BYD EPS14, Service Manual

Page 1: ...SERVICE MANUAL SM EPS142016002 EN EPS14...

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Page 3: ...This manual is used for authorized personnel to sevice BYD forklifts...

Page 4: ...l Replacement 11 Drive Axle and Motor Assembly Removal and Installation 12 Drive Axle and Motor Separation 13 Drive Axle and Motor Installation 14 Balance Mechanism and Castor Wheels Balance Inspectio...

Page 5: ...Hydraulic Unit Hydraulic Unit Removal and Installation 40 Hydraulic Unit Overhaul R930053808 Type 40 ELECTRIC MAINTENANCE Electric Checking Circuit Inspection 43 Fuses and Relays Inspection 43 Main Co...

Page 6: ...MAINTENANCE INTERVAL SERVICE MANUAL 2 MAINTENANCE INTERVAL This chapter explains the maintenance interval...

Page 7: ...daily inspection recheck for any fault and error found earlier Content Description 1 Exterior 1 Check the truck body for damage and deformation 2 Check if there is any leakage 3 Check the condition o...

Page 8: ...ons 3 Check if any fasteners loose or fall off 9 Electric Checking 1 Check if there any parts loose in the circuit and tighten them if necessary Check if there are anything abnormal of connectors for...

Page 9: ...te If the working environment is harsh the maintenance interval should be reduced and advice from aftersales personnel should be sought Category Amount And Type of Supplementary Material Item Category...

Page 10: ...CHASSIS MAINTENANCE SERVICE MANUAL 6 CHASSIS MAINTENANCE This chapter explains how to maintain the chassis of the truck...

Page 11: ...embly to steer the truck 11 12 13 Code Name QTY Information Code Name QTY Information 11 Tiller Head 1 13 Drive Axle And Motor Assembly 12 Tiller Arm 1 Tiller Head Removal and Installation 1 Removal 1...

Page 12: ...Screw M8 15 2 2 Installation Follow the removal steps in reverse to install the tiller head Tiller Head Overhaul Use the picture of the explosive view as the guide to overhaul the tiller head 10 11 12...

Page 13: ...ion Antistatic gloves are needed when the PCB is being removed or installed Tiller Arm Removal and Installation 1 Removal 1 Remove the mounting screws of the tiller head and arm assembly disconnect th...

Page 14: ...9 Code Name QTY Information Code Name QTY Information 10 Tiller Head 1 21 Bushing 1 11 Screw M5 16 4 22 Washer 1 12 Screw M4 16 8 23 Screw M6 16 1 13 Cover 1 24 Rubber Cushion 1 14 Tiller Arm 1 25 Scr...

Page 15: ...ng screw in the oil filler plug with the sealing ring 11 12 Code Name QTY Information 11 Oil Filler Plug 1 30 N m 12 Seal 1 Caution 2 When filling the oil care about the condition around to prevent du...

Page 16: ...keep children away and do not pour it into the sewer or onto the ground 5 The correct oil level and the correct oil quantity is achieved when the oil level is at the lower edge of the oil filler plug...

Page 17: ...me QTY Information 10 Tiller Head And Arm Assembly 1 33 Screw M8 45 6 11 Hexagon Flange Bolt M10 45 6 37 Washer M8 6 2 Installation Slowly set the drive axle and motor assembly down on the flat floor...

Page 18: ...Code Name QTY Information Code Name QTY Information 10 Drive Motor 1 14 Mounting Block 1 11 Nut M12 1 15 Hexagon Screw M8 50 3 12 Screw M8 25 2 18 Pinion 1 13 Washer M8 5 Drive Axle and Motor Installa...

Page 19: ...urn the retainer upward 2 When the front left side or the rear right side of the truck shakes turn the retainer downward 1 2 19 22 21 11 19 22 21 11 Code Name QTY Information Code Name QTY Information...

Page 20: ...as the guide to overhaul the balance mechanism A 11 12 13 13 14 15 16 17 18 19 22 21 20 20 23 23 23 24 A Code Name QTY Information Code Name QTY Information 11 Retainer 1 18 Spring Washer M16 1 12 Mou...

Page 21: ...forks 2 Loosen the screw to replace one wheel and then rotate the fork load wheel assembly by 180 degrees to replace the other wheel 3 Use the same method to replace wheels on the other side 12 13 81...

Page 22: ...MAST MAINTENANCE SERVICE MANUAL 18 MAST MAINTENANCE This chapter explains how to maintain the mast of the truck...

Page 23: ...per 1 110 N m 13 Nut Lower 1 110 N m 12 Nut Middle 1 110 N m 3 Stage Free Lift Mast 3 Cylinders Chain Adjustment The 3 stage free list mast 3 cylinders has a main lift chain set and a free lift chain...

Page 24: ...QTY Information Code Name QTY Information 11 Nut Upper 1 110 N m 13 Nut Lower 1 110 N m 12 Nut Middle 1 110 N m 2 Stage Standard Mast Chain Replacement 1 Explosive View 14 14 81 81 84 84 84 84 84 84 8...

Page 25: ...11 83 83 10 14 16 16 17 84 85 20 A 12 13 87 87 88 88 12 89 89 C 12 13 87 87 88 21 88 B A A C Code Name QTY Information Code Name QTY Information 10 Free Lift Chain Set 1 21 Chain 2 11 Chain Sheave 4 8...

Page 26: ...th a safety hook Slowly lift the hook to make chains slack and then block it 3 Move attachment hoses away from chains 4 Remove the split pin and the pin on the outer mast side and pull the chain off f...

Page 27: ...to lubricate the cylinder rod 4 After lubrication exhaust the air in the lift cylinder and then fasten the screw Lift Cylinder Shimming 1 Lift the mast to find the cylinder rod top of the shorter stro...

Page 28: ...e mast fully 2 Use a reliable hoisting strap to the hang the upper beam of the inner mast 2 stage mast or the middle mast 3 stage mast and secure the strap with a safety hook 3 Remove bolts clamps sup...

Page 29: ...ion 10 Lift Cylinder 2 15 Shim 1 0Mm 2 12 Support 2 81 Hexagon Flange Bolt M6 16 8 13 Cushion Rubber 2 82 Bolt M12 50 2 14 Shim 0 5Mm 2 2 Installation Follow the removal steps in reverse to install ma...

Page 30: ...10 Lift Cylinder 2 31 Back Up Ring 2 18 Dust Wiper 2 35 Bushing 2 19 Retainer Ring 2 36 Steel Retainer Ring 2 20 Seal 2 37 Safety Valve 2 21 Gland 2 91 Screw M6 16 1 22 O Ring 2 92 Washer 1 23 Steel...

Page 31: ...ation 2 Remove the gland with O rings and seals and then carefully take the rod and piston with O rings and seals out of the 3 cylinder tube and place them in a clean area 4 Remove the valve on the cy...

Page 32: ...der bottom side Free Lift Cylinder Removal and Installation 1 Removal 1 Lower the mast fully 2 Use a reliable hoisting strap to the hang the upper beam of the inner mast 2 stage mast or the middle mas...

Page 33: ...gland thoroughly to prevent contamination 2 Remove the gland with O rings and seals and then carefully take the rod and piston with O rings and seals out of the 3 cylinder tube and place them in a cle...

Page 34: ...inner wall of the gland and the cylinder tube in clean hydraulic oil before reassembly 2 Replace the dust wipers o rings seals of the gland and piston as a set 3 Carefully insert the rod and piston i...

Page 35: ...lled on the other side of the 85 84 82 83 86 81 A A A A A A A A A A A A A Code Name QTY Information Code Name QTY Information 81 Mast Roller 12 84 Secure Pin 12 82 Bearing 12 85 Adjust Screw 12 83 Dus...

Page 36: ...Bearing 8 85 Adjust Screw 8 83 Dust Protection 8 86 Circlip 8 3 3 Stage Mast And Carriage Roller Description In the 3 stage mast 2 mast rollers are installed on the top side of the outer mast 4 mast r...

Page 37: ...ge 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 A...

Page 38: ...Slowly set the mast down on the flat floor or sturdy pallets 11 11 11 11 12 12 Code Name QTY Information 11 Bolt Assy M14 35 4 100 N m 12 Screw M10 40 2 30 N m 2 Installation Follow the removal steps...

Page 39: ...flat floor or sturdy pallets 2 Installation Follow the removal steps in reverse to install the carriage After Installation adjust the clearance between the mast and the carriage Mast and Carriage Roll...

Page 40: ...Adjust Screw 8 83 Dust Protection 8 86 Circlip 8 2 Carriage Roller Replacement Check the adjusting screws and secure pins replace them if necessary after the carriage being removed A 81 82 83 86 85 84...

Page 41: ...EPS14 37 SM EPS142016002 EN HYDRAULIC MAINTENANCE This chapter explains how to maintain the truck hydraulic system...

Page 42: ...pes of hydraulic oil 4 When disposing the waste oil keep children away and do not pour it into the sewer or onto the ground 5 Unauthorized hydraulic oil may damage the hydraulic system and use only au...

Page 43: ...EPS14 39 SM EPS142016002 EN 12 Hose 1 16 Rubber Seal 1 13 Hose 1 17 Oil Tank 1 14 Hexagon Bolt M10 25 3 18 Hydraulic Unit 1...

Page 44: ...aulic unit mounting plate it apos s bolts 18 19 19 1 2 16 15 15 15 15 12 14 14 14 13 11 17 Code Name QTY Information Code Name QTY Information 11 Signal Line 1 16 Rubber Seal 1 12 Hose 1 17 Oil Tank 1...

Page 45: ...e QTY Information Code Name QTY Information 10 Hydraulic Unit R Type 1 22 Plastic Protection Plug 1 15 Hydraulic Unit Valve 1 23 Pump Screws M8 85 1 16 O Ring 1 24 Suction Pipe 1 17 Proportional Valve...

Page 46: ...ELECTRIC MAINTENANCE SERVICE MANUAL 42 ELECTRIC MAINTENANCE This chapter explains how to maintain the Electric of the truck...

Page 47: ...onnectors for example burn marks 3 Check if there any plugs and sockets loose and latch them tightly again if necessary Fuses and Relays Inspection Inspecting fuses and relays and replace them if nece...

Page 48: ...t Loosen screws and remove the brake and then move the electromagnetic brake Drive Motor Removal and Installation 1 Removal 1 Before removal remove the cover 2 Remove the tiller head and arm assembly...

Page 49: ...13 13 13 10 Code Name QTY Information Code Name QTY Information 10 Drive Motor 1 15 Hexagon Screw M8 50 3 12 Screw M8 25 2 33 Screw M8 45 6 13 Washer M8 5 37 Washer M8 6 14 Mounting Block 1 2 Installa...

Page 50: ...exagon Flange Bolt M8 20 4 2 Installation Follow the removal steps in reverse to install the main controller Main Controller Overhaul Use the picture of the explosive view as the guide to overhaul the...

Page 51: ...OWNLOADING Program Downloading Description 1 Software Name The name of the program downloading software is ZpCanFlasher 2 Software Interface 2 3 1 Code Name Code Name 1 Menu Bar 3 Information Textbox...

Page 52: ...confirm show the Configuration Can and set values according to the picture and then choose USE IXXAT CONFIGURATION 4 Click File in the menu bar choose Load File to load the file named adxt2b_2bd008 H8...

Page 53: ...bar choose Tester choose TILLER POT on the left and the corresponding parameter value will be shown on the right 2 Set the tiller arm in the vertical position and the rotate it downward for 10 and re...

Page 54: ...ELECTRIC MAINTENANCE SERVICE MANUAL 50 6 Click Store button to save parameters and then exit the software...

Page 55: ...e Name QTY Information Code Name QTY Information 11 Hexagon Flange Bolt M10 45 6 70 N m Thread Sealant 17 Hexagon Flange Bolt M8 20 2 25 N m Thread Sealant 12 Screw M8 25 5 30 N m Thread Sealant 18 Dr...

Page 56: ...formation Code Name QTY Information 11 Load Wheel Screw 4 90 N m 13 Drive Axle Nut 1 90 N m 12 Castor Wheel Nut 2 110 N m 3 Mast Fasteners Torque Checking 11 11 11 11 12 12 Code Name QTY Information 1...

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Page 58: ...o 230 Terminal Intermodal de Cargas TIC CEP 13069 119 CAMPINAS SP Tel 55193514 2551 E mail FORKLIFTSERVICE BYD COM Importer BYD Japan company Limited Address The fifth Yasuda Bldg 5F 2 20 3 Tsuya cho...

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