BYD ECB70 User manual

ECB70 | ECB80
OPERATOR MANUAL
< OM-ECB70/802019001-EN >

Welcome to use BYD electric forklift!
May our electric vehicles bring greater convenience to your work ！
Please read the instructions carefully before you use the electric vehicle。
The instructions is a general instruction. We reserve the right to make
technical modifications to electric vehicles. If there is discrepancy between the
contents of the instructions and the physical objects, the objects shall prevail and
instructions are only for reference
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Warning
The vehicle operators must strictly enforce the ISO3691:2013 "safety
code for powered industrial vehicles". Untrained personnel are strictly
prohibited to operate this vehicle.
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TABLE OF CONTENTS
FOREWORD
Declaration
Operation Notice
Forklift Delivery
OPERATOR NOTICE
Notice
Operator Qualification
Nameplate and Decals
VEHICLE VIEW AND TECHNICAL SPECIFICATIONS
Appearance
Forklift Appearance
Technical Specifications
Technical Drawing
Technical Specifications
Battery Specifications
Working Environment
Nameplate and Decals
Forklift Nameplate
Battery Nameplate
Loading Capacity Chart
Other Decals
OPERATING
Seat
Seat Appearance
Seat Operating
Dash Panel
Dash Panel Appearance
Dash Panel Operating
Start and Control
Using Area Overview
Start and Control
Ignition Switch
Combination Lights Control
Travelling, Steering and Braking
Low Speed Switch
Horn
Parking
Transporting Loads
Loading
Travelling
Unloading
Exiting from the Forklift
Battery
Charging
TRANSPORTATION AND STORAGE
Loading, Transporting and Unloading
Driving into the Transport Vehicle
Transporting and Unloading
Storage and Restoring
Procedures of Storage
Procedures of Restoring
MAINTENANCE
Daily Maintenance
Period and Items
Content Description
Regular Maintenance
Period and Items
Type and Parameters of Consumable Items
Content Description
Chassis System Maintenance
Front Wheel Replacement
Rear Wheel Replacement
Gear Oil Replacement
Braking Fluid Replacement
Steering Axle Lubrication
Hydraulic System Maintenance
Hydraulic Oil Filling
Hydraulic Oil Replacement
Return Filter Element Replacement
High Pressure Filter Element Replacement
Check and Replace the Air Filter
Electric System Maintenance
High Voltage Electric Inspection
Low Voltage Electric Inspection
OTHER INFORMATION
Contact Information

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Declaration
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.
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 forklifts 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 (for counterweight forklift and stacker)
7.Check high voltage circuits.
To avoid inconveniences in future warranty claims, please check the functions of the forklift
and check if the forklift is complete.
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 andmaintenance
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.

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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 data plate 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 industrial 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 industrial vehicles.
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
For the proprietor, make sure following safety instruction on your industrial vehicles are observed.
DANGER
1.Unauthorized persons are not allowed to operate the industrial vehicle.
2.Safety devices and features 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.
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.
Nameplate and Decals
The forklift has a forklift nameplate and a battery nameplate. Read them before using the
forklift.
The BYD forklift have notes or 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 notes or warning decals and signs are missing or difficult to read, please contact your
local BYD dealer for immediate replacement.

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VEHICLE VIEW AND TECHNICAL SPECIFICATIONS
This chapter explains the overview of the forklift and its relevant technical specifications.
Appearance
Forklift Appearance
No. Name No. Name No. Name
1 Rear Wheel 6 Load Backrest 11 Using Area
2 Charging Door 7 Mast 12 Counterweight
3 Front Wheel 8 Front Lamp 13 Tow Pin
4 Fork 9 Overhead Guard
5 Carriage 10 Rear Lamp
Technical Specifications
Technical Drawing
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y
l2
l1
b10
b1
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Technical Specifications
Identification
1.1 Manufacturer BYD BYD
1.2 Type ECB70 ECB80
1.3 Drive Electric Electric
1.4 Operator Type Seat Seat
1.5 Ratted Capacity Q kg 7000 8000
1.6 Load Center c mm 600 600
1.7 Load Distance, Center of Drive Axle to Fork x mm 660 660
1.8 Wheelbase y mm 2250 2250
Weight
2.1 Service Weight kg 10350 10800
2.2 Axle Load, with Load, Front/Rear kg 15270/2080 16320/2480
2.3 Axle Load, without Load, Front/Rear kg 4296/6054 4496/6304
Wheel
3.1 Tires Air inflated tyre Air inflated tyre
3.2 Tire Size, Front 8.25-15 8.25-15
3.3 Tire Size, Rear 8.25-15 8.25-15
3.4 Wheels, Number Front/Rear (X=Driven Wheels) 2x/2 2x/2
3.5 Track Width, Front b10 mm 1510 1510
3.6 Track Width, Rear b11 mm 1420 1420
Basic
Dimensions
4.1 Tilt of Mast/Fork Carriage Forward/Backward a/b deg 5/10 5/10
4.2 Height, Mast Lowered h1 mm 2500 2500
4.3 Free Lift Height h2 mm 155 155
4.4 Lift Height h3 mm 3000 3000
4.5 Height, Mast Extended h4 mm 4465 4465
4.6 Height of Overhead Guard h6 mm 2565 2565
4.7 Seat Height h7 mm 1410 1410
4.8 Coupling Height h10 mm 610 610
4.9 Overall Length l1 mm 4745 4745
4.10 Length to Face Of Forks l2 mm 3525 3525
4.11 Overall Width b1 mm 2000 2000
4.12 Fork Dimensions s/e/l mm 65/150/1220 65/150/1220
4.13 ISO2328, Frame/Type A,B 4A 4A
4.14 Fork Carriage Width b3 mm 2000 2000
4.15 Ground Clearance, with Load, Below Mast m1 mm 170 170
4.16 Ground Clearance, with Load, Center of Wheelbase m2 mm 220 220
4.17 Aisle Width for Pallets 1000x1200 Crossways Ast mm 5480 5480
4.18 Aisle Width for Pallets 800x1200 Lengthways Ast mm 5280 5280
4.19 Turning Radius Wa mm 3380 3380
4.20 Inward Turning Radius b13 mm - -
Performance
Data
5.1 Travel Speed, with/without Load Km/h 15/17 15/17
5.2 Lift Speed, with/without Load mm/s 350/400 350/400
5.3 Lowering Speed, with/without Load mm/s 500/400 500/400
5.4 Max. Drawbar Pull, S2=5min, with/without Load KN 40 40
5.5 Max. Gradeability, S2=5min, with/without Load % 15/20 15/20
5.6 Acceleration Time (0-10km/H), with/without Load s 6/5 6/5
5.7 Service Brake Hydraulic System Hydraulic System
Drive
6.1 Drive Motor Rating at S2=60 Min kW 14x2 14x2
6.2 Lift Motor Rating at S3=15%ED kW 24x2 24x2
Others
7.1 Type of Drive Control AC AC
7.2 Operating Pressure for Hydraulic System Mpa 18 18
7.3 Sound Level at the Driver's Ear dB(A) 75 75
7.4 Towing Coupling, Type - -
Battery Specifications
Forklift Type ECB70, ECB80
Battery Voltage, Nominal Capacity V/Ah 80/1000
Battery Weight kg 1150
Working Environment
Working temperature: -10 ~ 40° C
Working humidity: ≤ 90%
Operating Altitude: ≤ 2000m
Road: dry, hard, level and flat
Storage: in airy storehouse
Caution
If the working environment is harsh, decrease the goods or reduce the speed
Danger
1.No sharp obstacle.
2.No strong acid or base on the road.
3.Do not soak the tire in the water for a long time.
4.Do not expose the truck to the burning sun.
5.No flammable gas, no flammable dust and no volatile flammable liquid.
Note
Contact with your BYD local dealer if the forklift is intended to be used in the following
environments:
1.in places where explosives are stored
2.in dusty areas
3.in ports or water front with corrosive salt hazards
4.in chemical factories with acid and other chemical hazards
5.in potential explosive environments with dust or other explosive gas
6.in toxic environment
7.in radioactive environment
8.in other special environment

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Nameplate and Decals
Forklift Nameplate
Note
1.The nameplate is placed on the left of the forklift.
2.After receiving the forklift, check the information on the nameplate and confirm if it
complies with the one you've ordered.
Caution
1.Every forklift might have different specification. Check the nameplate before operation to
confirm the forklift specification.
2.When transporting the load, it should not exceed the rated loading capacity of the forklift.
Check and confirm the load of the forklift.
Battery Nameplate
Note
1.The battery nameplate is placed on the battery.
2.After receiving the forklift, check the information on the data plate and confirm if it
complies with the one you’ve ordered.
Add.: No.1, BYD Road, Zhenjiang Industrial Park, Shaoguan, Guangdong, China
Electric (Iron-Phosphate
Counterbalance Fo
Cond s
/Iron-Phosphate Battery
Ambient Temperature
Rela e Humidity
Cell Model
Nominal Capacity
Nominal Voltage
Voltage
Rated Current
Made in China
Weight
Basic
Performance
Caution: Before operation, you must be familiar with specific requirement
for output configuration by referring to the instruction manual.
Serial No.
Model

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Loading Capacity Chart
When the load center exceeds the rated one, the loading capacity of the forklift is reduced. The
Loading capacity chart indicates the maximum loading capacity the forklift has corresponding to the
different load center.
Suppose the cargo has the load center of 600mm and the expected lifting height is 4000mm.
1.Draw the vertical line at the coordinate of load center of 600mm and find the crossing point
of this vertical line and the curve line of lift height of 4000mm.
2.The ordinate on the Y-axis of the crossing point reads 7000kg, 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.
If you want to increase the lifting height, decrease the load center (more reasonable packaging)
and weight of the cargo.
Caution
1.Forklift specification varies depending on customer requirements. Refer to the load capacity
chart for confirmation on the maximum allowed load;
2.The load capacity chart reflects only compact, well palletized and evenly centered loads
within the load limit. Otherwise the stability of the forklift and the rigidity of the related parts will be
impaired.
Other Decals
Please pay attention to notes or warning decals and signs before using.
OPERATING
This chapter explains how to operate BYD forklift correctly.
Seat
Seat Appearance
No. Name No. Name No. Name
1 Seat Adjusting Handle 4 Seat Belt Retractor 7 Lumbar Support Adjusting Handle
2 Weight Adjustment Lever 5 Backrest 8 Seat Belt Buckle
3 Cushion 6 Seat Document Box 9 Backrest Adjusting Handle
Seat Operating
1.Weight adjustment
Fold out the weight adjustment lever completely, hold it at the front and move it upwards or
downwards (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 the middle of the viewing
window. With the operator weight setting completed, fold the handle fully to the initial locked
position.
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9
CAPACITY CHART
LOAD CENTER (mm)
LIFT HEIGHT（mm)
600 700 800 900 1000 1100 1200 1300
2000
3000
4000
5000
6000
7000
≤4000mm
≤5250mm
≤6000mm
CAPACITY (kg)

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2.Adjustment of lateral position of seat
Pull up the recess of the lever. Move the seat forward and/or backward to find the right seat
position.
Return the lever to its folded position and the seat has been adjusted.
3.Lumbar support adjustment
Lumbar support can be adjusted to improve ride comfort of the operator. Rotating the
adjusting lever upward can increase the bending extent of the upper portion of the backrest.
Rotating the adjusting handle downward can increase the bending extent of the lower portion of the
backrest.
4.Backrest adjustment
Raise the lock handle, then adjust the backrest angle (while adjusting the backrest angle,
ensure that the backrest is not blocked). Release the locking lever to lock the backrest.
5.Seat belt
Pull out the seat belt slowly from the retractor, and then put the buckle end into the lock.
6.Seat document box
There is a document box on the rear side of seat, which could store documents, work gloves
and other flat goods.
0
1
2

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Dash Panel
Dash Panel Appearance
No. Name No. Name No. Name
1 Motor Overheating Warning Indicator 7 Overload Warning Indicator 13 Voltage Message
2 Battery Error Warning Indicator 8 Checking and Diagnosis Indicator 14 Speed Mode
3 Parking Indicator 9 Speed Mode On Indicator 15 Gear
4 Left Turning Light 10 Enter 16 Total Hours
5 Warning Message 11 Functions 17 Odometer
6 Right Turning Light 12 Speed Mode Control Switch 18 Battery Message
Dash Panel Operating
1.Speed mode adjustment
Press the Speed Mode Control Switch to change the speed setting which including high, low
and OFF (without speed mode control).
Press the Speed Mode Control Switch for 2 seconds and the indicator will be lit. Pressing the
Speed Mode Control Switch will allow you to choose from the 3 speed settings including high,
middle, low and OFF (without speed mode control).
No. Name No. Name No. Name
1 Speed Mode Contr ol
Switch
2S p e e d M o d e O N
Indicator
3 Speed Mode
2.Working Indicator and Messages
During normal work, the message is the current speed.
After the forklift is switched on, if the seat is vacant, warning message of "Please return to
the seat" will be displayed.
When the battery charge is low and the buzzer sounds, warning message of "Charge the
battery at once" will be displayed.
3.Gear
Gear letter of the forklift is shown on the dash panel, which may be F (forward), N (neutral), or
R (reverse).
4.Dash panel setting
Press the middle button at the right to enter into the Setting.
The operator can change the setting on the time, unit, working hours, background light,
language and factory setting.
Functions of the 3 buttons:
(1)Upper button: Moving the cursor up. Increasing the value of digit and number.
(2)Middle button: Pressing this button to enter the Setting window. Select and enter the
sub-menu. Select and confirm the digit and number.
(3)Lower button: Moving the cursor down. Decreasing the value of digit and number.
km/h
XXX
565km
XXXXX 253h XXXXXX 80V
XXXX
XX
73%
1
2
3
4568 7
9
10
11
12
14
1516
17
18 13
XXXX
XX
12
3
km/h

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5.Indicators
Explanation on the 3 indicators:
(1)Indicator related to error, which appears in the case of error.
(2)Indicator related to the temperature, which appears when some components are overheated.
(3)Indicator related to the battery, which appears in the case of low battery and battery failure.
Trouble-shooting Methods:
The following table contains all the error messages that could be shown in the multifunction
display. Please refer to the trouble shooting method for solution when the following error occurs.
Category Warning Message Solution
Drive
LOGIC FAILURE #1 Battery charge is too low, charge the battery
LOGIC FAILURE #3 Restart the forklift
VMN LOW/VMN HIGH Restart the forklift
MASTER KO Restart the forklift
STBY I HIGH Restart the forklift
ENCODER ERROR Restart the forklift
INCORRECT START Return the gear switch to stop and restart the forklift
CAP CHARGE Restart the forklift
THERMIC SENSOR KO Restart the forklift
Chassis system
VACC NOT OK Check if the accelerator will return normally and restart the forklift
PEDAL WIRE KO Restart the forklift
Others
CONTACTOR OPEN Restart the forklift
AUX OUTPUT KO Restart the forklift
FORWARD+BACKWARD Switch off the forklift, return the lever to stop position and restart
the forklift
NO CAN MESSAGE #3 Restart the forklift
Battery WRONG SET BATTERY Restart the forklift
Temperature
HIGH TEMPERATURE Shut down the forklift for 5 minutes and restart it
HIGH MOTOR TEMPERATURE
After taking the recommended measures, contact the service personnel if the error message
reappears and repeats more than 3 times.
Start and Control
Using Area Overview
No. Name No. Name No. Name
1 EPB Switch 4 Steering Wheel 7 Combination Lights Control Lever
2 Get-On Handrail 5 Acceleration Pedal 8 Steering Wheel Adjusting Lever
3 Rear View Mirror 6 Brake Pedal 9 Ignition Switch
1
2
3
2
3
1
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Start and Control
Ignition Switch
Insert the key into the ignition switch and rotate it to turn on the forklift.
Rotate the key reversely and take off it to turn off the forklif
Note
Before starting the forklift, pull up the right emergency disconnect switch.
Combination Lights Control
1.Left turning light: push the switch forward.
2.Clearance light: turn the switch clockwise to the first stop.
3.Working light: turn the switch clockwise to the second stop.
4.Right turning light: pull the switch backward.
Note
When the turning indicator is switched on, it would return automatically to neutral when
changing direction is completed.
Travelling, Steering and Braking
1.Travelling
Set the vehicle at the Forward gear. Depress the accelerator pedal, then the forklift travel
forward.
Set the vehicle at the Reverse gear. Depress the accelerator pedal, then the forklift travel
backward.
2.Steering
When travelling, turn the steering wheel right or left to steer.
3.Braking
Depress the brake pedal to brake.
Low Speed Switch
Press the low speed control on the dash panel to choose low speed mode.
Horn
Press the horn button to send audible warning.
Parking
1.After bringing the forklift to a stop with the service brake, hold the 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.
OFF
1
2
3
4

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Transporting Loads
Loading
Load on the ground:
1.Drive the forklift carefully up to the load and brake the forklift to a stop.
2.Lower the forks on the floor.
3.Insert the forks under the load.
4.Lift the forks.
5.When transporting, drive with caution, pay attention to the route condition and to the people
ahead and maintain a proper driving speed. Transport the load to the designated place.
Load on the high shelf:
1.Drive the forklift carefully up to the load and brake the forklift to a stop.
2.Set the mast in the vertical position and raise the forks to the bottom of the load.
3.Insert the forks under the load.
4.Raise the load until it has left the shelf completely.
5.Reverse the forklift with caution at a low speed until the forklift leaves the stacking area.
6.Lower the forks.
7.When transporting, drive with caution, pay attention to the route condition and to the people
ahead and maintain a proper driving speed. Transport the load to the designated place.
Danger
1.When approaching the load, do not travel at high speed to avoid crashing.
2.Do not stay beneath the raised load.
Caution
When transporting the load, the load should be securely fastened on a pallet with the gravity
center well centered and with the proper stacking height. Do not damage the packing of the load.
The operator should be held responsible for the safe loading and unloading.
Travelling
1.When travelling with load, make sure that the load is well centered on the forks.
2.After the load is placed on the forks, keep the mast tilted backwards and raise the forks
above the floor.
3.During the travelling of the forklift, do not try raising the forks to avoid the danger of forklift
nose over and losing stability.
4.If the stacked loads are high and affect the operator’s visibility of the route ahead, operate
the forklift in reverse except when the forklift is climbing the slope or inclines.
Warning
1.When driving the forklift on a slope, keep the forks always facing the uphill direction and
drive in turtle speed mode when facing the downhill direction.
2.Do not cross or turn around on a slope.
Caution
1.Have a second person as lookout if the visibility of the operator is reduced.
2.Do not depress the brake pedal with a lot of force, since excessive force might cause
damage to the braking system.
Unloading
1.Drive the forklift carefully up to the stacking destination and decelerate when approaching.
2.Raise the forks to the proper height.
3.Drive the forks and load into the shelf.
4.Set the mast in the vertical position and lower the forks to the proper height until they get
separated from the forks.
5.Slowly remove the forks from the bottom of the load.
6.After driving the forks out, raise them and start the next.
Exiting from the Forklift
1.Lower the forks after unloading.
2.Turn the key anticlockwise to OFF position and take it out.
3.Pull off the hand brake.
4.Exit from the forklift.

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Battery
Charging
Open the charge port, and then connect the charger connector. Follow the user manual of the
charger to charge the forklift.
TRANSPORTATION AND STORAGE
This chapter explains how to transport and store the forklift.
Loading, Transporting and Unloading
Driving into the Transport Vehicle
Drive the forklift into the transport vehicle on turtle speed mode.
Caution
1.Have a supervisor or a second person on site as a lookout.
2.Make sure that the ground is strong enough to avoid the transport vehicle sinking into the
floor.
3.Secure the transport vehicle with fixed block.
4.During loading and unloading, constantly check the rigidity and the stability of the ramp.
Transporting and Unloading
1.Use a transport truck or a low flat bed truck to transport the vehicle.
2.Unloading the forklift by crane follows the same procedure as the loading of the forklift.
3.When driving the forklift out of the transport vehicle, reverse the forklift with caution at low
speed. The rest of the procedure is the same as required for driving the forklift onto the transport
vehicle.

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Storage and Restoring
Procedures of Storage
Clean and remove the dust on the forklift components and conduct the following procedures:
1.Check forklift for oil and water leakage and abnormal components. If yes, repair the forklift
first.
2.Fully lift and lower the forks several times.
3.Lower the forks.
4.Spray a layer of lubricant over the parts left unpainted.
5.Check the hydraulic oil level and add if necessary.
6.Lubricate all the components.
7.Take off the key and make sure that forklift is disconnected from 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.
8.Use and operate the forklift for a while every month.
Procedures of Restoring
Clean and remove the dust on the forklift components and conduct the following procedures:
1.Lubricate all the components.
2.Fully lift and lower the forks and tilt masts several times.
3.Check the status of charge of the traction battery.
4.Check the hydraulic oil. Replace it if necessary.
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.
MAINTENANCE
This chapter explains how to maintain the forklift.
Daily Maintenance
Period and Items
Daily (or every 8 hours) and weekly (or every 40 hours) for daily inspection items, whichever
comes first. If the forklift works 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. Item 1 day 1 week
8 hours 40 hours
1 Exterior Check
2 Wheel Clean and tighten Clean and tighten
3 Mast Check
4 Hydraulic System Check
5 Display Check
6 Warning Equipment Check
7 Brake Check Check
8 Travel, Steering and Control Check
9 Electric Connector and Fuse Check
10 Clean Clean
11 Others Check
Caution
These inspections should be conducted before operating the forklift.
Note
Before conducting the daily inspection, recheck for any fault and error found
earlier.
Content Description
1.Exterior
(1)Check the forklift body for damage and deformation.
(2)Check the floor where the forklift is parked for oil leakage.
(3)Check the condition of the nameplate and decals.
(4)Check if any parts loose or fall off.
Note
If oil leakage occurs, confirm the location of the oil leakage and contact the BYD after sales
service.

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2.Wheel
(1)Check on a daily basis 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 wheels.
3.Mast
(1)Check the cylinders, oil pipes, and hoses for oil leakage.
(2)Check the working equipment for deformation and damage. check if the bolts are securely
fastened.
4.Hydraulic system
Check the hydraulic oil level in the oil tank.
5.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.
6.Warning equipment
(1)Press horn to see if it works.
(2)Check if other warning equipment work properly.
7.Braking System
Move the handle to the braking zone while the forklift is travelling, to check whether the brakes
operate efficiently.
8.Travel, Steering and Control Inspection
(1)Check for the operation of the tiller and abnormal sounds by rotating the tiller forward or
backward and turning the tiller right or left.
(2)Check for the operation of buttons.
(3)Check the fasteners for looseness or missing.
9.Electric System Inspection
(1)Check connectors and tighten the loose parts. Check electrical connectors for abnormality (for
example, sign of burning).
(2)Check fuses of main controller and replace them if necessary. Check whether the copper bus bar
of the main controller is burnt. If so, replace it.
(3)Check whether low voltage fuse and relay work properly. Replace them if necessary.
Warning
Disconnect the battery before checking the electric system.
10.Clean
Clean the whole forklift with the compressed air.
11.Others
Check if there are others problems.
Regular Maintenance
Period and Items
Period for regular inspection and maintenance, whichever comes first. For example, if the forklift
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 Item 6 (Weeks) 3 6 12 Months
250 500 1000 2000 Hours
Chassis
System
Gear Oil Replacement 1st replacement Replacement
Braking Fluid Replacement Replacement
Steering Axle Lubrication Lubrication
Mast Chains Adjustment Adjustment
Chains Lubrication Lubrication
Mast Cleaning Clean
Mast Clearance Adjustment Adjustment
Mast Tilt Rotating Pin 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 Element Replacement 1st Replacement Replacement
Air Filter Replacement Replacement
Electric
System
Electric System Inspection Check
Note
If the working environment is harsh, the maintenance interval should be reduced, and advice
from BYD after sales personnel should be sought.

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Type and Parameters of Consumable Items
Item Consumable Items Volume Needed Type
Gear Oil Replacement Gear Oil As Needed Mobilfluid424
Braking Fluid Replacement Brake Fluid As Needed DOT-4
Steering Axle Lubrication Lithium Lubrication Grease As Needed EP3
Chains Lubrication Machine Oil As Needed 20#(Winter), 40#(Other Seasons)
Mast Tilt Rotating Pin Lubrication Lithium Lubrication Grease As Needed EP2
Hydraulic Oil Replacement of Main
Oil Tank
Hydraulic Oil 130L ISOVG46, ISOVG68
Hydraulic Oil Replacement of Tilt
Mechanism
Hydraulic Oil Used for Planes As Needed 10# Hydraulic Oil Used for
Planes
Note
The given quantities are maximum values and take the actual quantities as the standard.
Content Description
1.Chassis system
(1)Replace the gear oil.
(2)Replace the brake fluid.
(3)Lubricate the steering axle.
2.Mast
(1)Check the tension the lift chains, adjust them if necessary.
(2)Lubricate the chains
(3)Clean the mast.
(4)Lubricate the mast tilt rotating pin.
3.Hydraulic system
(1)Periodically replace hydraulic oil of the main oil tank.
(2)Periodically replace hydraulic oil of the tilt mechanism.
(3)Replace the return filter and high pressure filter element periodically.
(4)Replace the air filter.
4.Electric System
(1)Check connectors and tighten the loose parts. Check electrical connectors for abnormality (for
example, sign of burning).
(2)Check fuses of main controller and replace them if necessary. Check whether the copper
busbar of the main controller is burnt. If so, replace it.
(3)Check if fuse and relay work properly and replace them if necessary.
Warning
Disconnect the battery before checking the electric system.
Chassis System Maintenance
Front Wheel Replacement
1.Park the forklift on a flat place. Turn the key switch to OFF then remove it. Press the emergency
disconnect button. Place a wedge under the wheels to prevent unexpected motion of the wheels.
2.Jack up the forklift 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.
Rear Wheel Replacement
1.Park the forklift on a flat place. Turn the key switch to OFF then remove it. Press the emergency
disconnect button. Place a wedge under the wheels to prevent unexpected motion of the wheels.
2.Jack up the forklift 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.
Gear Oil Replacement
Before replacement, run the forklift until the gear box 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. Open the
rear cover and remove the wheels.
1.Clean the surrounding areas around the "Oil dipstick plug", "Oil filler plug" and "Oil drain
plug". Place a container below the "Oil drain plug".
2.Remove "Oil dipstick plug", "Oil filler plug" and "Oil drain plug" and drain all the gear oil and
then tighten "Oil drain plug".
3.Add the gear oil through oil filler hole until the gear oil overflows out of "Oil dipstick plug"
and then tighten "Oil dipstick plug" and "Oil filler plug".

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Braking Fluid Replacement
1.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.
2.Clean the surrounding area around the braking fluid drains plug, and place a container below it.
3.Remove the braking fluid drain plug and drain the braking fluid.
4.Reinstall the braking fluid drain plug and tighten it securely.
5.Add some braking fluid into the braking fluid reservoir. Slightly loosen the braking fluid drains
plug and press down brake pedal once completely to exhaust air out. Repeat this procedure more
than 3 three times until the air is removed completely and add braking fluid to 2/3 of the braking
reservoir.
6.Tighten braking fluid drain plug and clean the residual fluid spill.
Steering Axle Lubrication
Add grease to the steering axle through the lubrication nozzle in the steering axle.
Operate the grease applicator until fresh grease overflows.
Note
1.If the forklift is used in a place dusty, dirty, or having a lot of chemicals, lubricate the bearings
on a weekly basis to extend their service life.
2.The method of increasing grease application times but decreasing grease amount applied each
time is better than the method of decreasing grease application times but increasing great amount
applied each time.
Mast Maintenance
Chains Adjustment
The standard mast has the main lift chain that is needed to be adjusted, the free list mast has the
main lift chain set and the free lift chain that are needed to be adjusted. Before adjustment, park the
forklift on a level ground and fully lower the mast, switch off the forklift, take off the key and press
down the emergency disconnect button.
1.Standard mast lift chain adjustment
Loosen the upper and lower nuts of the lift chain, and then screw the middle nut to adjust the
length of the chain. After adjustment, make the forks remain level and the chains remain the same
tightness, and then tighten nuts.
Caution
After adjustment, make sure that the chains aren't slack when the lift cylinder is in the original
position.
2.Free lift mast lift chain adjustment
(1)Loosen the upper and lower nuts of the lift chain, and then screw the middle nut to adjust the
length of the chain. After adjustment, make the chains remain the same tightness, and them tighten
nuts.
(2)Loosen the upper and lower nuts of the free lift chain, and then screw the middle nut to adjust
the length of the chain. After adjustment, make the forks remain level and the chains remain the
same tightness, and them tighten nuts.
Chains Lubrication
1.Clean the exterior of the lift chain and remove dust and debris.
2.Add the machine oil and let it penetrate the chain joint.
3.After lubrication, lift and lower the mast several times.
Mast Cleaning
Take out debris between the roller and the channel of the mast.
Mast Clearance Adjustment
1.General Description of Mast Roller
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. Adjusting screw is secured by a
secure pin.
2.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.
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3.Adjustment Order
2-stage mast:
(1)Clearance between the outer mast and the inner mast.
(2)Clearance between the inner mast and the carriage.
3-stage mast:
(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.
Hydraulic System Maintenance
Hydraulic Oil Filling
1.Park the forklift on the level floor and apply the handbrake, remove the key, press down the
emergency disconnect switch and open the seat cover fully.
2.Open the seat cover plate completely to observe the oil level gauge.
3.If there is no hydraulic oil in the oil level gauge, open the top cover of the return oil filter and
add oil.
Caution
1.While adding oil, be careful to prevent dust and water from entering the oil tank.
2.Do not mix different types of hydraulic oil.
3.When disposing the waste oil, keep children away and do not pour it into the sewer or onto
the ground.
4.Using unauthorized hydraulic oil might cause damage to hydraulic system. Use only authorized
hydraulic oil. If you need to switch to other types of hydraulic oils, contact with the BYD forklift after
sales service people.
Hydraulic Oil Replacement
1.Drive the forklift to the maintenance ditch, switch off the handbrake, remove the key and press
down the Emergency Disconnect Switch.
2.Fully lower the forks, apply the hand brake, and place a container below the oil drain of the
tank. Unplug the oil drains plug at the bottom of the oil tank and drain the hydraulic oil.
3.Before putting the plug back on, make sure that the seal ring is complete and intact and then
secure the plug.
4.Add a small amount of hydraulic oil first to check if the seal ring on the drains plug is OK.
Tighten the plug if oil leakage 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.While adding oil, be careful to prevent dust and water from entering the oil tank.
2.Do not mix different types of hydraulic oil.
3.When disposing the waste oil, keep people away and do not pour it into the sewer or onto
the ground.
4.Using unauthorized hydraulic oil might cause damage to hydraulic system. Use only
authorized hydraulic oil. If you need to switch to other types of hydraulic oils, contact with the BYD
forklift after sales service people.
Return Filter Element Replacement
1.Park the forklift on a level ground and fully lower the mast and apply the parking brake. Take
off the key, press down the emergency disconnect switch and open the seat cover fully.
2.Put the clean cloth around the return filter.
3.Unscrew the filter bowl and pull the out filter element.
4.Clean the cover plate and check if the seal and the O-ring are in good condition, replace
them if necessary.
5.Check if the spread and the O-ring of the new element are in good condition, replace them if
necessary.
6.Use clean hydraulic oil to lubricate the O-ring of the new element, fit the new element
carefully and screw the cover plate.
7.After replacement, operate the hydraulic system to check if there is any leakage.