BYD EPS14 Service Manual
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BYD EPS14 Service Manual

BYD EPS14 Service Manual

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EPS14
SERVICE MANUAL
< SM-EPS142016002-EN >

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  • Page 1 EPS14 SERVICE MANUAL < SM-EPS142016002-EN >...
  • Page 3 This manual is used for authorized personnel to sevice BYD forklifts...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS MAINTENANCE INTERVAL Daily Maintenance Integral and Items Content Description Regular Maintenance Integral and Items Category, Amount And Type of Supplementary Material Content Description CHASSIS MAINTENANCE Tiller Head and Tiller Arm Description Tiller Head Removal and Installation Tiller Head Overhaul Tiller Arm Removal and Installation Tiller Arm Overhaul...
  • Page 5 EPS14 Free Lift Cylinder Removal and Installation Free Lift Cylinder Overhaul Mast and Carriage Mast and Carriage Roller Description General Carriage and Mast Clearance Adjustment Mast Removal and Installation Carriage Removal and Installation without Removing Mast Carriage Removal and Installation after Removing Mast...

  • Page 6: Maintenance Interval

    MAINTENANCE INTERVAL MAINTENANCE INTERVAL This chapter explains the maintenance interval. SERVICE MANUAL...

  • Page 7: Daily Maintenance

    EPS14 DAILY MAINTENANCE Integral and Items The period is accumulated in days or hours of operation whichever comes first. For example, if the forklifts works less than 8 hours per day, conduct the following inspection and checks on a daily basis. If daily working hours exceed 8 hours, conduct the following inspection and checks every 8 hours.
  • Page 8 MAINTENANCE INTERVAL (2) Check if other warning equipments work properly. Braking Performance Brake the truck when driving it to checking it&apos;s performance. Travel, Steering and Control Checking (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.

  • Page 9: Regular Maintenance

    EPS14 REGULAR MAINTENANCE Integral and Items The period is accumulated in months or hours of operation whichever comes first. For example, if the truck works less than 250 hours in 6 weeks, conduct the following inspection and checks every 6 weeks, otherwise conduct the following inspection and checks every 250 hours.

  • Page 10: Chassis Maintenance

    CHASSIS MAINTENANCE CHASSIS MAINTENANCE This chapter explains how to maintain the chassis of the truck. SERVICE MANUAL...

  • Page 11: Tiller Head And Tiller Arm

    EPS14 TILLER HEAD AND TILLER ARM Description The tiller head is fixed on the tiller arm, which is connected to the drive axle and motor assembly to steer the truck. Code Name Information Code Name Information Tiller Head Drive Axle And Motor Assembly...

  • Page 12: Tiller Head Overhaul

    CHASSIS MAINTENANCE Code Name Information Code Name Information Screw M6×10 Tiller Head Mounting Bracket Tiller Head Screw M6×30 Dataline Screw M8×15 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. Code Name Information...

  • Page 13: Tiller Arm Removal And Installation

    EPS14 Spring For Horn And Low Speed Switch Screw M6×10 Emergency Reverse Switch Spring Lower Part Bearing Hinge Spring Shaft Sensor Rocker Lever Washer Magnet Screw M3×16 Butterfly Switch (Lh) Magnet Holder Butterfly Switch (Rh) Rocker Lever (Lh) Hinge Spring (Lh)

  • Page 14: Tiller Arm Overhaul

    CHASSIS MAINTENANCE Tiller Arm Overhaul Use the picture of the explosive view as the guide to overhaul the tiller arm. Code Name Information Code Name Information Tiller Head Bushing Screw M5×16 Washer Screw M4×16 Screw M6×16 Cover Rubber Cushion Tiller Arm Screw M6×16 Retainer Support Retainer Shaft...

  • Page 15: Drive Axle And Wheel

    EPS14 DRIVE AXLE AND WHEEL Drive Wheel Replacement Use the floor jack to raise the turk, and then place the hardwood block under it. Loosen the nuts to replace the wheel. Code Name Information 90 N-m Hexagon Nut Spherical Spring Washer Gear Oil Level Checking (1) Clean the surrounding areas around the oil filler plug, and then unscrew it with the seal.

  • Page 16: Drive Axle And Motor Assembly Removal And Installation

    CHASSIS MAINTENANCE Code Name Information Code Name Information Oil Filler Plug 30 N-m Oil Drain Plug 30 N-m Seal Caution (2) Oil drain time of approximate 5 minutes must not be exceeded. (3) When filling the oil, care about the condition around to prevent dust and water entering the gear box. (4) When disposing the waste oil, keep children away and do not pour it into the sewer or onto the ground.

  • Page 17: Drive Axle And Motor Separation

    EPS14 < 1 > < 2 > < 3 > < 4 > Code Name Information Code Name Information Tiller Head And Arm Assembly Screw M8×45 Hexagon Flange Bolt M10×45 Washer M8 Installation Slowly set the drive axle and motor assembly down on the flat floor or sturdy pallets.

  • Page 18: Drive Axle And Motor Installation

    CHASSIS MAINTENANCE Code Name Information Code Name Information Drive Motor Mounting Block Nut M12 Hexagon Screw M8×50 Screw M8×25 Pinion Washer M8 Drive Axle and Motor Installation Follow the separation steps in reverse to install the motor on the drive axle. SERVICE MANUAL...

  • Page 19: Balance Mechanism And Castor Wheels

    EPS14 BALANCE MECHANISM AND CASTOR WHEELS Balance Inspection and Adjustment If the abnormal shaking occurs, the truck balance is needed to adjusted. Remove the back cover, and then use the retainer to adjust the balance. Before adjustment, place the truck on the sturdy and level ground, and then loosen the mounting bolt of the castor wheel assembly.

  • Page 20: Balance Mechanism Overhaul

    CHASSIS MAINTENANCE Bushing Spring Washer Spring Washer M16 Wahser Washer M12 Balance Mechanism Overhaul Use the picture of the explosive view as the guide to overhaul the balance mechanism. < A > < A > Code Name Information Code Name Information Retainer Spring Washer M16...

  • Page 21: Load Wheel

    EPS14 LOAD WHEEL Load Wheel Replacement Use the hoist equipment to raise the forks until the fork load wheel assembly can be rotated by 90 degrees, and then place the hardwood block under the forks. Loosen the screw to replace one wheel, and then rotate the fork load wheel assembly by 180 degrees to replace the other wheel.

  • Page 22: Mast Maintenance

    MAST MAINTENANCE MAST MAINTENANCE This chapter explains how to maintain the mast of the truck. SERVICE MANUAL...

  • Page 23: Chain

    EPS14 CHAIN 2-Stage Standard Mast Lift Chain Adjustment The 2-stage standard mast has the main lift chain that is needed to be adjusted. Fork-to-ground clearance adjustment: (1) Lower the mast fully. (2) Loosen the upper nut (that some masts have) and the lower nut.

  • Page 24: 2-Stage Standard Mast Chain Replacement

    MAST MAINTENANCE (2) Loosen the upper nut (that some masts have) and the lower nut. (3) Screw the middle nut to adjust the chain until it meet the requirement. (4) Tighten the upper and lower nuts. Code Name Information Code Name Information Nut (Upper)

  • Page 25: 3-Stage Free Lift Mast (4 Cylinders) Chain Replacement

    EPS14 Main Lift Chain Replacement Replacement Procedure (1) Lower the mast fully. (2) Use a reliable hoisting strap to the hang the upper beam of the carriage, and secure the strap with a safety hook. Slowly lift the hook to make chains slack, and then block it.
  • Page 26 MAST MAINTENANCE Free Lift Chain Replacement (1) Lower the mast fully. (2) Use a reliable hoisting strap to the hang the upper beam of the carriage, and secure the strap with a safety hook. Slowly lift the hook to make chains slack, and then block it. (3) Move attachment hoses away from chains.

  • Page 27: Lift Cylinder

    EPS14 LIFT CYLINDER Lift Cylinder Air-Exhausting (1) Lower the mast fully. (2) Remove the screw and washer on the top side of the cylinder. (3) Fully lift the main lift cylinder (or free lift cylinder) to exhaust the air in the cylinder.

  • Page 28: Main Lift Cylinder Removal And Installation

    MAST MAINTENANCE Code Name Information Code Name Information Shim 0.5Mm Bolt M12×50 Shim 1.0Mm Main Lift Cylinder Removal and Installation 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 mast(3-stage mast), and secure the strap with a safety hook.

  • Page 29: Main Lift Cylinder Overhaul

    EPS14 Code Name Information Code Name Information Lift Cylinder Shim 1.0Mm Support Hexagon Flange Bolt M6×16 Cushion Rubber Bolt M12×50 Shim 0.5Mm Installation Follow the removal steps in reverse to install main lift cylinders. Main Lift Cylinder Overhaul Explosive View...
  • Page 30 MAST MAINTENANCE Code Name Information Code Name Information Lift Cylinder Back-Up Ring Dust Wiper Bushing Retainer Ring Steel Retainer Ring Seal Safety Valve Gland Screw M6×16 O-Ring Washer Steel-Backed Bearing Screw M6×6 Glyd Ring Rubber Piston Screw M4×6 Seal Kit (2) 3-stage Mast Main Cylinder Explosive View SERVICE MANUAL...
  • Page 31 EPS14 Code Name Information Code Name Information Left Main Lift Cylinder Seal Kit Right Main Lift Cylinder Back-Up Ring Connecting Shaft Bushing Dust Wiper Steel Retainer Ring Retainer Ring Safety Valve Seal Screw M6×16 Gland Washer O-Ring Screw M6×6 Steel-Backed Bearing...

  • Page 32: Free Lift Cylinder Removal And Installation

    MAST MAINTENANCE (4) Inspect the valve in the piston. Cylinder Reassembly (1) Coat all o-rings, seals, bushings, back-up rings, the rod and piston, valves, and the 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.
  • Page 33 EPS14 Code Name Information Code Name Information Free Lift Cylinder Free Lift Cylinder Seal Kit Dust Wiper Back-Up Ring Retainer Ring Check Valve Seal Washer Gland Bushing Steel-Backed Bearing Safety Valve Bushing O-Ring Screw M6×16 Retainer Ring Washer Steel Retainer Ring Screw M6×6...
  • Page 34 MAST MAINTENANCE (3) Inspect the cylinder tube and bore for cracks, pining, scoring, or other irregularities that may require replacement of the cylinder. (4) Inspect the valve in the piston. Cylinder Reassembly (1) Coat all o-rings, seals, bushings, back-up rings, the rod and piston, valves, and the inner wall of the gland and the cylinder tube in clean hydraulic oil before reassembly.

  • Page 35: Mast And Carriage

    EPS14 MAST AND CARRIAGE Mast and Carriage Roller Description General Description A circlip locks the mast roller, bearing, and the dust protection that are installed on the mast or the carriage stub. The bearing is used to adjust the clearance of the mast and carriage by the adjusting screw, which is installed on the other side of the <...
  • Page 36 MAST MAINTENANCE < A > < A > < A > < A > < A > < A > < A > < A > < A > Code Name Information Code Name Information Mast Roller Secure Pin Bearing Adjust Screw Dust Protection Circlip...

  • Page 37: General Carriage And Mast Clearance Adjustment

    EPS14 < A > < A > < A > < A > < A > < A > < A > < A > < A > < A > < A > < A > < A >...

  • Page 38: Mast Removal And Installation

    MAST MAINTENANCE (1) Clearance between the outer mast and the middle mast. (2) Clearance between the middle mast and the inner mast. (3) Clearance between the inner mast and the carriage. Mast Removal and Installation Removal (1) Use a reliable hoisting strap to the hang the hoisting hole of the mast, and secure the strap with a safety hook. (2) Lift the mast to expose the mast mounting bolts, block the mast by the wood, and then remove bolts.

  • Page 39: Carriage Removal And Installation After Removing Mast

    EPS14 Installation Follow the removal steps in reverse to install the carriage. After Installation, adjust the clearance between the mast and the carriage. Carriage Removal and Installation after Removing Mast Removal (1) Remove the mast, and then set it down on the flat floor or sturdy pallets.
  • Page 40 MAST MAINTENANCE < 1 > < 2 > Code Name Information Code Name Information Mast Roller Secure Pin Bearing Adjust Screw Dust Protection Circlip Carriage Roller Replacement Check the adjusting screws and secure pins, replace them if necessary after the carriage being removed. <...

  • Page 41: Hydraulic Maintenance

    EPS14 HYDRAULIC MAINTENANCE This chapter explains how to maintain the truck hydraulic system. SM-EPS142016002-EN...

  • Page 42: Hydraulic Oil

    HYDRAULIC MAINTENANCE HYDRAULIC OIL Hydraulic Oil Level Checking (1) Pull out the oil dipstick, use the clean cloth to wipe the oil on it, and then insert it back. (2) Pull out the oil dipstick again, and then see if the oil level is between two marks. (3) If the oil level is under the lower mark, take of the oil filter cap and refill the oil.
  • Page 43 EPS14 Hose Rubber Seal Hose Oil Tank Hexagon Bolt M10×25 Hydraulic Unit SM-EPS142016002-EN...

  • Page 44: Hydraulic Unit

    HYDRAULIC MAINTENANCE HYDRAULIC UNIT Hydraulic Unit Removal and Installation Removal (1) Disconnect the electric line and the pressure hose from the hydraulic unit, and remove it after loosening the bolts. (2) Remove fasteners to separate the hydraulic from the oil tank, and then remove the hydraulic unit mounting plate it&apos;s bolts.
  • Page 45 EPS14 xxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx R930053808 xxxxxx Code Name Information Code Name Information Hydraulic Unit (R Type) Plastic Protection Plug Hydraulic Unit Valve Pump + Screws M8×85 O-Ring Suction Pipe Proportional Valve Coil Suction Filter Coil Coupling...

  • Page 46: Electric Maintenance

    ELECTRIC MAINTENANCE ELECTRIC MAINTENANCE This chapter explains how to maintain the Electric of the truck. SERVICE MANUAL...

  • Page 47: Electric Checking

    EPS14 ELECTRIC CHECKING Warning Disconnect the battery before checking the electric system. Circuit Inspection (1) Check if there any parts loose in the circuit and tighten them if necessary. (2) Check if there are anything abnormal of connectors (for example, burn marks).

  • Page 48: Drive Motor

    ELECTRIC MAINTENANCE DRIVE MOTOR Drive Motor Electromagnetic Brake Replacement Loosen screws and remove the brake, and then move the electromagnetic brake. Drive Motor Removal and Installation Removal (1) Before removal, remove the cover. (2) Remove the tiller head and arm assembly. (3) Disconnect cables(high and low voltage cables).
  • Page 49 EPS14 < 1 > < 2 > < 3 > Code Name Information Code Name Information Drive Motor Hexagon Screw M8×50 Screw M8×25 Screw M8×45 Washer M8 Washer M8 Mounting Block Installation Follow the removal steps in reverse to install the drive motor.

  • Page 50: Main Controller

    ELECTRIC MAINTENANCE MAIN CONTROLLER Main Controller Removal and Installation Removal Remove bolts and then remove the main controller. Code Name Information Controller Panel Assy Hexagon Flange Bolt M8×20 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 main controller.

  • Page 51: Main Controller Program Downloading

    EPS14 MAIN CONTROLLER PROGRAM DOWNLOADING Program Downloading Description Software Name The name of the program downloading software is "ZpCanFlasher". Software Interface Code Name Code Name Menu Bar Information Textbox Status Area Connecting the computer to the truck SM-EPS142016002-EN...

  • Page 52: Program Downloading Procedure

    ELECTRIC MAINTENANCE Code Name Code Name Computer Dataline From Can Box To Diagnostic Interface Can Box With The Dataline Interface Program Downloading Procedure (1) Use the dataline to connect the computer to the truck. (2) Run the software "ZpCanFlasher", click "File" in the menu bar, choose "Load ConfigFlash" to load the file named "adx_ zp002(2560).cfi".

  • Page 53: Parameter Adjustment

    EPS14 PARAMETER ADJUSTMENT Parameter Adjustment Description Software Name The name of the parameter adjustment software is "ZpCanFlasher". Software Interface Code Name Code Name Menu Bar Connection Status Area Shortcut Icon Bar Function Buttons Status Area Connecting the computer to the truck The connection method is the same as the program downloading.
  • Page 54 ELECTRIC MAINTENANCE (6) Click "Store" button to save parameters, and then exit the software. SERVICE MANUAL...

  • Page 55: Critical Fasteners Torque Checking

    EPS14 OTHERS Critical Fasteners Torque Checking Drive Axle and Drive Motor Fasteners Torque Checking Code Name Information Code Name Information 70 N-m + Thread 25 N-m + Thread Hexagon Flange Bolt M10×45 Hexagon Flange Bolt M8×20 Sealant Sealant 30 N-m + Thread Screw M8×25...
  • Page 56 OTHERS < 1 > < 2 > Code Name Information Code Name Information Load Wheel Screw 90 N-m Drive Axle Nut 90 N-m Castor Wheel Nut 110 N-m Mast Fasteners Torque Checking Code Name Information Bolt Assy M14×35 100 N-m Screw M10×40 30 N-m SERVICE MANUAL...
  • Page 57 EPS14 SM-EPS142016002-EN...

  • Page 58: Other Information

    Tel: 045-290-6550; 045-290-6616 Fax: 81-(0)45-319-1506 Importer: BYD Auto Industry Company Limited Address: No.3009, BYD Road, Pingshan, Shenzhen, 518118, P.R.China Tel: +86-755-89888888 Fax: +86-755-84202222 Manufacturer: BYD (SHAOGUAN) CO.,LTD. Address:No.1, BYD Road, Zhenjiang Industrial Zone, Shaoguan, Guangdong, 512040, P.R.China Tel:+86-751-810 8888 SERVICE MANUAL...

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