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BYD PMW20 User Manual

BYD PMW20
104 pages
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SM-PMW202020001-EN
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PMW
20
SERVICE MANUAL

Table of Contents

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BYD PMW20 Specifications

General IconGeneral
Rated Load2000 kg
Load Capacity2000 kg
Standard Lift Height3000 mm
Lift Height3000 mm
Load Centre Distance500 mm
Battery Voltage48 V
Power TypeElectric
Lift Speed (laden/unladen)0.4/0.5 m/s
Lift Speed (loaded/unloaded)0.4/0.5 m/s

Summary

INTRODUCTION

1.1 ENTIRE FORKLIFT

Overview of the forklift's main components and structure.

1.2 ATTACHMENTS

Details about various attachments for the forklift.

CHASSIS

1.3 CHASSIS

Description of the forklift's chassis structure and components.

HYDRAULIC DEVICE

1.4 HYDRAULIC DEVICE

Explanation of the forklift's hydraulic system components.

ELECTRIC DEVICE

1.5 ELECTRIC DEVICE

Details on the electrical system, components, and their functions.

DAILY MAINTENANCE

2.1 TIME AND ITEMS

Specifies inspection schedule and items for daily forklift maintenance.

2.2 DESCRIPTION

Detailed explanation of daily maintenance checks for various forklift parts.

REGULAR MAINTENANCE

3.1 TIME AND ITEMS

Outlines the schedule and items for regular forklift maintenance.

3.2 CATEGORY, DOSAGE AND MODEL OF ACCESSORIES

Lists required accessories, dosages, and models for maintenance.

3.3 DESCRIPTION

Describes tasks for regular maintenance of hydraulic and electric systems.

MAINTAIN ATTACHMENTS

4.1 REMOVE AND INSTALL GUARD

Instructions for removing and installing the forklift guard.

MAINTAIN CHASSIS

5.1 REMOVE AND INSTALL THE OPERATING HANDLE

Steps to remove and install the operating handle assembly.

5.2 REMOVE AND INSTALL THE HANDLE LEVER

Procedure for removing and installing the handle lever.

5.3 REPLACE THE AIR-ACTUATED SPRING

Guide to replacing the air-actuated spring.

5.4 REMOVE AND INSTALL THE STEERING-CONNECTED ASSEMBLY

Instructions for removing and installing the steering assembly.

5.5 REMOVE AND INSTALL DRIVE ASSEMBLY

Steps to remove and install the drive assembly.

5.6 SEPARATE DRIVE MOTOR ASSEMBLY FROM REDUCTION GEARBOX ASSEMBLY

Procedure to separate drive motor from gearbox assembly.

5.7 REPLACE DRIVE WHEELS

Guide to replacing the drive wheels.

5.8 REPLACE BALANCE WHEELS

Steps for replacing balance wheels.

5.9 REPLACE THE BALANCE MECHANISM

Procedure to replace the balance mechanism.

5.10 REMOVE AND INSTALL THE ASSISTING SUPPORT ASSEMBLY

Instructions for removing and installing the assisting support.

5.11 REMOVE AND INSTALL THE ASSISTING SUPPORT ASSEMBLY

Steps to remove and install the assisting support wheel assembly.

5.12 REMOVE AND INSTALL THE LIFT MECHANISM

Procedure for removing and installing the lift mechanism.

5.13 REMOVE AND INSTALL MAIN BEARING OF COMPOUND ROLLERS

Guide to removing and installing main bearing of compound rollers.

MAINTAIN THE HYDRAULIC DEVICE

6.1 WORKING PRINCIPLE OF THE HYDRAULIC SYSTEM

Explains the operational principles of the forklift's hydraulic system.

6.2 PARTS OF THE HYDRAULIC SYSTEM

Identifies and illustrates the main components of the hydraulic system.

6.3 ADD HYDRAULIC OIL

Procedure for adding hydraulic oil to the system.

6.4 REMOVE AND INSTALL THE POWER UNIT

Steps for removing and installing the hydraulic power unit.

6.5 REMOVE AND INSTALL THE POWER UNIT

Instructions for removing and installing the hydraulic power unit assembly.

MAINTAIN ELECTRIC DEVICE

7.1 ELECTRIC CHECK

Procedures for checking the electrical system and components.

7.2 CHECK THE MAIN CONTROLLER

Steps to check the main controller's connections and condition.

7.3 REMOVE THE MAIN CONTROLLER

Guide for removing and replacing the main controller.

7.4 REMOVE THE HORN

Instructions for removing the electric horn.

7.5 REMOVE THE MAIN CONTACTOR

Steps to remove the main contactor.

7.6 REMOVE THE LIMIT SWITCH

Procedure for removing the limit switch.

TROUBLE SHOOTING

Safety and General Guidelines

Important safety warnings and general guidelines for troubleshooting.

Electrical Maintenance Diagnosis

Steps for diagnosing electrical faults using MDI display and error codes.

Error Code Reference

Cross-reference table for display and controller error codes.

Common Error Code Diagnoses

Detailed troubleshooting for common error codes like 02A00, 02A08, 02A09.

PROGRAM AND SOFTWARE

Tools and Software

Lists necessary tools and software for controller programming.

Import Parameters

1.3 Import Parameters

Steps to import controller parameters using software.

ADJUST PARAMETERS

Parameter Descriptions

Description of controller parameters and their adjustment options.

Drive Wheel Adjustment

Procedure for adjusting the drive wheel position.

ACCELERATOR VOLTAGE DIAGNOSIS

2.3 ACQUIRE THE VOLTAGE INFORMATION OF THE ACCELERATOR

Procedure to acquire accelerator voltage for diagnostics.

MONITOR DATA

1. Monitor Menu

How to use the monitor menu to view real-time forklift data.

Export Parameters

2. Export Parameters

Steps to export controller parameters for troubleshooting.

SERIAL PORT BURNING PROCEDURES

1.AC-0 Program Burning

Procedure for burning AC-0 program using serial port.

TABLE OF FAULT CODES

8.7 TABLE OF FAULT CODES

Comprehensive list of fault codes and their remedies.

ELECTRICAL MAINTENANCE DIAGNOSIS

8.1 ELECTRICAL MAINTENANCE DIAGNOSIS

Steps to diagnose electrical faults using MDI display and error codes.

Description of Electrical Component System Control

Power System of the Entire Forklift

Overview of the forklift's electrical power system components and functions.

MAINTAIN TUQUE

9.1 CHECK THE TORQUE OF THE KEY FASTENERS

Instructions for checking and tightening key fasteners to specified torque.

APPENDIX

10.1 TABLE OF THE TORQUE VALUE

Table providing torque values for various bolts.

10.2 ONBOARD TOOL

Lists and illustrates onboard tools included with the forklift.

WIRING HARNESS

10.3.1 LOW-VOLTAGE WIRING HARNESS ASSEMBLY

Details the low-voltage wiring harness connections for the forklift.

ELECTRICAL SCHEMATIC DIAGRAM

1. GB +CAN

Electrical schematic diagram for the GB +CAN system.

CONTROLLER PARAMETERS

Acceleration and Braking Parameters

Parameters controlling acceleration, deceleration, and braking behavior.

Speed and Steering Parameters

Parameters related to speed limits, steering, and turning.

System Configuration Parameters

Parameters for battery, system modes, and auxiliary functions.

OTHER INFORMATION

OTHER INFORMATION

Contact information and addresses for BYD.

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