BALL BEARING 2
26 PIN 2 96 SCREW M4.8×19 3
27 HOLLOW PIN 2 97 SCREW M4×25 2
28 SLOTTED PIN 2 98 SPRING WASHER M10 4
81 HEXAGON FLANGE NUT
M12
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
11 DUST CAP 1 15 TAPERED BEARING 1
12 SPLIT PIN 1 16 HUB 1
13 CASTLE NUT 1 17 TAPERED BEARING 1
14 WASHER M30 1 18 SEAL 1

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2.Bearing Reassembly
(1)Press new bearing cups into the hub and ensure cups being seated correctly. Pack the bearings
with grease and install the inner bearing. Pack cavity between bearing and seal half full with grease.
Apply coating of grease to inside diameter of seal lips prior to assembly, then install seal in hub.
(2)Install the hub on knuckle carefully to avoid damage grease seal lip when moving the hub over
the end of spindle and threads. Pack cavity in hub between bearings one-half full with grease. Install
the outer wheel bearing after it has been packed with grease, and then install the washer
(3)Install the castle nut, tighten it, and then unscrew it by 1/8~1/6 turn. Recheck for correct
bearing adjustment by rotating the hub by hand. The hub should rotate free. Readjust bearings by
adjusting the castle nut as necessary to avoid binding in bearings.
(4)Install the split pin, pack the area around castle nut with grease, and then install the dust cap.
Drive Axle
Gear Oil Replacement
Run the forklift until the driving axle gets lightly heated. Park the forklift on a level floor, apply the
hand brake, switch off the forklift, remove the key and press down the emergency disconnect switch.
Lift the forklift with jack and secure the wheels with wedges. Remove the wheels.
(1)Clean the surrounding areas around the oil drain plug, oil filler plug and oil dipstick plug. Place
a container below the oil drain plug.
(2)Remove oil drain plug, oil filler plug and oil dipstick plug and drain all the gear oil.
(3)Put the oil drain plug back on and tighten it.
(4)Add the gear oil through oil filler hole until the gear oil overflows out of oil dipstick plug.
(5)Tighten both oil dipstick plug and oil filler plug.
(6)Refit the wheel and replace the gear oil in the driving axle on the other side.
Wheel and Tire
Appearance Check
Check the condition of wheels and tires. Remove things imbedded in tires.
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
11 DUST CAP 1 18 SEAL 1
12 SPLIT PIN 1 19 BEARING CUP 1
13 CASTLE NUT 1 20 INNER BEARING 1
14 WASHER M30 1 21 BEARING CUP 1
16 HUB 1 22 INNER BEARING 1
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
11 OIL FILLER PLUG 1 20N-m 13 OIL DRAIN PLUG 1 20N-m
12 OIL DIPSTICK PLUG 1 20N-m

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Wheel Removal and Mounting
1.Front Wheel Removal and Mounting
(1)Park the vehicle on the level floor, apply the handbrake, switch off the vehicle, remove the
key and press down the emergency disconnect switch.
(2)Jack up the vehicle until the tires are off the ground and loosen the wheel nuts.
(3)Remove the wheel nuts and wheels.
(4)Follow the reverse procedures to install the wheels back on.
2.Front Wheel Removal and Mounting
(1)Park the vehicle on the level floor, apply the handbrake, switch off the vehicle, remove the
key and press down the emergency disconnect switch.
(2)Jack up the vehicle until the tires are off the ground and loosen the wheel nuts.
(3)Remove the wheel nuts and wheels.
(4)Follow the reverse procedures to install the wheels back on.
Tire Replacement
For this kind of wheel, the tire will be damaged when pulled out the rim, so the tire can only be
removed and replaced by machine.
MAST MAINTENANCE
This chapter will explain how to maintain mast.
Chain
2-Stage Standard Mast Chain Adjustment
The 2-stage standard mast has a main lift chain set that is needed to be adjusted.
No. Chain Adjustment Purpose Requirement
1 Main Lift Chain Fork-to-Ground Clearance 10~20mm
1.Fork-to-ground clearance adjustment
(1)Tilt the mast to be on the vertical position, and then fully lower the mast.
(2)Loosen the upper nut (that some masts have) and the lower nut.
(3)Screw the middle nut to adjust the chain until it meets the requirement.
(4)Tighten the upper and lower nuts.
CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
11 NUT 1 13 NUT 1
12 NUT 1
3-Stage Free Lift Mast (4 Cylinders) Chain Adjustment
The 3-stage free list mast (4 cylinders) has a main lift chain set and a free lift chain set that are
needed to be adjusted.
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1.Inner mast bottom height adjustment
(1)Tilt the mast to be on the vertical position, and then fully lower the mast.
(2)Loosen the upper nut (that some masts have) and the lower nut.
(3)Screw the middle nut to adjust the chain until it meet the requirement.
(4)Tighten the upper and lower nuts.
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No. Chain Adjustment Purpose Requirement
1 Main Lift Chain Inner Mast Bottom Height ≤ 2mm
2 Free Lift Chain Fork-to-Ground Clearance 10~20mm

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(1)Tilt the mast to be on the vertical position, and then fully lower the mast.
(2)Loosen the upper nut (that some masts have) and the lower nut.
(3)Screw the middle nut to adjust the chain until it meet the requirement.
(4)Tighten the upper and lower nuts.
Lift Cylinder
Lift Cylinder Air-Exhausting
(1)Tilt the mast to be on the vertical position, and then fully lower the mast.
(2)Remove the screw and washer on the top side of the cylinder.
(3)Fully lift the lift cylinder to exhaust the air in the cylinder.
(4)Install the screw and the washer, and then tighten the screw.
Lift Cylinder Rod Lubrication
(1)Tilt the mast to be on the vertical position, and then fully lower the mast.
(2)Remove the screw and washer on the top side of the cylinder.
(3)Add some hydraulic oil into the cylinder tube to lubricate the cylinder rod.
(4)After lubrication, exhaust the air in the lift cylinder, install the screw and the washer, and then
tighten the screw.
Lift Cylinder Shimming Adjusting
(1)Lift the mast to find the cylinder rod top of the shorter stroke.
(2)Tilt the mast to be on the vertical position, and then fully lower the mast.
(3)Use a reliable hoisting strap to hang the upper beam of the inner mast (2-stage mast) or the
middle mast (3-stage mast), and secure the strap with a safety hook.
(4)Remove the piston rod bolt.
(5)Slowly lift the hoisting strap to expose both cylinder rod tops.
(6)Insert several shims over the cylinder rod top of the shorter stroke to achieve equal stroke
length.
(7)Slowly lower the mast back onto the rod tops, and then screw and tighten cylinder rod bolt
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
11 NUT 1 13 NUT 1
12 NUT 1
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
11 NUT 1 13 NUT 1
12 NUT 1

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Mast and Carriage
Description of Mast and Carriage Roller
1.General Description
A circlip locks the mast roller, bearing, and the dust protection that are installed on the mast
or the carriage stub. The bearing is used to adjust the clearance of the mast and carriage by the
adjusting screw, which is installed on the other side of the stub and secured by a secure pin.
2.2-Stage Mast and Carriage Roller Description
In the 2-stage mast, 2 mast rollers are installed on the top side of the outer mast, 2 mast
rollers are installed on the bottom side of the inner mast, and 6 mast rollers are installed on the
carriage. Being different from others, the upper 2 mast rollers of the carriage are installed by roller
protections and bolts.
3.3-Stage Mast and Carriage Roller Description
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
14 SHIM 1mm 2 82 BOLT ASSY M12×40 1
15 SHIM 0.5mm 1
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
81 MAST ROLLER 1 84 ADJUSTING SCREW 1
82 BEARING 1 85 SECURE PIN 1
83 DUST PROTECTION 1 86 CIRCLIP 1
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
12 PROTECTION 2 84 ADJUST SCREW 8
81 MAST ROLLER 10 85 SECURE PIN 8
82 BEARING 8 86 CIRCLIP 8
83 DUST PROTECTION 8 88 BOLT ASSY M8×16 2

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Carriage and Mast Clearance Adjustment
1.General Carriage and Mast Clearance Adjustment Procedure
(1)Lift the mast to expose the position of the adjusting screw.
(2)Bend the secure pin to expose the adjusting screw.
(3)Use the screw to adjust the clearance.
(4)After adjustment, bend the secure pin to secure the adjustment screw.
2.Order of adjusting 2-stage mast and carriage clearance
(1)Clearance between the outer mast and the inner mast.
(2)Clearance between the inner mast and the carriage.
3.Order of adjusting 3-stage mast and carriage clearance
(1)Clearance between the outer mast and the middle mast.
(2)Clearance between the middle mast and the inner mast.
(3)Clearance between the inner mast and the carriage.
Carriage Removal and Installation after Mast Removal
1.Carriage Removal
(1)Remove the mast, slowly set the mast down on the flat floor or sturdy pallets.
(2)Loosen chain nuts to release the carriage.
(3)Remove the carriage by sliding it out from the bottom of the mast.
2.Carriage Installation
Follow the removal steps in reverse to install the carriage. After installation, adjust the clearance
between the carriage and the mast.
Mast and Carriage Roller Replacement
1.Mast Roller Replacement
Before mast roller replacement, remove the mast, slowly set the mast down on the flat floor
or sturdy pallets, and then remove the carriage and cylinders away from the mast.
(1)Slide the mast in the direction of bottom side of the mast, and then replace mast rollers.
(2)Slide the mast in the direction of top side of the mast, and then check the adjusting screws
and secure pins, replace them if necessary.
After replacement, adjust the clearance of the mast.
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CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
12 PROTECTION 2 84 ADJUST SCREW 12
81 MAST ROLLER 14 85 SECURE PIN 12
82 BEARING 12 86 CIRCLIP 12
83 DUST PROTECTION 12 88 BOLT ASSY M8×16 2
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2.Carriage Roller Replacement
(1)Check the adjusting screws and secure pins, replace them if necessary.
(2)Replace carriage rollers.
CODE PART NAME QTY INFORMATION CODE PART NAME QTY INFORMATION
81 MAST ROLLER 8 84 ADJUST SCREW 8
82 BEARING 8 85 SECURE PIN 8
83 DUST PROTECTION 8 86 CIRCLIP 8
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12 PROTECTION 2 84 ADJUST SCREW 4
81 MAST ROLLER 6 85 SECURE PIN 4
82 BEARING 4 86 CIRCLIP 4
83 DUST PROTECTION 4 88 BOLT ASSY M8×16 2
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OTHER INFORMATION
Contact Information
Importer: BYD Europe B.V.
Address: s-Gravelandseweg 256, 3125 BK Schiedam, Netherlands
Tel:[phone] Fax:[phone]
Importer: BYD Motors Inc.
Address: 1800 South Figueroa Street, Los Angeles, CA, 90015
Tel: [phone] Fax: [phone]
E-mail: [email protected]
Importer: BYD do Brasil
Address: Av. Antonio Boscato, 230 Terminal Intermodal de Cargas – TIC, CEP 13069-119 CAMPINAS - SP
Tel: [phone]
E-mail: [email protected]
Importer: BYD Japan company Limited
Address: The fifth Yasuda Bldg.5F,2-20-3 Tsuya-cho, Kanagawa-ku, Yokohama-shi,Kanagawa-
ken,221-0835,Janpan
Tel: [phone] Fax: [phone]
Importer: BYD Auto Industry Company Limited
Address: No.3009, BYD Road, Pingshan, Shenzhen, 518118, P.R.China
Tel: [phone] Fax: [phone]
Manufacturer: BYD (SHAOGUAN) CO.,LTD.
Address:No.1, BYD Road, Zhenjiang Industrial Zone, Shaoguan, Guangdong, 512040, P.R.China
Tel:[phone]