BYD ECB16 User manual

OPERATOR MANUAL
ECB16 ECB18
< OM-ECB162015006-EN-US >
Lift truck must be inspected at the
beginning of each shift
ATTENTION
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OPERATOR MANUAL
< OM-ECB162015006-EN-US >
ECB16 ECB18
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TABLE OF CONTENTS
OPERATOR MANUAL 4
FOREWORD
Declaration
Operation Notice 2
Truck Delivery 2
Working Environment 3
SAFETY STANDARD
General Safety Practices
Modifications, Nameplates, Markings, and Capacity 6
Stopping Distance (Descending Grades) 6
Stability 7
Changing and Charging Storage Batteries for Electric Trucks 7
Trucks and Railroad Cars 7
Relocating Powered Industrial Trucks 7
Operator Training 8
Testing, Retraining, and Enforcement 10
Operating Safety Rules and Practices
Operator Responsibility 11
General 11
Traveling 13
Loading 15
Operator Care of the Truck 16
Maintenance And Rebuild Practices
Operation 18
Maintenance and Inspection 18
Inspection and Repair of Forks in Service on Fork Lift Trucks 19
Tip Over 21
OPERATOR NOTICE
Notice
Operator Qualification 26
Warning decals and signs 27
Data Plate and Loading capacity chart
Date Plate 28
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Loading Capacity Chart 29
TRUCK VIEW AND TECHNICAL SPECIFICATIONS
View
General View 32
Specifications
Technical Drawing 34
Technical Specifications (Dual Drive) 36
Mast Specifications 37
Battery Specifications 37
OPERATING THE FORKLIFT
Seat
Descriptions 40
Basic Seat
Adjustment of lateral position of seat 41
Backrest adjustment 41
Weight adjustment 42
Seat belt 42
Comfort Seat
Adjustment of lateral position of seat 43
Backrest adjustment 43
Weight adjustment 44
Seat belt 44
Document box 45
Drive Control System
Drive control system overall view 46
Adjusting the steering wheel 48
Ignition Switch 48
Horn 49
Check the Braking Oil 50
Parking Brake 51
Selecting Travel Direction 52
Combination Lights Control 53
Multifunction Display
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TABLE OF CONTENTS
OPERATOR MANUAL 6
Overview on Multifunction Display 54
Adjusting Speed Mode (Class) 55
Working Indicator and Messages 56
Setting 57
Error Indicator 58
Trouble-shooting Methods 59
Working Equipment Controlling System
Mechanical levers 60
Fingertip Control 61
Forks
Adjusting the Forks 62
Towing Pin
Use of the Towing Pin 63
Transporting the Forklift
Crane-lifting the Forklift 64
Driving into the Transport Truck 65
Transporting and Unloading the Forklift 65
Transporting Loads
Loading 66
Travelling 66
Unloading 67
Exiting from the Forklift 68
DAILY OR WEEKLY CHECK AND INSPECTION
Daily Inspection
Checklist and Time Interval 72
Forklift Exterior 72
Tires 72
Working Equipment 73
Hydraulic System 73
Seat 73
Multifunction display 73
Lights, Horn and Other Warning Equipment 74
Braking System 74
Driving System and Controlling System 74
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Counterweight 74
Others 74
Weekly Inspection
Checklist and Time Interval 75
Electric System Inspection 75
Tires 75
Braking System 75
REGULAR INSPECTION AND MAINTENANCE
Checklist and Procedures
Inspection Checklist and Procedures 78
Regular Maintenance Checklist 79
Type and Parameters of Oil and Grease 79
Working Equipment
Mast Channel Cleaning and Adjustment 80
Tilt Rotating Pin Lubrication 80
Adjusting the Chains 81
Changing and Replacing Chains 81
Electric
Electric System Inspection 82
Hydraulic System
Before Inspection and Maintenance 84
Hydraulic Oil Level 85
Return Filter Element State Indicator 85
Return Filter Element Replacement 86
High Pressure Filter Element Replacement(Comfort Type Forklift) 87
Check and Replace the Air Filter 87
Hydraulic Oil Replacement 88
Tires Replacement
Condition needs replacement 89
Front Wheels Replacement 90
Rear Wheels Replacement 90
Gear Oil
Gear Oil replacement (Dual Drive) 91
Braking Oil Replacement
Braking Oil Reservoir 92
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OPERATOR MANUAL 8
Braking Oil Drain Plug 92
Methods of Replacing Braking Oil 93
Steering Axle
Clean 94
Torque On Critical Fasteners
Drive Axle Fasteners 95
Steering Axle Fasteners 95
Wheel Fasteners 96
Counterweight Fasteners 96
Mast Fasteners 97
DECOMMISSIONING AND RESTORING
Decommissioning the Forklift
Decommissioning the forklift for long-term Storage 102
Storage Environment 102
Restoring the Forklift to Service
Procedures to Restore the Forklift to Service 103
OTHER INFORMATION
Contact Informaiton 104
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1
FOREWORD
Thank you for choosing BYD electric forklifts.
The BYD electric forklifts have the best price for value, high safety and easy access to
maintenance and they offer great operating experience. To ensure that the BYD electric forklifts
deliver its utmost performance, it is essential for operators/proprietors to conduct a correct
operation, checking, maintenance and repair.
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.
Upon receiving the forklift, use the shipping list to check for missing items. If there is anything
missing, please contact with the after sales service immediately.
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 Even for the professional, complying with the instructions will ensure a better operation of the the BYD
forklift.
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FOREWORD
OPERATOR MANUAL 2
Declaration
Operation Notice
BYD electric forklifts can only be operated in the designated areas in the factory or in other
specific environments, in compliance with local safety regulations on similar 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.
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.
Please contact with BYD if you have any question or if you need the complete test report.
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 truck should therefore be
assumed from the present operator manual.
Truck Delivery
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 brake.
4. Check the motors.
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)
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To avoid inconveniences in future warranty claims, please check the functions of the forklift
and check if the forklift is complete. Only sign in the Product Quality Certificate of the BYD forklift
after you confirmed that the forklift has complied with the requirements.
Working Environment
Working temperature: 14 ~ 104°F
Gradeability: ≤ 20%
Others: no flammable gas, no flammable dust and no volatile flammable liquid
Contact with your BYD local dealer if the forklift is intended to be used in the following
environments:
1. in 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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5
SAFETY STANDARD
This Standard defines the safety requirements relating to the elements of operation and
maintenance.
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SAFETY STANDARD
OPERATOR MANUAL 6
General Safety Practices
Modifications, Nameplates, Markings, and Capacity
Except as provided in next paragraph, no modifications or alterations to a powered industrial
truck that may affect the capacity, stability, or safe operation of the truck shall be made without the
prior written approval of the original truck manufacturer or its successor thereof. When the truck
manufacturer or its successor approves a modification or alteration, appropriate changes shall be
made to capacity plates, decals, tags, and operation and maintenance manuals.
If the truck manufacturer is no longer in business and there is no successor to the business,
the user may arrange for a modification or alteration to a powered industrial truck, provided
however, the user
1. arranges for modification or alteration to be designed, tested, and implemented by an
engineer(s) expert in industrial trucks and their safety.
2. maintains a permanent record of the design test(s), and implementation of the
modification or alteration.
3. makes appropriate changes to the capacity plate(s), decals, tags, and operation and
maintenance manuals.
4. affixes a permanent and readily visible label on the truck stating the manner in which the
truck has been modified or altered together with the date of the modification or alteration,
and the name of the organization that accomplished the tasks.
The user shall see that all nameplates and caution and instruction markings are in place and
legible before operation.
The user shall consider that changes in load dimension may affect truck capacity.
When modifications involve rebuild and repair of the basic unit, they shall be made in
accordance with the manufacturer’s established criteria and procedures.
Batteries used in electric trucks shall comply with the minimum/maximum battery weight range
shown on the truck nameplate.
Stopping Distance (Descending Grades)
When descending a grade, stopping distance will be greater than on-level operation. Methods
shall be provided to allow for this condition. Some methods are:
1. Descend grades slowly and carefully.
2. On all grades the load and load-engaging means shall be tilted back, if applicable, and
raised only as far as necessary to clear the road surface.
3. Avoid turning, if possible, and use extreme caution on grades, ramps, or inclines;
normally travel straight up and down.
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4. If the load are high and affect the operator’s visibility of the route ahead,operate the
forklift in reverse.
Stability
Some of the conditions that may affect stability are: ground and floor conditions, grade, speed,
loading (trucks equipped with attachments behave as partially loaded trucks even when operated
without a load on the attachment), battery weight, dynamic and static forces, and the judgment
exercised by the operator.
On electric trucks, use only a battery or batteries having a total service weight within the
minimum/maximum range specified on truck nameplate.
Changing and Charging Storage Batteries for Electric Trucks
Battery changing and charging facilities and procedures shall be in accordance with ANSI/
NFPA 505.
The charger connector shall not be plugged into the truck connector under any circumstances.
To avoid damage to equipment or injury to personnel, consult manufacturer’s procedures when
replacing contacts in any battery connector.
Failure to comply with specified nameplate battery weight range could result in truck instability.
Lighting for Operating Areas
Controlled lighting of adequate intensity should be provided in operating areas in conformance
with ANSI/IES RP7.
Trucks and Railroad Cars
When powered industrial trucks are driven on and off highway trucks or trailers, the brakes
on the highway trucks or trailers shall be applied, and wheel chocks or other positive mechanical
means shall be used to prevent unintentional movement of highway trucks and trailers.
Provision shall be made to prevent railroad cars from being moved during loading and
unloading. Wheel stops, hand brakes, or other recognized positive means shall be used to prevent
movement during loading and unloading.
Whenever powered industrial trucks are driven on and off semitrailers not coupled to a tractor,
supports may be needed to prevent upending or corner dipping.
Maintain a safe distance from the edge of ramps, platforms, or other similar working surfaces.
Do not move railroad cars or trailers with a powered industrial truck unless the truck is
properly designed and equipped for that operation.
Relocating Powered Industrial Trucks
When utilizing lifting equipment such as elevators, cranes, ship hoisting gear, etc., to relocate
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SAFETY STANDARD
OPERATOR MANUAL 8
a powered industrial truck, the user shall ensure that the capacity of the hoisting equipment being
used is not exceeded.
Personnel who have not been trained to operate powered industrial trucks may operate a truck
for the purposes of training only, and only under the direct supervision of the trainer. This training
should be conducted in an area away from other trucks, obstacles, and pedestrians.
Operator Training
The operator training program should include the user’s policies for the site where the trainee
will operate the truck, the operating conditions for that location, and the specific truck the trainee
will operate. The training program shall be presented to all new operators regardless of previous
experience.
The training program shall inform the trainee of the following:
1. The primary responsibility of the operator is to use the powered industrial truck safely
following the instructions given in the training program.
2. Unsafe or improper operation of a powered industrial truck can result in
(1) death or serious injury to the operator or others
(2) damage to the powered industrial truck or other property
The training program shall emphasize safe and proper operation to avoid injury to the operator
and others and prevent property damage, and shall cover the following areas:
1. fundamentals of the powered industrial truck(s) the trainee will operate, including
(1) characteristics of the powered industrial truck(s), including variations between trucks
in the workplace
(2) similarities to and differences from automobiles
(3) significance of nameplate data, including rated capacity, warnings, and the
instructions affixed to the truck
(4) operating instructions and warnings in the operating manual for the truck, and
instructions for inspection and maintenance to be performed by the operator.
(5) type of motive power and its characteristics
(6) method of steering
(7) braking method and characteristics, with and without load,(8) visibility, with and
without load, forward and reverse
(8) load handling capacity, weight and load center
(9) stability characteristics with and without load, with and without attachments
(10) controls: location, function, method of operation, identification of symbols
(11) load handling capabilities, forks, attachments
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(12) hazards due to production of carbon monoxide by internal combustion engines and
common initial symptoms of exposure
(13) fueling and battery charging
(14) guards and protective devices for the specific type of truck
(15) other characteristics of the specific industrial truck
2. operating environment and its effect on truck operation including
(1) floor or ground conditions including temporary conditions
(2) ramps and inclines, with and without load
(3) trailers, railcars, and dockboards (including the use of wheel chocks, jacks, and other
securing devices)
(4) fueling and battery charging facilities
(5) the use of “classified” trucks in areas classified as hazardous due to risk of fire or
explosion, as defined in ANSI/NFPA 505
(6) narrow aisles, doorways, overhead wires and piping, and other areas of limited
clearance
(7) areas where the truck may be operated near other powered industrial trucks, other
vehicles, or pedestrians
(8) use and capacity of elevators
(9) operation near edge of dock or edge of improved surface
(10) other special operating conditions and hazards that may be encountered
3. operation of the powered industrial truck, including:
(1) proper preshift inspection and approved method for removing from service a truck
that is in need of repair
(2) load handling techniques: lifting, lowering, picking up, placing, tilting
(3) traveling, with and without loads; turning corners
(4) parking and shutdown procedures
(5) other special operating conditions for the specific application
4. operating safety rules and practices including:
(1) provisions of this Standard in Operating Safety Rules and Practices address operating
safety rules and practices
(2) provisions of this Standard in Operating Safety Rules and Practices address care of
the truck
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SAFETY STANDARD
OPERATOR MANUAL 10
(3) other rules, regulations, or practices specified by the employer at the location where
the powered industrial truck will be used
5. Operational training practice, including:
(1) if feasible, practice in the operation of powered industrial trucks shall be conducted in
an area separate from other workplace activities and personnel
(2) training practice shall be conducted under the supervision of the trainer
(3) training practice shall include the actual operation or simulated performance of all
operating tasks such as load handling, maneuvering, traveling, stopping, starting, and
other activities under the conditions that will be encountered in the use of the truck
Testing, Retraining, and Enforcement
1. During training, performance and oral and/or written tests shall be given by the employer
to measure the skill and knowledge of the operator in meeting the requirements of the
Standard. Employers may delegate such testing to others but shall remain responsible
for the testing. Appropriate records shall be kept.
2. Operators shall be retrained when new equipment is introduced, existing equipment
is modified, operating conditions are changed, or an operator’s performance is
unsatisfactory.
3. The user shall be responsible for enforcing the safe use of the powered industrial truck
according to the provisions of this Standard
NOTE: Information on operator training is available from such sources as powered industrial
truck manufacturers, government agencies dealing with employee safety, trade organizations of
users of powered industrial trucks, public and private organizations, and safety consultants.
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