BYD P20PS User manual
P20PS
OPERATOR MANUAL
<OM-P20PS2019001-EN >
P20PS
OPERATOR MANUAL
<OM-P20PS2019001-EN >
CONTENTS
OPERATOR MANUAL 1
P20PS
2OM-P20PS2019001-EN
CONTENTS
FOREWORD
Descriptions
Operation Notice 6
Forklift Delivery 6
OPERATOR NOTICE
Notice
Operator Qualification 8
Warning Decals and Signs 9
INTRODUCTION
View, Technical Specifications and Operating Environment
General View 11
Vehicle Drawing 12
Technical Specifications 13
Working Environment 14
Nameplate and Decals
Forklift Nameplate 15
Battery Nameplate 16
Other Decals 16
OPERATING
Startup and Control
Key Switch 18
Emergency Disconnect Switch 18
Fork Carriage and Pedal 19
Tiller 20
Travel, Steering and Braking 20
Low Speed Control 22
Fork Lifting and Lowering 22
Horn 23
Emergency Reversal Switch 23
Display Using
Display 24
Transporting Loads
Loading 25
Travel 25
Unloading 26
Exiting 26
Battery
Charging 27
TRANSPORTATION AND STORAGE
Loading, Transportation and Unloading
Hoisting 29
Driving into the Transport Vehicle 29
Transporting and Unloading 30
Decommissioning and Restoring
Procedures of Decommissioning 31
Procedures to Restoring 31
MAINTENANCE
Daily Maintenance
Period and Items 33
Content Description 33
FOREWORD
OPERATOR MANUAL 5
P20PS
6OM-P20PS2019001-EN
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 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
OPERATOR MANUAL 7
P20PS
8OM-P20PS2019001-EN
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 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.
OPERATOR NOTICE
OPERATOR MANUAL 9
P20PS
10 OM-P20PS2019001-EN
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.
INTRODUCTION
OPERATOR MANUAL 11
P20PS
12 OM-P20PS2019001-EN
VIEW, TECHNICAL SPECIFICATIONS AND
OPERATING ENVIRONMENT
General View
1
2
3
6
8
7
9
5
4
10
11
12
13
No. Name No. Name No. Name
1Load Wheel 6Display 11 Shield
2Fork 7Tiller 12 Front Body
3Rear Body 8Emergency Disconnect Switch 13 Pedal
4Battery Pack Cover 9Key Switch
5Dashboard 10 Fork Carriage
Vehicle Drawing
L1
L2
S
L
L1
y
C
h14
h16
m2
h13
h3
h14
X
Q
b1
b10
e
b5
b11
Wa
a/2 a/2
AST
L6
b12
INTRODUCTION
OPERATOR MANUAL 13
P20PS
14 OM-P20PS2019001-EN
Technical Specifications
Identification
1.1 Manufacturer BYD BYD
1.2 Model P20PS-U P20PS
1.3 Power Electric Electric
1.4 Operating mode Stand-on Stand-on
1.5 Rated loading capacity Q (Kg) 2000 2000
1.6 Load center distance c (mm) 600 600
1.8 Axle centre to fork face x (mm) 966 1036
1.9 Track width (Max. fork height/Min. fork height y (mm) 1311/1373 1381/1443
Weight
2.1 Net weight kg 660 630
2.2 Axle load with load, drive/load side kg 1160/1500 1140/1490
2.3 Axle load without load, drive/load side kg 520/140 500/130
Wheel
3.1 Wheel type Polyurethane Polyurethane
3.2 Drive wheel size Φx w (mm) Φ230×75 Φ230×75
3.3 Load wheel size Φx w (mm) Φ85×110 Φ85×110
3.4 Caster size Φx w (mm) Φ100×50 Φ100×50
3.5 Wheels, number caster/load (X=number of drive
wheels) 1×+2/2(4) 1×+2/2(4)
3.6 Track width (front), drive side b10 (mm) 510 510
3.7 Track width (rear), load side b11 (mm) 370 505
Basic
Dimensions
4.4 Lift height h3 (mm) 120 120
4.9 Handle height when operating, Min./Max. h14 (mm) 970/1300 970/1300
4.15 Min. fork height h13 (mm) 85 85
4.19 Overall length l1 (mm) 1820/2290 1890/2360
4.20 Body length( to fork face ) l2 (mm) 670 670
4.21 Overall width b1 (mm) 726 726
4.22 Fork dimensions s/e/l (mm) 55×180×1150 55×180×1220
4.25 Width over forks b5 (mm) 685 685
4.32 Ground clearance m2 (mm) 25 25
4.34 Aisle width, 800x1200mm lengthwise Ast (mm) 1919/2403 1989/2473
4.35 Turning radius Ast (mm) 1680 1750
Performance
Data
5.1 Travel speed, with/without load km/h 9/12 6/6
5.2 Travel speed, with/without load mm/s 40/50 40/50
5.3 Lower speed, with/without load mm/s 50/40 50/40
5.8 Gradeability, with/without load %6/15 8/15
5.10 Service brake Electromagnetic Electromagnetic
Motor
6.1 Drive motor output kW 1.9 1.3
6.2 Lift motor output kw 1.2 1.2
6.4 Battery voltage/capacity kW 24/130 24/130
6.5 Battery weight (+/-5%) V/ Ah 70 70
Other 8.4 Sound level at driver's ear dB(A) 70 70
Working Environment
Temperature：-5 ~ 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
INTRODUCTION
OPERATOR MANUAL 15
P20PS
16 OM-P20PS2019001-EN
NAMEPLATE AND DECALS
Forklift Nameplate
Add.: No.1, BYD Road, Zhenjiang Industrial Park, Shaoguan, Guangdong, China
Electric (Iron-Phosphate Battery) Pallet Truck
Type
Serial NO.
Rated load capacity
Max. lifting height
Battery mass (Max.)
Service weight
Mass of truck
(w/o battery)
Rated battery voltage
Rated battery capacity
Mass of battery (Min.)
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
产品使用环境
Environment
环境温度
Ambient Temperature
相对湿度
Cell Model
电池容量
Nominal Capacity
中国制造
Made in China
电池包重量
Weight
产品基本性能
Basic
Performance
Caution: Before operation, you must be familiar with specific requirement
for output configuration by referring to the instruction manual.
出厂编号
Serial No.
产品型号
电池型号
Model
工作电压
电池能量
Working Voltage
Nominal energy
铁电池/Iron-Phosphate Battery
Note
(1) The battery nameplate is placed on the battery.
(2) After receiving the forklift, check the information on the nameplate and confirm if it
complies with the one you've ordered.
Other Decals
Please pay attention to notes or warning decals and signs before using.
OPERATING
OPERATOR MANUAL 17
P20PS
18 OM-P20PS2019001-EN
OPERATING
This chapter explains how to operate BYD electric forklift correctly.
STARTUP AND CONTROL
Key Switch
After the key is inserted into the key switch, Rotate the key clockwise to the start position
and start the vehicle, and the key will automatically return to the on position. When the vehicle is
powered on for a period of time, the vehicle will automatically power off; at this time, rotate the key
to the start position to continue working.
Rotate the key anticlockwise to off position and take it out to turn off the forklift.
Emergency Disconnect Switch
Press down the emergency disconnect switch to shut off the power. Rotate and pull up it to
resume the power.
OPERATING
OPERATOR MANUAL 19
P20PS
20 OM-P20PS2019001-EN
Fork Carriage and Pedal
1. Fork carriage
Before using the forklift, open the fork carriage to protect the operator during turning
2. Pedal
Open the pedal downward to use
3. Speed mode
P20PS-U (High speed)
Fork carriage Pedal Person Speed
1 1 1 High speed 12km/h, adjustable
1 1 0 Cannot run
0 1 1 Low speed 6km/h, adjustable
0 1 0 Cannot run
1 0 0 Cannot run
0 0 0 Turtle speed 3km/h, adjustable
Fork carriage: 1: Open, 0: Retract
Pedal: 1: Open, 0: Retract
Person: 1: Person on the pedal, 0: Person off the pedal
P20PS (Low speed)
Put down the fork carriage, 6km/h;
Retract the fork carriage, 3km/h.
Tiller
1
2
3
4
5
6
1
2
3
4
5
6
No. Name No. Name No. Name
1Lower Control Button 3Horn Button 5Direction Control
2Lift Button 4Emergency Reversal Switch 6Low Speed Control
Travel, Steering and Braking
1. Travel
Rotate the control handle to the area of A2. Rotate the direction control forward or backward
to travel forward or backward.
A1
A2
A3
OPERATING
OPERATOR MANUAL 21
P20PS
22 OM-P20PS2019001-EN
2. Steering
When travelling, turn the tiller right or left to steer.
3. Braking
Rotate the tiller to the areas of A1 or A3 to brake; Release the accelerator button B to brake;
when the vehicle speed is 0, apply the brake immediately.
A1
A2
A3
B
Low Speed Control
Press the low speed control below the tiller, and then the vehicle goes into low speed mode.
Fork Lifting and Lowering
Press the lift control button to lift the fork.
OPERATING
OPERATOR MANUAL 23
P20PS
24 OM-P20PS2019001-EN
Horn
Press the horn button to send audible warning.
Emergency Reversal Switch
When the emergency reverse switch is struck, the vehicle will travel forward for some distance
until it's not been touched.
DISPLAY USING
Display
There is a screen and an indicator in the display. The screen shows the battery level, repairing
sign, low speed sign, hour meter and fault code. The indicator light indicates low battery level or
maintenance condition.
序号 Name Descriptions
1Warning Indication When the battery is low or the vehicle has fault, the light ring displays red, and the
interface displays the current fault code.
2Speed Display It displays the current speed when the vehicle being normally started.
3Working Hour Display The time worked appears after the vehicle being normally started.
4Battery State of Charge Battery level is shown as a percentage.
OPERATING
OPERATOR MANUAL 25
P20PS
26 OM-P20PS2019001-EN
TRANSPORTING LOADS
Loading
1. Load on the ground
(1) Drive the forklift carefully up to the load and brake the forklift to a stop.
(2) Lower the forks.
(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.
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 load , the load should be securely fastened on a pallet with the gravity
center well centered and proper stacking height. Do not damage the packaging of the goods and
the handling personnel should bear the responsibility of safe loading.
Travel
(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 tilt the mast forward or 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
downhill direction in contrast and drive in turtle speed mode.
(2) Do not cross or turn around on a slope.
Caution
Have a second person as lookout if the visibility of the operator is reduced.
Unloading
(1) Drive the forklift carefully up to the stacking destination and decelerate when approaching.
(2) Lower the forks.
(3) Slowly remove the forks from the bottom of the load.
(4) After driving the forks out, start the next task.
Exiting
(1) Lower the forks after unloading.
(2) Turn the key anticlockwise to OFF position and take it out.
(3) Press down the emergency disconnect switch.
(4) Exit.
OPERATING
OPERATOR MANUAL 27
P20PS
28 OM-P20PS2019001-EN
BATTERY
Charging
Open the charging door cover, open the charging door, and then connect the charger
connector. Follow the user manual of the charger to charge the forklift.
国标口 REMA口（选配）
Note
(1) If the charge port cover is opened, it is impossible to use the stacker. To use the pallet
truck, close the charge port cover.
(2) The environment temperature influences the charging time, it's suggested the forklift be
charged at room temperature.
TRANSPORTATION AND STORAGE
This chapter explains how to transport and store the forklift.
TRANSPORTATION AND STORAGE
OPERATOR MANUAL 29
P20PS
30 OM-P20PS2019001-EN
LOADING, TRANSPORTATION AND UNLOADING
Hoisting
(1) Lower the fork to the position.
(2) Hoist the truck by the hoisting hole on rear body.
Danger
During the hoisting process, it must be ensured that no one is within the working range of the
hoist.
Warning
Use only a hoisting equipment with sufficient loading capacity (Refer to the vehicle nameplate
in detail for the weight of the vehicle).
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 trailer to transport the forklift.
(2) Unloading the truck by hoisting follows the same procedure as the loading of the truck.
(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.
TRANSPORTATION AND STORAGE
OPERATOR MANUAL 31
P20PS
32 OM-P20PS2019001-EN
DECOMMISSIONING AND RESTORING
Procedures of Decommissioning
Clean and remove the dust on the forklift components and conduct the following procedures:
(1) Check forklift for any 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 to 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 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.
MAINTENANCE
OPERATOR MANUAL 33
P20PS
34 OM-P20PS2019001-EN
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
1Exterior Check
2Wheel Clean and tighten Clean and tighten
3Hydraulic System Check
4Display Check
5Warning Equipment Check
6Brake Check Check
7Travel, Steering and Control Check
8Connectors and Fuse Check Check
9Clean Clean
10 Others Check
Caution
These inspections should be conducted before operating the forklift.
Note
Before conducting the daily inspection, recheck for any fault and fault 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.
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. Hydraulic System
Check the hydraulic oil level in the oil tank.
4. Display
(1) Check if the battery voltage and status of charger displayed are correct.
(2) Check if any fault indicator appears on the display.
5. Warning Equipment
(1) Press horn to see if it works.
(2) Check if other warning equipment work properly.
6. Braking System
Move the handle to the braking zone while the forklift is travelling, to check whether the brakes
operate efficiently.
7. 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.
8. 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
busbar 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.
MAINTENANCE
OPERATOR MANUAL 35
P20PS
36 OM-P20PS2019001-EN
9. Clean
Clean the whole forklift with the compressed air.
10. Others
Check if there are others problems.
Vehicle Maintenance
Category Item
1 Day 1 week 3 6 12 Months
840 600 1200 2400 Hours
Vehicle Body and power supply line Check
All the
components
Fastener, hydraulic
connector, structural wear,
etc.
Check
Driving lift Gear, bearing, fork, wheel,
brake pad, etc.
Lubricate and
clean
Hydraulic
system
Cylinder, hydraulic
connector and hose,
hydraulic oil, etc.
Check and
replace
Electric
system
Electrical connector,
electrical insulation
resistance, etc.
Check
Note (1) Hydraulic oil type is IS0 VG46 / ISO VG68.
(2) It is forbidden to repair vehicles without professional training.
SCHEMATICS
Hydraulic Schematic
M
T T
3
4
1
2
5
6
6L/min
Table of contents
Other BYD Forklift manuals
