BYD ECB50 Service Manual 2021001

BYD ECB50 Service Manual 2021001

Data Size: 66.95 MB
File Type: PDF
Language: English
Manufacturer: BYD
Applicable Machine: Forklift
Document: Service Manual, Error Code, Electrical Schematic, Hydraulic Schematic
Machine Model: BYD ECB50 Forklift
Book Number: 2021001
Page: 243 Pages

List Contents:

1 How to Use This Manual
1.1 Overview of the Manual
1.2 Use of the Manual
1.2.1 Storage of the Manual
1.2.2 Conventions Used in the Manual
1.2.3 Explanations for Abbreviations
1.2.4 Notes for Reading
2 Safety Instructions
2.1 Safety and Warning Symbols
2.1.1 Safety Categories
2.1.2 Hazard Symbols
2.1.3 Prohibition Symbols
2.1.4 Symbols About Mandatory Action
2.2 Safety Specifications
2.2.1 Safety Requirements for Industrial Forklift
2.2.2 Operation Safety Principles
2.3 Maintenance Principles
2.3.1 Safety Principles Before the Maintenance
2.3.2 Safety Principles During the Maintenance
2.3.3 Safety Principles After the Maintenance
2.4 Disposal of the Forklift and Materials
2.5 Possible Hazards
2.5.1 Restrictions
2.5.2 Emergency Procedures
3 Overview of the Forklift
3.1 Dimensions of the Forklift
3.2 Major Parameters of the Forklift
3.3 Nameplate on ECB50 Forklift
3.4 Nameplate on the Battery
3.5 Signs and Labels
3.6 Intended Use
3.7 Prohibition
4 Maintaining Forklift Parts
4.1 Overview of the Forklift
4.1.1 Manual Valve of the Entire Forklift
4.1.2 Proportional Valve of the Entire Forklift
4.1.3 Chassis
4.1.4 Mast (2-stage Standard Mast)
4.1.5 Hydraulic Manual Valve
4.1.6 Hydraulic Proportional Valve
4.1.7 Electrical Parts
4.2 Maintain Accessory System
4.2.1 Cover of the Display Desk
4.2.2 Horn Cover of the Steering Wheel
4.2.3 Control Lever Cover
4.2.4 Seat Cover
4.2.5 Seat
4.2.6 Right Side Plate of the Forklift Body
4.2.7 Left Side Plate of the Forklift Body
4.2.8 Front and Rear Foot Pedals
4.3 Maintain Steering and Control System
4.3.1 Wheels
4.3.2 Replace Tires
4.3.3 Steering Wheel
4.3.4 Combination Switch
4.3.5 Steering Column
4.3.6 Display
4.3.7 Control Lever
4.3.8 Replacement and Adjustment of Micro Switch of the Control Lever
4.3.9 Steering Axle System
4.4 Drive Unit
4.4.1 Introduction of the Drive Unit
4.4.2 Check Oil Level of the Drive Unit
4.4.3 Adding Gear Oil into the Drive Unit
4.4.4 Replacing Drive Unit
4.5 Brake System Maintenance
4.5.1 Brake System Specification
4.5.2 Parking Brake
4.5.3 Service Brake
4.5.4 Energy Accumulator
4.5.5 Brake Discs
4.6 Maintenance of Electrical Parts
4.6.1 Check Lines
4.6.2 Low Voltage Distribution Box
4.6.3 Main Controller Fuse
4.6.4 Ignition Switch
4.6.5 Ignition Switch Fuse
4.6.6 Pre-charge Resistor
4.6.7 Main Contactor
4.6.8 DC/DC Converter
4.6.9 Controller
4.6.10 Horn and Reversing Buzzer
4.6.11 Emergency Power Off (EPO) Switch
4.7 Maintaining Battery
4.7.1 Overview of the Battery Box
4.7.2 Opening the Battery Box
4.7.3 Cleaning the Outside of the Battery Box
4.7.4 Battery Manager System (BMS)
4.7.5 Controller Contactor of the Battery
4.7.6 Charge-discharge Contactor
4.7.7 Hall Sensor
4.7.8 Battery Box Connector Base
4.7.9 Battery Information Collector (BIC)
4.7.10 Removal, Replacement and Installation of the Battery Box
4.7.11 Charging Port Base
4.8 Motor
4.8.1 Bearing of the Motor
4.8.2 Terminal Nut
4.8.3 Test of the Motor
4.8.4 Pump/Steering/Lift Motors
4.8.5 Drive Motor
4.9 Hydraulic Parts
4.9.1 Hydraulic Oil
4.9.2 Return Oil Filter
4.9.3 Steering Control Unit
4.9.4 Manual Multi-way Valve
4.9.5 Adjustment of Relief Valve Pressure
4.9.6 Hydraulic System Pressure Relief
4.9.7 Hydraulic Pump
4.9.8 Tilt Cylinder
4.9.9 Lifting Cylinder (Side Cylinder)
4.9.10 Fully Free Lifting Cylinder (Middle Cylinder)
4.9.11 Lifting Cylinder Seal
4.10 Mast
4.10.1 2-stage Standard Mast
4.10.2 Disassembly and Assembly of Mast
4.10.3 Adjustment of the 2-stage Standard Mast
4.10.4 Chain
4.10.5 Fork
4.10.6 3-stage Fully Free Mast
4.10.7 Lift Cylinder Shim
5 Program Debug
5.1 Update of Applications
5.1.1 Connecting the Forklift and the Computer
5.1.2 Standard Operation Procedures of Refreshing Controller Application
5.1.3 Controller Node & Application Introduction
5.1.4 Scan and Select the Node
5.1.5 Choose the Node and Start Updating
5.1.6 Finish Refreshing and Exit
5.1.7 Restart for Saving the Configuration
5.1.8 Resolution of Application Failure
5.2 Usage of the BYD Forklift Upper Computer
5.2.1 Software Icons and Interfaces
5.2.2 Scan and Select the Node
5.2.3 Introduction of Software Interface
5.2.4 Operation Instruction of Parameter List Reading
5.2.5 Software Sensor Calibration
5.2.6 Introduction of Software Parameter
5.2.7 Intercept CAN Message
5.3 Advanced Monitoring Software of the Motor Controller-DriveTool-4.9
5.3.1 Software Icons and Interfaces
5.3.2 Scan and Select the Node
5.3.3 Choose and Update a Node
5.3.4 Description of Parameter Debugging Interface
5.3.5 Calibration of Sensor Values
5.3.6 Restart for Saving Configuration
6 Maintenance Checklist
6.1 Maintenance Content and Basic Requirements
6.2 Basic Safety Principles
6.3 List of Routine Maintenance
6.4 Routine Maintenance
6.4.1 Time and Items
6.4.2 Description
6.5 Regular Maintenance
6.5.1 Time and Items
6.5.2 Description
6.6 Accessories
6.6.1 Types, Dosages and Models of Accessories
7 Trouble Shooting
7.1 Electrical Maintenance Diagnosis
7.1.1 Overview
7.1.2 Comparison Table of Error Codes for the Display and Controller
7.2 Troubleshooting Explanation
7.3 Error Codes
8 Theory of Operation
8.1 Operation Theory of Hydraulic System
8.1.1 Function Introduction of Hydraulic System
8.1.2 Hydraulic Working Principle
8.2 Operation Theory of Electric System (Manual Valve)
8.2.1 Electric System of the Entire Forklift
8.2.2 Power System of the Entire Forklift
8.2.3 Control System
8.2.4 Lifting System
8.2.5 Brake System
8.2.6 Steering System
8.3 Operation Theory of Electric System (Proportional Valve)
8.3.1 Electric System of the Entire Forklift
8.3.2 Power System of the Entire Forklift
8.3.3 Control System
8.3.4 Lifting System
8.3.5 Brake System
8.3.6 Steering System
9 Appendix
9.1 Forklift Tools
9.2 Table of the Torque Value
9.2.1 Table of the Torque Value
9.3 Hydraulic Schematic Diagram (Manual Valve)
9.3.1 Hydraulic Schematic Diagram (Proportional Valve)
9.4 Electrical Schematic Diagram (Manual Valve)
9.4.1 Electrical Schematic Diagram (Manual Valve)
9.4.2 Electrical Schematic Diagram (Proportional Valve)
9.4.3 Electrical Schematic Diagram (Proportional Valve)
9.5 Parameters of the Controller
9.6 Charging Instructions
9.7 Weekly Check
9.8 Other Information