BYD PMW20 Bedienungsanleitung
<SM-PMW202020001-EN >
PMW20
SERVICE MANUAL
This manual is applicable to the maintenance of BYD
forklift for authorized personnel.
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TABLE OF CONTENTS
INTRODUCTION
1.1 ENTIRE FORKLIFT 8
1.2ATTACHMENTS 9
1.3 CHASSIS 10
1.4 HYDRAULIC DEVICE 11
1.5 ELECTRIC DEVICE 12
DAILY MAINTENANCE
2.1 TIME AND ITEMS 13
2.2 DESCRIPTION 14
REGULAR MAINTENANCE
3.1 TIME AND ITEMS 17
3.2 CATEGORY, DOSAGE AND MODEL OF ACCESSORIES 17
3.3 DESCRIPTION 17
MAINTAIN ATTACHMENTS
4.1 REMOVE AND INSTALL GUARD 19
MAINTAIN CHASSIS
5.1 REMOVE AND INSTALL THE OPERATING HANDLE 22
5.2 REMOVE AND INSTALL THE HANDLE LEVER 24
5.3 REPLACE THE AIR-ACTUATED SPRING 25
5.4 REMOVE AND INSTALL THE STEERING-CONNECTED ASSEMBLY 26
5.5 REMOVE AND INSTALL DRIVE ASSEMBLY 2 7
5.6 SEPARATE DRIVE MOTOR ASSEMBLY FROM REDUCTION GEARBOX
ASSEMBLY
29
5.7 REPLACE DRIVE WHEELS 30
5.8 REPLACE BALANCE WHEELS 31
5.9 REPLACE THE BALANCE MECHANISM 32
5.10 REMOVE AND INSTALL THE ASSISTING SUPPORT ASSEMBLY 36
5.11 REMOVE AND INSTALL THE ASSISTING SUPPORT ASSEMBLY 37
5.12 REMOVE AND INSTALL THE LIFT MECHANISM 38
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MAINTAIN THE HYDRAULIC DEVICE
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6.1 WORKING PRINCIPLE OF THE HYDRAULIC SYSTEM
6.2 PARTS OF THE HYDRAULIC SYSTEM
6.3 ADD HYDRAULIC OIL
6.4 REMOVE AND INSTALL THE POWER UNIT
6.5 REMOVE AND INSTALL THE POWER UNIT 56
5.13 REMOVE AND INSTALL MAIN BEARING OF COMPOUND ROLLERS
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8.7 TABLE OF FAULT CODES 122
8.8 ELECTRICAL MAINTENANCE DIAGNOSIS 128
8.9 DESCRIPTION OF ELECTRICAL COMPONENT SYSTEM CONTROL 166
MAINTAIN TUQUE
9.1 CHECK THE TORQUE OF THE KEY FASTENERS 185
APPENDIX
10.1 TABLE OF THE TORQUE VALUE 186
10.2 ONBOARD TOOL 187
10.3 WIRING HARNESS 188
10.4 ELECTRICAL SCHEMATIC DIAGRAM 192
10.5 PARAMETERS OF THE CONTROLLER 196
OTHER INFORMATION 204
6.6 REMOVE AND INSTALL THE LIFT CYLINDER 58
6.7 COMPLETE MAINTENNACE OF THE LIFT CYLINDER 59
MAINTAIN ELECTRIC DEVICE
7.1 ELECTRIC CHECK 62
7.2 CHECK THE MAIN CONTROLLER 60
7.3 REMOVE THE MAIN CONTROLLER 61
7.4 REMOVE THE HORN 66
7.5 REMOVE THE MAIN CONTACTOR 67
7.6 REMOVE THE LIMIT SWITCH 68
TROUBLE SHOOTING
8.1 ELECTRICAL MAINTENANCE DIAGNOSIS 72
8.2 COMPARISON TABLE OF THE DISPLAY ERROR CODES AND
CONTROLLER ERROR CODES
73
8.3 PROGRAM AND SOFTWARE 76
8.4 ADJUST PARAMETERS 97
8.5 MONITOR DATA 105
8.6 BURNING PROCEDURES OF THE SERIAL PORT 112
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OTHER INFORMATION
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1.1 ENTIRE FORKLIFT
1.2 ATTACHMENTS
INTRODUCTION
Fork
Front
Forklift
Body
Rear
Forkift
Body
Operating
Handle
Assembly
Cover Plate Of The Battery Box
Instrument Panel
Guard Of Tiller
Guard Plate Of The Rear Forklift Body
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1.3 CHASSIS 1.4 HYDRAULIC DEVICE
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Steering-Connected Assembly
Welding Assembly of Handle Lever
Operating Handle Assembly
Drive Assembly
Support
Wheel
Assembly
Lift Mechanism
Support Wheel Assembly
Lift Mechanism
Balance Mechanism
Drive Wheel
Balance Mechanism
Cylinder
Hydraulic Power Unit
Cylinder
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Note
Inspect before each operation.
Hint
Review the last failure before routine inspection.
1.5 ELECTRIC DEVICE
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Controller Assembly
Safety Device
Instrument
Assembly
Emergency Switch
Electric Horn
USB Charging
Connector
DAILY MAINTENANCE
2.1 TIME AND ITEMS
Daily items are inspected daily (or every 8 hours) and weekly (or every 40 hours),
whichever
comes first. For example, if the working hours are less than 8 hours per day, the forklift
shall be inspected daily. If the working hours are more than 8 hours per day, the forklift
shall be inspected every 8 hours.
The list of items to be checked are as follows:
No. Item 1 Day 1 Week
8 Hours 40 Hours
Shape Check
2Wheels Clean and tighten Clean and tighten
3Hydraulic Device Check
4Instrument Check
5Warning Apparatus Check
6Brake Check Check
7Driving, Steering and Operating Check
8Electric Device Check
9Clean Clean
10 Other Abnormalities Check
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2.2 DESCRIPTION
1. Shape
(1) Check whether the forklift is damaged or deformed.
(2) Check whether oil is leaked on the ground where forklifts are put.
(3) Check whether nameplates or signs are complete.
(4) Check whether parts are loose or fall off.
Note
If oil leaks, please identify the position and contact after-sale personnel of BYD.
2. Wheels
(1) Check whether the fastener of wheels is loose. If yes, tighten it.Remove debris
embedded in the tire.
(2) If wheels are worn seriously wherein the wear between left and right wheels are
uneven, or rims are found broken or bent, please replace wheels.
3. Hydraulic Device
Check the device through the level of hydraulic oil.
4. Instrument
(1) Check whether the battery voltage and power on the instrument are displayed
normally.
(2) Check whether a fault indicating lamp appears on the instrument.
5. Warning Device
(1) Press "horn" button and check whether the horn can honk.
(2) Check whether other warning devices are working normally.
6. Brake Performance
Put the handle lever in the brake area and check whether the brake performance is good.
7. Driving, Steering and Checking
(1) Swing the control handle right and left and up and down. Check whether it can rotate
smoothly and make sure no abnormal sound appears in the operation process.
(2) Check whether buttons can work normally.
(3) Check whether fasteners are loose or fall off.
8. Electric Check
(1) Check whether connection terminals of electric device are loose. If any, tighten it.
Check whether joints among the wiring-connected sections are abnormally.
(2) Check whether the safety device of the master controller works normally. If necessary,
replace it.
(3) Check whether the copper bar of the master controller is burned. If
necessary, replace it.
(4) Check whether the low-voltage insurance and relay can work normally. If
necessary,replace them.
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Warning
Disconnect power before the electric check.
9. Clearance
Clear the entire forklift with compressed air.
10. Other Abnormal Parts
Check whether there are other abnormal parts.
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REGULAR MAINTENANCE
3.1 TIME AND ITEMS
For example, if the service time within 6 weeks are less than 250 hours, the reference
time will be calculated as 6 weeks. Otherwise, 250 hours are preferred. Other reference
time is calculated likewise.
If the operating conditions are relatively poor, the maintenance period should be
shortened and negotiated with the after-sales personnel.
3.2 CATEGORY, DOSAGE AND MODEL OF ACCESSORIES
The amount of accessories is marked with the maximum while the actual amount should
be subject to use.
3.3 DESCRIPTION
1. Hydraulic device
Replace hydraulic oil regularly.
2. Electric device
(1) Check the circuit of the entire forklift.
(2) Check safety device and relay.
(3) Check the main controller.
3. Other Checks
Check the torque of key fasteners.
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Note
Category Item 6（Weeks） 3 6 9 12 Month
250 500 1000 1500 2000 Hour
Hydraulic
Device Replace Hydraulic Oil Replace
Electric
Device Check Electric Device Check
Other
Checks
Check Torque of
Key Fasteners Check
Item Category Dosage Model
Replace
Hydraulic Oil Hydraulic Oil 1L Anti-Wear Hydraulic Oil _Hydraul Ⅰ C-O Ⅰ L-AW46
Note
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4.1 REMOVE AND INSTALL GUARD
1. REMOVE（Remove the cover plate of the battery box）
1) Remove the guard with the cross screwdriver (Codes13/15/18).
2) Remove the fastener on the battery cover plate with a 4mm Allen wrench (Code 10).
3) Unscrew the instrument assembly on the instrument panel, dual USB charging
connector, self-resetting ignition switch and emergency switch.
4) Unplug the wire harness connectors (H02/G17/Ln01/Ln02/G10).
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MAINTAIN ATTACHMENTS
This chapter will describe how to maintain attachments.
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Cover Plate of the Battery Box
Instrument Panel
Guard of Tiller
Guard Plate of the Rear Forklift Body
Inhaltsverzeichnis
Andere BYD Gabelstapler Handbücher
