"Service Manual ECB302016001 for BYD ECB30 and ECB35 Forklifts"

ECB30

ECB35

SERVICE MANUAL < SM-ECB302016001-EN >

This manual is used for authorized personnel to sevice BYD forklifts

TABLE OF CONTENTS

CHECK, INSPECTION AND SERVICE Interval Instruction

9

Daily (or Every 8 Hours) Inspection

10

Weekly (or Every 40 Hours) Inspection

12

Regular Inspection and Service

13

STEERING COLUMN Description

15

Steering Column Removal and Installation

16

Steering Column Overhaul

18

STEERING AXLE Steering Axle Service

21

Steering Axle Wheel Bearing Service

22

Steering Axle Removal and Installation

24

Steering Axle Overhaul

25

Steering Cylinder Removal and Installation

27

Steering Cylinder Overhaul

28

BRAKE SYSTEM Specifications and Description

31

Service Brake Disassembly and Reassembly

32

Parking Brake Disassembly and Reassembly

35

DRIVE AXLE Drive Axle and Motor Assembly Removal and Installation

39

Drive Motor Removal and Installation

40

Gear Oil Replacement

43

Brake Discs Replacement

44

WHEEL AND TIRE General Checks

47

Wheel Removal and Mounting

48

Tire Replacement

49

MAST Chain Adjustment

51

Chain Replacement

53

Lift Cylinder Rod Lubrication, Air-Exhausting and Shimming

56

SERVICE MANUAL

4

ECB30 ECB35

Main Lift Cylinder Removal and Installation

58

Main Lift Cylinder Overhaul

60

Free Lift Cylinder Removal and Installation

63

Free Lift Cylinder Overhaul

64

Mast and Carriage Roller and Clearance Adjustment

66

Mast Removal and Installation

70

Carriage Removal and Installation

71

Carriage and Mast Roller Replacement

72

INTEGRAL SIDESHIFT Descriptions

75

Integral Sideshift Gliding Strip Replacement

76

Integral Sideshift Cylinder Overhaul

78

STEERING CONTROL UNIT Steering Control Unit Removal and Installation

81

HYDRAULIC OIL TANK AND FILTER Hydraulic Oil Tank

83

Return Filter

84

High Pressure Filter

87

HYDRAULIC OIL PUMP Descriptions

91

Removal and Installation

92

MAIN VALVE Manual Main Valve

95

Electric Main Valve

98

TILT CYLINDER Descriptions

101

Tilt Cylinder Unequal Stroke Adjustment

102

Tilt Cylinder Removal and Installation

103

Tilt Cylinder Overhaul

104

MAIN CONTROLLER Main Controller Assembly Removal and Installation

107

Main Controller Assembly Disassembly and Reassembly

108

5

SM-ECB302016001-EN

TABLE OF CONTENTS

MAIN CONTROLLER PROGRAMMING Descriptions

111

Programming

114

SENSOR MONITORING AND ADJUSTMENT Descriptions

117

General Using

118

Accelerator Sensor Monitoring and Adjustment

123

Steering Axle Sensor Monitoring and Adjustment

124

Main Manual Valve Monitoring and Adjustment

125

SERVICE MANUAL

6

ECB30 ECB35

7

SM-ECB302016001-EN

CHECK, INSPECTION AND SERVICE

ECB30 ECB35

Interval Instruction Daily or Weekly Check and Inspection Interval Instruction Intervals for daily or weekly check and inspection interval are as follows: Standard

Interval

Interval Standard 1

1 day

1 week

Interval Standard 2

8 hours

40 hours

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.

If the forklifts work less than 40 hours per week, conduct the following inspection on weekly basis. Otherwise conduct the inspection every 40 hours.

Regular Inspection and Service Interval Instruction To allow the truck to deliver high performance, it is essential to conduct regular inspections and service. Intervals for regular inspections and service are as follows: Standard

Interval

Interval Standard 1

6 weeks

3 months

6 months

12 months

Interval Standard 2

250 hours

500 hours

1000 hours

2000 hours

Conduct the regular inspection and service in accordance with the above mentioned two interval standards, whichever comes first.

For example, if the working hours within a period of 6 weeks have exceeded 250 hours, then use the 250 hours as the interval standard and perform the service service accordingly.

If interval standard two is adopted, use the working hours displayed on the display unit as reference for service.

9

SM-ECB302016001-EN

CHECK, INSPECTION AND SERVICE Daily (or Every 8 Hours) Inspection Daily (or Every 8 Hours) Inspection Checklist Inspection Items

Content

Forklift Exterior

Body

Tires

Wheel nuts and bolts

Working Equipment

Cylinder, hoses, mast, forks

Hydraulic System

Hydraulic oil level, filter indicator

Seat

Seat belt

Multifunction Display

Indicators

Lighting, Horn And Warning Equipments

Lights combination, horn, reverse lights, reverse beeper

Braking System

Braking fluid, handbrake, brake pedal

Driving System And Controlling System

Steering wheel, mechanical levers

Counterweight

Counterweight bolts and the tow pin

Others

Others

Note 1.

These inspections should be conducted before operating the forklift.

2.

Before conducting the daily inspection, recheck for any fault and error found earlier.

Forklift Exterior 1.

Check the forklift truck body for damage and deformation.

2.

Check the floor where the forklift is parked for oil leakage.

Note If oil leakage occurs, confirm the location of the oil leakage and contact the BYD after sales service.

Tires 1.

Check on a daily basis (every 8 hours) if the wheel nuts are secured or loose. Fasten them if they are loose.

2.

Take out debris embedded in the tire.

3.

If the four tires are unevenly worn, or the tires are found damaged, or the rims are bent, then replace the tires.

Working Equipment 1.

Check the cylinders, oil pipes, and hoses for oil leakage.

2.

Check the working equipment for deformation and damage. check if the bolts are securely fastened.

Note If oil leakage occurs, confirm the location of oil leakage and contact the BYD after sales service.

Hydraulic System 1.

Check the hydraulic oil level in the oil tank.

2.

Check the state of the filter indicator.

Seat The seat belt provides protection to the operator. Regular inspection can ensure its correct working in case of an emergency.

1.

Pull the seat belt fully out and check for fraying.

2.

Check the locking device (belt buckle) of the seat belt, and check if the retractor functions properly.

3.

Check if the seat can be adjusted forward and backward, and if the back rest angle and seat suspension can be adjusted.

SERVICE MANUAL

10

ECB30 ECB35 DANGER In the case of seat belt failure, stop operating the forklift and replace the seat belt.

Multifunction display 1.

Check if the battery voltage and status of charger displayed are correct.

2.

Check if any error/fault indicator appears on the instrument panel.

3.

Set the direction control switch to “forward”, “neutral” and “reverse” and check if corresponding gear indicator appears.

4.

Check if the turning indicator signs appear when the turning indicator is activated.

5.

Check if the 3 control buttons on the instrument panel functions properly.

Lights, Horn and Other Warning Equipment 1.

Check if working lights work properly.

2.

Check if turning indicators work properly.

3.

Set the travel direction control switch to “Reverse” and check if reversing lights work and reversing beeper sounds.

4.

Press horn to see if it works.

5.

Check if other warning equipments work properly.

Braking System 1.

Fully depress and then release the braking pedal and check if there is any abnormality.

2.

heck if the parking brake works properly when it is applied. Check the operating force needed to fully apply the parking brake C by using an ergometer. Check for abnormal wear on the parking brake.

3.

heck the braking fluid level and see if it reaches 2/3 of the braking fluid cup. Add braking fluid if it does not reach 2/3 of the C braking fluid cup.

Driving System and Controlling System 1.

Turn the steering wheel clockwise and anti-clockwise and check if the steering is smooth.

2.

Operate the mechanical levers and check if lifting and tilting are smooth.

3.

Depress the acceleration pedal to see if the forklift can accelerate normally.

4.

Check for abnormal sounds during forklift operation.

Counterweight 1.

Check the counterweight bolts.

2.

Check the tow pin.

Others Check if there are others problems.

11

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CHECK, INSPECTION AND SERVICE Weekly (or Every 40 Hours) Inspection Weekly (or Every 40 Hours) Inspection Checklist Inspection Items

Content

Electric System Inspection

Connector, fuses, connect bars, Relays

Tires

Wheel, fasten parts

Braking System

Braking fluid, handbrake, brake pedal

Electric System Inspection 1.

Check connectors.

2.

check fuses and connect bars of the main controller.

3.

check fuses and relays in the fuses box.

WARNING Disconnect the battery before checking the electric system.

Tires 1.

Check on a daily basis (every 8 hours) if the wheel nuts are secured or loose. Fasten them if they are loose.

2.

Take out debris embedded in the tire.

3.

If the four tires are unevenly worn, or the tires are found damaged, or the rims are bent, then replace the tires.

Braking System 1.

Fully depress and then release the braking pedal and check if there is any abnormality.

2.

heck if the parking brake works properly when it is applied. Check the operating force needed to fully apply the parking brake C by using an ergometer. Check for abnormal wear on the parking brake.

3.

heck the braking fluid level and see if it reaches 2/3 of the braking fluid cup. Add braking fluid if it does not reach 2/3 of the C braking fluid cup.

SERVICE MANUAL

12

ECB30 ECB35

Regular Inspection and Service Regular Inspection and Service Checklist Interval

6 weeks

3

6

12

months

250

500

1000

2000

hours

Chains Adjustment

Check

Chains Lubrication

Lubrication

Mast Channel Cleaning And Adjustment

Check

Electric System

Check

Braking Oil

Replacement

Return Filter Element

1st replacement 2nd replacement

High Pressure Filter Element

1st replacement 2nd replacement

Return Filter's Air Filter

Replacement

Hydraulic Oil

Replacement

Tilt Rotating Pin Lubrication

Lubrication

Gear Oil (Dual Drive)

Replacement

Steering Axle

Lubrication

Torque On Critical Fasteners

Check

Type and Parameters of Oil and Grease Item

Needed

Volume Needed

Type

Drive Axle (Dual Drive)

Gear Oil

(1.2~1.3 L)×2

Mobilfluid 424

Hydraulic oil

Hydraulic Oil

53 L

ISO VG46, ISO VG68

Braking System

Brake Fluid

As Needed

DOT4

Tilt Rotating Pin Lubrication

Lithium lubrication grease

As Needed

EP2

Steering Axle

Lithium lubrication grease

As Needed

EP3

Chian

Machine Oil

As Needed

20#(Winter);40#(Other Seasons)

13

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STEERING COLUMN

ECB30 ECB35

Description Explosive View

11

12

13

12

14

15

CODE

PART NAME

QTY

11

STEERING WHEEL

1

12

SWITCH ASSY (BASIC)

1

12

SWITCH ASSY (COMFORT)

1

13

FRONT STEERING COLUMN COVER

1

14

REAR STEERING COLUMN COVER

1

15

STEERING SHAFT ASSEMBLY

1

INFORMATION

CODE

PART NAME

QTY

INFORMATION

Descriptions The switch assy (basic or comfort) is fixed between the steering shaft assembly and the steering wheel.

Connected to the bottom of the steering shaft assembly, the steering control unit is operated by the steering wheel, which is supplied with oil pressure from the main hydraulic pump and directs oil flow to the steering cylinder in the steering axle.

The cover and the entire column can be removed for service or replacement.

15

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STEERING COLUMN Steering Column Removal and Installation Cover, Steering Wheel and Switch Assembly Removal 1.

oosen 4 screws15 in the Rear Steering Column Cover12 and remove them. Loosen 4 Bolts14 to remove the Front Steering L Column Cover11 (4 clip nuts don’t need to be removed).

2.

Open the cover of the steering wheel17, loosen the nut16, and remove them.

3.

Loosen 4 screws18 to remove the switch assembly19. <1>

<2>

16

11

13 13

17

13 13 14 12

14

14

<3>

14

18 15

18 19

15

18

15 15

CODE

PART NAME

QTY

11

FRONT STEERING COLUMN COVER

1

12

REAR STEERING COLUMN COVER

13

18

INFORMATION

CODE

PART NAME

QTY

17

STEERING WHEEL

1

1

18

SCREW M5×14

4

CLIP NUT M6

4

19

SWITCH ASSY (BASIC)

1

14

BOLT M6×30

4

15

SCREW M6×20

4

16

HEXAGON FLANGE NUT M12

1

SERVICE MANUAL

16

INFORMATION

ECB30 ECB35 Steering Column Removal 1.

Lossen nuts14 on the steering column.

2.

Lossen the insert nut15.

3.

Remove them.

12

<1>

<2>

11

11 13 14

15

11 12 13 11

14

<3>

CODE

PART NAME

QTY

11

FLAT WASHER

4

12

FLAT ROUND BOLT

2

13

SPRING WASHER

2

14

FLAT NUT

2

15

INSERT NUT

1

INFORMATION

CODE

PART NAME

QTY

INFORMATION

Steering Column, Cover, Steering Wheel and Switch Assembly Installation Follow the steps in reverse to install Steering Column, Cover, Steering Wheel and Switch Assembly.

17

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STEERING COLUMN Steering Column Overhaul Explosive View 89

81

96

95

96

13

96 22

95 83 82 23

17

84

28

27

16

26

97

24

16 84

84

12

25

84

16 15

23

28

27

15

26

97

19 18

85 98 87

21 88

PART NAME

83

94

14

CODE

15

<A>

16

85 98

15

86

<A>

87 93

85 98 85 98

91

90 92 11

90 90

QTY

INFORMATION

CODE

PART NAME

92 QTY

11

STEERING BRACKET

1

83

CIRCLIP

2

12

CARDAN SHAFT ASSY

1

84

HEXAGON FLANGE BOLT M10×16

4

13

TOP FLANGE

1

85

SCREW M10×35

4

14

BOTTOM FLANGE

1

86

BOLT M8×35

2

15

INSERT

4

87

SPRING WASHER M8

2

16

RUBBER

4

88

CIRCLIP

1

17

SUPPORT PLATE

1

89

CIRCLIP

1

18

WASHER

1

90

FLAT WASHER

4

19

INNER SHAFT

1

91

FLAT ROUND BOLT

2

21

WASHER

1

92

SPRING WASHER

2

22

SUPPORT PLATE

1

93

FLAT NUT

2

23

JOINT

2

94

BALL BEARING

1

24

SPLINE ROD

1

95

BALL BEARING

2

25

SPLINE COLUMN

1

96

SCREW M4.8×19

3

26

PIN

2

97

SCREW M4×25

2

27

HOLLOW PIN

2

98

SPRING WASHER M10

4

28

SLOTTED PIN

2

81

HEXAGON FLANGE NUT M12

1

82

BALL BEARING

1

SERVICE MANUAL

18

91

90

86

93

INFORMATION

ECB30 ECB35 Steering Column Disassembly and Reassembly Use the picture of the explosive view as the guide to disassemble and reassemble the steering column.

19

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STEERING AXLE

ECB30 ECB35

Steering Axle Service Descriptions The steering axle has the steering cylinder, knuckles, and links mounted on it. All these components can be removed, serviced, and replaced.

The steering control unit at the base of the steering column directs hydraulic oil to one end or the other of the steer cylinder to pivot the steer wheels.

The steer axle is bolted to the truck frame. The steer cylinder is connected to the steering knuckles by links.

All bearings used in the steer axle linkage have lubrication fittings and are serviceable.

21

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STEERING AXLE Steering Axle Wheel Bearing Service Bearing Disassembly 1.

Remove the Wheel.

2.

Open the dust cap11, remove the split pin12, the castle nut13 and washer14.

3.

ull off the hub16 from the knuckle. Support the wheel or hub to avoid dragging the grease seal at the back side across the P thread on spindle end.

4.

Clean the old grease out of center of the wheel or hub.

5.

Lay the hub down with outer edge up (support hub on blocking), and then remove the inner bearing cone 17 and grease seal18.

6.

Clean and inspect the bearing cups and cones for wear or other damage. Replace them as a set if necessary.

7.

I nspect grease seal for wear and damage. Replace as necessary. It is recommended to install a new grease seal whenever old ones are removed.

8.

Use a standard puller to remove bearing cups from hub or wheel if bearings require replacement.

16

18 17

15 14

11

CODE

PART NAME

12

13

QTY

INFORMATION

CODE

PART NAME

QTY

11

DUST CAP

1

17

TAPERED BEARING

1

12

SPLIT PIN

1

18

OIL SEAL

1

13

CASTLE NUT

1

14

WASHER M30

1

15

TAPERED BEARING

1

16

HUB

1

SERVICE MANUAL

22

INFORMATION

ECB30 ECB35 Bearing Reassembly 1.

ress new bearing cups19, 21 into the hub16 and ensure cups being seated correctly.Pack the bearings with grease and install the P inner bearing20.Pack cavity between bearing20 and seal18 half full with grease.Apply coating of grease to inside diameter of seal lips prior to assembly, then install seal in hub.

2.

I nstall the hub on knuckle carefully to avoid damage grease seal lip when moving the hub over the end of spindle and threads.

Pack cavity in hub between bearings one-half full with grease.Install the outer wheel bearing22 after it has been packed with grease, and then install the washer14.

3.

I nstall the castle nut13, tighten it, and then unscrew it by 1/8~1/6 turn. Recheck for correct bearing adjustment by rotating the hub by hand. The hub should rotate free. Readjust bearings by adjusting the castle nut as necessary to avoid binding in bearings.

4.

Install the split pin12, pack the area around castle nut with grease, and then Install the dust cap11. <1>

<2>

18

16

22

20

14

19 21

<4>

<3>

12

13 11

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

11

DUST CAP

1

19

BEARING CUP

1

12

SPLIT PIN

1

20

INNER BEARING

1

13

CASTLE NUT

1

21

BEARING CUP

1

14

WASHER M30

1

22

INNER BEARING

1

16

HUB

1

18

SEAL

1

23

INFORMATION

SM-ECB302016001-EN

STEERING AXLE Steering Axle Removal and Installation Removal 1.

Disconnect the connectors11, and loosen and remove hydraulic steering lines13 and fittings12 .

2.

Lossen bolts20 to remove the steering axle. <1>

<2>

16

11 13

12

14

13

15 12

15 14 17

16

18

19

19 19 20 20

19

20

CODE

PART NAME

QTY

INFORMATION

20

CODE

PART NAME

QTY

11

CONNECTOR

1

17

MOUNTING BLOCK (FRONT)

1

12

FITTING

2

18

MOUNTING BLOCK (REAR)

1

13

STEERING HOSE

2

19

SPRING WASHER M16

4

14

BUSHING

2

20

BOLT M16×70

4

15

SHIM

4

16

GREASE NIPPLE M6

2

Installation Follow the steps in reverse to install the steering axle.

SERVICE MANUAL

24

INFORMATION

220 N-m

ECB30 ECB35

Steering Axle Overhaul Explosive View

81

81

13

13 11

12 10 14 15 15

15 15 14

<A> 87

25

94

88 18

23

17

89

83

22

21

96

77

90

95

19

91

20

96

94

96 97 96 97

98

97

97

86 84

31

85

98 80 98 78 79 78

24 29

98

99

31

28

99

95 77

86 84

27 27

87 94

83

<B>

80

85

30 16

27

91

87

<A> 80 78 79

95 77

90

80 88

82

18

82 17 26

25

20

21

30

28

78

19

89

27

94

82

82

22

<B>

SM-ECB302016001-EN

STEERING AXLE CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

11

BRAKE PEDAL BRACKET

1

89

SPRING WASHER

3

12

ROTATING SHAFT

1

90

SPRING WASHER M8

2

13

PEDAL

1

91

WASHER

1

14

INSERT BUSHING

2

15

BUSHING

1

16

LINK

1

17

YOKE

1

18

RUBBER PAD

1

19

SPRING

1

30

SWITCH

2

31

MASTER BRAKE CYLINDER

1

81

NUT M8

1

82

BOLT M6×12

1

83

PIN

1

84

SPLIT PIN

1

85

HEXAGON SCREW M6×45

1

86

FLAT NUT M6

1

87

BOLT M8×20

2

88

BOLT M12×30

3

Disassembly and Reassembly Use the picture of the explosive view as the guide to disassemble and reassemble.

SERVICE MANUAL

26

INFORMATION

ECB30 ECB35

Steering Cylinder Removal and Installation Removal 1.

loosen and remove hydraulic steering lines13 and fittings12.

2.

Remove pins14, tie-rod15, circlip16 to disconnect the steering cylinder and the axle.

3.

Loosen steering cylinder mounting bolts17 to remove the steering cylinder. <1> 13

12

13 12

<2>

<3>

17 14

18

19

14 15 16 16

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

12

FITTING

2

18

SPRING WASHER M14

4

13

STEERING HOSE

2

19

WASHER M14

4

14

PIN

2

15

TIE-ROD

1

16

CIRCLIP

2

17

BOLT M14×40

4

INFORMATION

130 N-m

Installation Follow the steps in reverse to install the steering cylinder. And thread sealant is needed before screwing steering cylinder mounting bolts17.

27

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STEERING AXLE Steering Cylinder Overhaul Explosive View

10

10

12 20 11

16

15

14

13 24

17

22

18

15 17 24

25

27

11 25

26

23

21 18

26

17 16

22 13 17

19

11

14

15

12

15 11

CODE

PART NAME

QTY

10

STEERING CYLINDER

1

11

DUST WIPER

2

12

GLAND

2

13

WASHER

2

14

RETAINER RING

2

15

SEAL

2

16

BUSHING

2

17

O-RING

2

18

BUSHING

2

19

STEERING CYLINDER BARREL

1

20

CYLINDER SEAL KIT

1

21

STEEL BALL

25

22

BACK-UP RING

1

23

PISTON

1

24

BACK-UP RING

1

25

O-RING

1

26

O-RING

1

27

PISTON ROD

1

SERVICE MANUAL

INFORMATION

CODE

28

PART NAME

QTY

INFORMATION

ECB30 ECB35 Disassembly Ensure that correct parts and tools are available before the service.

Follow the procedure below to disassemble the steering axle: 1.

Carefully clamp the steering cylinder10 in a vise and do not tighten.

2.

Unscrew one gland, for example, the left gland12.

3.

Remove the rod27 and the piston23 with other parts on them.

4.

Unscrew the other gland12.

5.

Remove all seals, O-rings, support rings, and dust wipers.

Reassembly 1.

Install all seals, O-rings, support rings, and dust wipers as a set.

2.

Lubricate the mating surface of the rod, piston, and glands with the hydraulic oil.

3.

Install one gland, and then carefully install the rod and piston assembly.

4.

Category install the other gland.

29

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BRAKE SYSTEM

ECB30 ECB35

Specifications and Description Specifications 1.

Service Brake

Type: Wet disc brake Brake Oil: DOT4 2.

Parking Brake

Type: Hand brake linked to service brake at each wheel Holding Test: Rated load on 15% grade

Description 1.

General Description

The brake pedal operates the master cylinder, which delivery the brake oil to the service brake.

Parking brake cables are linked to the levers of the service brake to operate them.

2.

Operation

Step on the brake pedal to operate the master cylinder, which operates the wheel cylinder, and then the wheel cylinder push the shoe linings to be contacted on drum.

Pull the hand brake, the lever connected to the tension cable push the service cylinder at each brake assembly.

To operate the forklift, press down the button on the hand brake to release it, and then fully push it forward, it will operates the parking brake indicator switch.

3.

Service Requirements

Check linkage, brake lining, and brake lines.

The leaking master cylinder or leaking tubes cylinder should be replaced.

The broken cables of hand brake should be replaced.

31

SM-ECB302016001-EN

BRAKE SYSTEM Service Brake Disassembly and Reassembly Service Brake Explosive View <A>

88

18

88

89 88

89 89 13

19

16

11

83

81

15 17

14

91 84

31 86

90 90

14

85

87 <A> 87

30

12

30

82

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

11

BRAKE PEDAL BRACKET

1

89

SPRING WASHER

3

12

ROTATING SHAFT

1

90

SPRING WASHER M8

2

13

PEDAL

1

91

WASHER

1

14

INSERT BUSHING

2

15

BUSHING

1

16

LINK

1

17

YOKE

1

18

RUBBER PAD

1

19

SPRING

1

30

SWITCH

2

31

MASTER BRAKE CYLINDER

1

81

NUT M8

1

82

BOLT M6×12

1

83

PIN

1

84

SPLIT PIN

1

85

HEXAGON SCREW M6×45

1

86

FLAT NUT M6

1

87

BOLT M8×20

2

88

BOLT M12×30

3

SERVICE MANUAL

32

INFORMATION

ECB30 ECB35 Service Brake Disassembly Use the picture of the explosive view as the guide to disassemble.

Service Brake Reassembly 1.

Reassembly

Use the picture of the service brake explosive view as the guide to reassemble the service brake. Adjust the service brake pedal, switches and the master cylinder when reassembling.

2.

Service Brake Pedal, Switches and Master Cylinder Adjustment (1) Intall the brake pedal at the initial position where the angle between the switch contact surface and the horizontal plane is 90°, and then use the 85_screw and 86_nut to restrict the pedal.

(2) Install switches and make them be triggered by the pedal at the initial position.

(3) Install the spring to hold the pedal.

(4) Install the master cylinder, 16_link, 81_nut and 17_yoke, use 81_nut to adjust 16_link to just contact the master cylinder and the master isn't triggered. <1>

<2>

86

90°

85

<4>

<3>

16 81 17

33

SM-ECB302016001-EN

BRAKE SYSTEM Braking System Bleeding Run the forklift until the driving axle gets lightly heated. Park the forklift on a level floor, apply the hand brake, switch off the forklift, remove the key and press down the emergency disconnect switch.

(1) Add brake oil into the brake oil reservoir.

(2) Clean the surrounding area around the braking oil drain plug, connect it to a container. Loosen the braking oil drain plug.

(3) Press the service brake pedal.

(4) Repeat the action of adding the brake oil and press the pedal until there aren't any bubbles in the container. Tighten the drain oil plug(Torque: 20N-m) and add braking oil to 2/3 of the braking reservoir.

SERVICE MANUAL

<1>

<2>

<3>

<4>

34

ECB30 ECB35

Parking Brake Disassembly and Reassembly Parking Brake Explosive View

29

18 19

19

84

83 81 83 81

85

24

85

24

10

12

13

17 14

82 11

82

82

15

16

CODE

PART NAME

QTY

10

HAND BRAKE LEVER

1

11

HAND BRAKE CABLE (LH)

1

12

HAND BRAKE CABLE(RH)

1

13

LOOM PROTECTION

1

14

CONNECTION BLOCK

1

15

SUPPORT BLOCK UPPER

1

16

SUPPORT BLOCK LOWER

1

17

CLAMP

1

18

SWITCH

1

19

SCREW M3×16

2

24

BUSHING

2

29

SUPPORT

1

81

CASTLE NUT M8

2

82

SCREW M6×16

3

83

SPLIT PIN

2

84

NUT M6

1

85

HEXAGON SCREW M8×55

2

INFORMATION

CODE

35

PART NAME

QTY

INFORMATION

SM-ECB302016001-EN

BRAKE SYSTEM Parking Brake Disassembly Use the picture of the explosive view as the guide to disassemble the parking brake.

Parking Brake Reassembly 1.

Parking Brake Reassembly Preparation

Grease the clearance between the in inner wire and the outer wire cover to reduce wear.

2.

Initial Reassembly

Use the picture of the explosive view as the guide to reassemble. Don't tighten all nuts and don't install 15_support block upper and 16_support block upper.

3.

Parking Brake Switch Assembly and Adjustment (1) Push the hand lever forward fully.

(2) Rotate the switch support to find the position where the switch is just triggered by the hand lever, and then tighten the upper castle nut. Ensure not tightening the lower castle nut.

(3) install split pins.

>>>

SERVICE MANUAL

36

ECB30 ECB35 4.

Parking Brake Return Force Adjustment

Pull the hand lever fully backward and then release it to feel the return force. Adjust the return force to feel well.

(1) Install the cable on the support, and make the lower nut close to lower end of the thread rod.

(2) Move the upper nut to adjust the position of the thread rod. If the thread rod move upward, the cable will be loose and the return force will be reduced. If the thread rod move downward, the cable will be tight and the return force will be increased.

5.

Eliminate Vacant Path (1) Loose nuts of the longer cable on both sides of the connection block.

(2) Hold the connection block and pull the longer cable.

(3) Tighten the nut. <1>

<2>

<3>

5.Final Reassembly (1) Install 15_support block upper and 16_support block upper.

(2) Use the picture of the explosive view as the guide to tighten all nuts and screws except the lower castle nut of the hand lever.

37

SM-ECB302016001-EN

DRIVE AXLE

ECB30 ECB35

Drive Axle and Motor Assembly Removal and Installation Removal and Installation 1.

Remove Wheels.

2.

Remove lever on the drive axle.

3.

Use the picture as the guide to remove or install the drive axle and motor assembly.

1

2

CODE

PART NAME

QTY

INFORMATION

1

HEXAGON SCREW M16×65

2

165 N-m

2

HEXAGON SCREW M16×95

6

165 N-m

CODE

39

PART NAME

QTY

INFORMATION

SM-ECB302016001-EN

DRIVE AXLE Drive Motor Removal and Installation Drive Motor Removal Use the picture as the guide to remove or install the drive axle and motor assembly.

1_Drive Axle and Motor Mounting Bolt (Torque: 50N-m) 2_Drive Axle and Motor Mounting Bolt (Torque: 50N-m)

1 2 2 2

1

SERVICE MANUAL

40

ECB30 ECB35 Drive Motor Installation 1.

Installation Waring

The drive axle must match with the motor by sliding axially and avoiding to connect it sideways. <1>

2.

<2>

Reassembly Preparation (1) Grease the splined shafts on motor and on the drive axle using hydro repulsive grease.

(2) Insert 3 studs M10 suitably long in the housings of the fixing screws on motors as guides.

>>>

1

41

SM-ECB302016001-EN

DRIVE AXLE 3.

Installation Procedure (1) Secure the motor and lift it up to match the axe of engine with the input shaft of the drive axle. Bringing the parties and match them.

(2) Insert in the empty housings the two side screws and tighten them.

(3) Remove the upper stud and replace them with the appropriate screw and tighten them.

(4) After installation, recheck if the screws are tightened. <1>

<2>

>

>>

>

>>

<4>

<3>

>

>> >

>>

>

>>

SERVICE MANUAL

>>

>

42

>>

>

ECB30 ECB35

Gear Oil Replacement Gear Oil Replacement Procedure Run the forklift until the gear box gets lightly heated. Park the forklift on a level floor, apply the hand brake, switch off the forklift, remove the key and press down the emergency disconnect switch.Lift the forklift with jack and secure the wheels with wedges.Remove the wheels.

1.

lean the surrounding areas around the oil drain plug13, oil filler plug11 and oil dipstick plug12. Place a container below the oil C drain plug13.

2.

Remove oil drain plug13, oil filler plug11 and oil dipstick plug12 and drain all the gear oil.

3.

Put the oil drain plug13 back on and tighten it.

4.

Add the gear oil through oil filler hole until the gear oil overflows out of oil dipstick plug12.

5.

Tighten both oil dipstick plug12 and oil filler plug11.

6.

Refit the wheel and replace the gear oil in the gear box on the other side.

12 11

12

CODE

PART NAME

13

QTY

INFORMATION

CODE

11

OIL FILLER PLUG

1

20 N-m

13

12

OIL DIPSTICK PLUG

1

20 N-m

43

PART NAME OIL DRAIN PLUG

QTY

INFORMATION

1

20 N-m

SM-ECB302016001-EN

DRIVE AXLE Brake Discs Replacement Brake Discs Removal 1.

Unscrew the brake oil plugs64 and drain the brake oil off, at least in part, and then screw and tighten them.

2.

Loosen screws63 to remove the brake cartridge cover65. Check the seal66, replace it if necessary.

3.

Remove circlips70 to remove the pusher74, discs75,76,77 and other parts. <1>

<2>

66 64

65

64 64

64

63

<3>

48 81 81 81 48

81

79 78 77 76

78

78

78

83

82 70

83

CODE

PART NAME

QTY

INFORMATION

82

70

75

CODE

74

PART NAME

QTY

48

LOCATION PIN

2

77

STEEL DISK

7

63

SCREW M8×35

8

78

SPRING

24

64

SCREW PLUG

4

79

SUPPORT DISK

1

65

BRAKE CARTRIDGE COVER

1

80

RETAINER RING

2

66

SEAL

1

81

LOCKING PIN

4

74

ELASTIC DISC

1

82

SPRING

2

75

DISK PUSHER

1

83

STUD

2

76

FRICTION DISK

6

INFORMATION

Parts Inspection Inspect all parts removed from the drive axle and replace them if necessary. The friction discs should be replaced as a set.

SERVICE MANUAL

44

ECB30 ECB35 New Brake Discs Installation 1.

Ensure 2 location pins38 are installed, and then insert the reaction disc79.

2.

nsure 4 locking pins81 are installed, insert a steel disc77, 4 elastic spacer78 on each locking pin81, and the friction disc76. Repeat E this step for 5 times and insert the final steel disc.

3.

I nsert springs in the studs83, and then insert the disc pusher device(the disk pusher65 and the elastic disc64) onto the studs83.

Press down all and place circlips70 into the seat on the studs83.

4.

laced the seal66 on the flange contact surface. Insert the brake cartridge cover65, centre on the location pins38 and on the P brake locking pins81, using a rubber hammer to finetune it until it's completely inserted, and then insert and tighten mounting screws63. <1>

<2>

81 81 81 48

81

78 77 78

79

76 78

78

48

<4>

<3>

81 48

81

81 66 65

83

83

70 82

74 70

CODE

PART NAME

81 48

82

QTY

48

LOCATION PIN

2

63

SCREW M8×35

65

63

75

INFORMATION

CODE

PART NAME

QTY

78

SPRING

24

8

79

SUPPORT DISK

1

BRAKE CARTRIDGE COVER

1

80

RETAINER RING

2

66

SEAL

1

81

LOCKING PIN

4

74

ELASTIC DISC

1

82

SPRING

2

75

DISK PUSHER

1

83

STUD

2

76

FRICTION DISK

6

77

STEEL DISK

7

45

INFORMATION

SM-ECB302016001-EN

WHEEL AND TIRE

ECB30 ECB35

General Checks Appearance Check Check the condition of wheels and tires. Remove things imbedded in tires.

47

SM-ECB302016001-EN

WHEEL AND TIRE Wheel Removal and Mounting Front Wheel Removal and Mounting 1.

ark the forklift on the level floor, apply the handbrake, switch off the forklift, remove the key and press down the emergency P disconnect switch.

2.

Jack up the forklift until the tires are off the ground and loosen the wheel nuts.

3.

Remove the wheel nuts and wheels.

4.

Follow the reverse procedures to install the wheels back on(Torque: 200 N-m).

1

Front Wheel Removal and Mounting 1.

ark the forklift on the level floor, apply the handbrake, switch off the forklift, remove the key and press down the emergency P disconnect switch.

2.

Jack up the forklift until the tires are off the ground and loosen the wheel nuts.

3.

Remove the wheel nuts and wheels.

4.

Follow the reverse procedures to install the wheels back on(Torque: 160 N*m).

SERVICE MANUAL

48

ECB30 ECB35

Tire Replacement For this king of wheel, the tire will be damaged when pulled out the rim, so the tire can only be removed and replaced by machine.

49

SM-ECB302016001-EN

MAST

ECB30 ECB35

Chain Adjustment 2-Stage Standard Mast Chian Adjustment The 2-stage standard mast has a main lift chain set that is needed to be adjusted. See the adjustment form below: No.

Chian

Adjustment Purpose

Requirement

1

Main lift chain

Fork-to-ground clearance

10~20 mm

Fork-to-ground clearance adjustment: 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

Loosen the upper nut11 (that some masts have) and the lower nut13.

3.

Screw the middle nut12 to adjust the chain until it meet the requirement.

4.

Tighten the upper and lower nuts.

11 12 13

CODE

PART NAME

QTY

11

NUT

1

12

NUT

1

13

NUT

1

INFORMATION

CODE

PART NAME

QTY

INFORMATION

130 N-m

3-Stage Free Lift Mast (4 Cylinders) Chain Adjustment The 3-stage free list mast (4 cylinders) has a main lift chain set and a free lift chain set that are needed to be adjusted.

No.

Chian

Adjustment Purpose

Requirement

1

Main lift chain

Inner mast bottom height

≤ 2 mm

2

Free lift chian

Fork-to-ground clearance

10~20 mm

51

SM-ECB302016001-EN

MAST Inner mast bottom height adjustment: 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

Loosen the upper nut11 (that some masts have) and the lower nut13.

3.

Screw the middle nut12 to adjust the chain until it meet the requirement.

4.

Tighten the upper and lower nuts.

11 12 13

CODE

PART NAME

QTY

11

NUT

1

12

NUT

1

13

NUT

1

INFORMATION

CODE

PART NAME

QTY

INFORMATION

PART NAME

QTY

INFORMATION

130 N-m

Fork-to-ground clearance adjustment: 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

Loosen the upper nut11 (that some masts have) and the lower nut13.

3.

Screw the middle nut12 to adjust the chain until it meet the requirement.

4.

Tighten the upper and lower nuts.

11 12 13

CODE

PART NAME

QTY

11

NUT

1

12

NUT

1

13

NUT

1

SERVICE MANUAL

INFORMATION

CODE

130 N-m

52

ECB30 ECB35

Chain Replacement 2-Stage Standard Mast Chain Replacement Lift chain explosive view:

10

<A>

<A> 12 82 83

82 12 83

83 83

83 83

<A>

19

81

19 81

86

85

14 11 85

86

CODE

PART NAME

QTY

CODE

INFORMATION

PART NAME

13

QTY

81

SPLIT PIN

2

2

82

CIRCLIP

2

CHAIN SHEAVE

2

83

CHAIN NUT M20

6

13

ANCHOR

2

85

SPLIT PIN

4

14

LONG ANCHOR

2

86

PIN

4

19

WASHER

2

10

MAIN CHAIN ASSY

1

11

CHAIN

12

INFORMATION

Main lift chain replacement replacement procedure: 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

se a reliable hoisting strap to the hang the upper beam of the carriage, and secure the strap with a safety hook. Slowly lift the U carriage to make chains slack, and then block it.

3.

Remove the split pin85 and the pin86 on the outer mast side and pull the chain off from the sheave.

4.

Remove the split pin85 and the pin86 on the other side.

5.

Follow the steps in reverse to replace chains as a set, and adjust the chian after replacement.

53

SM-ECB302016001-EN

MAST 3-Stage Free Lift Mast (4 Cylinders) Lift chain explosive view: <A>

89 18

89

16 13

88 15

86

<A>

11

16

81 <B>

22

90 83

11

21 14

81

88

86

82

<B> 10

23 12 84

<B>

20 20

88 88 87

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

10

MAIN CHAIN ASSY SET

1

86

PIN

4

11

CHAIN SHEAVE

2

87

PIN

4

12

WASHER

2

88

SPLIT PIN

8

13

CHAIN SHEAVE

2

89

HEXAGON SCREW M6×12

4

14

SUPPORT

2

90

BOLT ASSY M12×40

2

15

PIN

2

16

RING

4

17

SHORT ANCHOR

2

18

PROTECTION

2

19

CHAIN

2

20

FREE LIFT CHAIN

2

21

CHAIN

2

22

ANCHOR

2

23

ANCHOR

2

24

LONG ANCHOR

2

81

CIRCLIP

2

82

CHAIN NUT M20

18

83

CIRCLIP

2

84

SPLIT PIN

2

SERVICE MANUAL

24

82

82

CODE

17

87

54

INFORMATION

ECB30 ECB35 Main lift chain replacement replacement: 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

se a reliable hoisting strap to the hang the upper beam of the carriage, and secure the strap with a safety hook. Slowly lift the U carriage to make chains slack, and then block it.

3.

Remove the split pin88 and the pin87 on the outer mast side and pull the chain off from the sheave.

4.

Remove the split pin88 and the pin87 on the other side.

5.

Follow the steps in reverse to replace chains as a set.

6.

Adjust the chian after replacement.

Free lift chain replacement replacement: 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

se a reliable hoisting strap to the hang the upper beam of the carriage, and secure the strap with a safety hook. Slowly lift the U carriage to make chains and attachment hoses slack, and then block it.

3.

Move attachment hoses away from chains.

4.

Remove the split pin88 and the pin86 on the inner mast side and pull the chain off from the sheave.

5.

Remove the split pin88 and the pin86 on the other side.

6.

Follow the steps in reverse to replace chains as a set, move attachment hoses back.

7.

Adjust the chian after replacement.

55

SM-ECB302016001-EN

MAST Lift Cylinder Rod Lubrication, Air-Exhausting and Shimming Cylinder Rod Lubrication 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

Remove the screw and washer on the top side of the cylinder.

3.

Add some hydraulic oil into the cylinder tube through the upper hole to lubricate the cylinder rod.

4.

After lubrication, exhaust the air in the lift cylinder, and then fasten the screw.

Lift Cylinder Air-Exhausting 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

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.

4.

Install the washer and the screw, and then tighten the screw.

SERVICE MANUAL

56

ECB30 ECB35 Lift Cylinder Shimming 1.

Lift the mast to find the cylinder rod top of the shorter stroke.

2.

Tilt the mast to be on the vertical position, and then fully lower the mast.

3.

se a reliable hoisting strap to the hang the upper beam of the inner mast(2-stage mast) or the middle mast(3-stage mast), U and secure the strap with a safety hook.

4.

Remove the piston rod bolt82.

5.

Slowly lift the hoisting strap to expose both cylinder rod tops.

6.

Insert several shims14,15 over the cylinder rod top of the shorter stroke to achieve equal stroke length.

7.

Slowly lower the inner (or middle) mast back onto the rod tops, and then screw and tighten cylinder rod bolt82.

82

14 15

82

14 15

CODE

PART NAME

QTY

14

SHIM 1MM

2

15

SHIM 0.5MM

1

82

BOLT ASSY M12×40

1

INFORMATION

CODE

57

PART NAME

QTY

INFORMATION

SM-ECB302016001-EN

MAST Main Lift Cylinder Removal and Installation 2-Stage Mast Main Lift Cylinder Removal 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

se a reliable hoisting strap to the hang the upper beam of the inner mast(2-stage mast) or the middle mast(3-stage mast), U and secure the strap with a safety hook.

3.

Remove bolts, clamps, supports from cylinders.

4.

Slowly lift the hoisting strap to release cylinders, and then remove all shims and note down quantities and location.

5.

Disconnect fittings and hoses from the bottom of cylinders.

6.

Remove cylinders.

82 81 14

12

15

81 81 81

11 11

13

10 83 80

81

CODE

PART NAME

QTY

CODE

INFORMATION

PART NAME

QTY

10

LIFT CYLINDER

1

80

BOLT M12×50

1

11

RUBBER CUSHION

2

81

BOLT ASSY M10×25

5

12

SUPPORT

1

82

BOLT ASSY M12×40

1

13

SUPPORT

1

83

NUT M12

1

14

SHIM 1MM

2

15

SHIM 0.5MM

1

2-Stage Mast Main Lift Cylinder Installation Follow the removal steps in reverse to install main lift cylinders.

SERVICE MANUAL

58

INFORMATION

ECB30 ECB35 3-Stage Mast Main Lift Cylinder Removal 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

se a reliable hoisting strap to the hang the upper beam of the inner mast(2-stage mast) or the middle mast(3-stage mast), U and secure the strap with a safety hook.

3.

Remove bolts, clamps, supports from cylinders.

4.

Slowly lift the hoisting strap to release cylinders, and then remove all shims and note down quantities and location.

5.

Disconnect fittings and hoses from the bottom of cylinders.

6.

Remove cylinders.

82

14 15

13

11

81 81

12 16

17

10

84

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

10

MAIN CYLINDER

1

16

WASHER

1

11

SUPPORT

1

17

ADJUST WASHER

1

12

SUPPORT

1

81

HEXAGON FLANGE BOLT M10×45

2

13

SOFT WASHER

1

82

BOLT ASSY M12×40

1

14

SHIM 1MM

2

84

BOLT M12×50

1

15

SHIM 0.5MM

1

INFORMATION

3-Stage Mast Main Lift Cylinder Installation Follow the removal steps in reverse to install main lift cylinders.

59

SM-ECB302016001-EN

MAST Main Lift Cylinder Overhaul Main Lift Cylinder Explosive View 2-Stage main lift cylinder:

18 19 21 22 25

91 92

20 10

26 27 28 29 30 31 33 34 35 36 37

93

CODE

PART NAME

QTY

CODE

INFORMATION

PART NAME

QTY

34

WASHER

1

1

35

BUSHING

1

SEAL

1

36

RETAINER RING

1

20

SEAL KIT

1

37

VALVE ASSY

1

21

GLAND

1

91

SCREW M5×5

1

22

O-RING

1

92

WASHER

1

27

RETAINER RING

1

93

PIN

1

28

BACK-UP RING

1

29

PISTON

1

30

RETAINER RING

1

31

SEAL

1

33

CHECK VALVE

1

10

LIFT CYLINDER

1

18

DUST WIPER

19

SERVICE MANUAL

60

INFORMATION

ECB30 ECB35 3-Stage main lift cylinder: 18 19 21 22 23 24 25

91 92

20

10

26 27 28 29 30 31 33 34 35 36 37

93

CODE

PART NAME

QTY

10

MAIN CYLINDER

1

18

DUST WIPER

19

INFORMATION

CODE

PART NAME

QTY

31

BACK-UP RING

1

1

33

CHECK VALVE

1

SEAL

1

34

WASHER

1

20

SEAL KIT

1

35

BUSHING

1

21

GLAND

1

36

RETAINER RING

1

22

O-RING

1

37

VALVE ASSY

1

23

O-RING

1

91

SCREW M5×5

1

24

BUSHING

1

92

WASHER

1

27

RETAINER RING

1

93

PIN

1

28

BACK-UP RING

1

29

SEAL

1

30

PISTON

1

INFORMATION

Main Lift Cylinder Disassembly 1.

Clean rod tops and gland thoroughly to prevent contamination.

2.

emove the gland (with O-rings and seals), and then carefully take the rod and piston (with O-rings and seals) out of the R cylinder tube and place them in a clean area.

3.

Remove the valve on the cylinder bottom side, and then cover the cylinder to prevent contamination.

4.

Remove all O-rings and seals from the gland and the piston.

5.

Remove the snap ring from the piston bore to release the check valve.

61

SM-ECB302016001-EN

MAST Parts Inspection 1.

Clean all parts completely in a suitable solvent. Dry all parts with a soft clean cloth.

2.

I nspect dust wipers, o-rings, seals, bushings, back-up rings of the gland or the rod and piston. And inspect all O-rings and seals grooves for nicks, burrs, and scratches that can damage components during reinstallation.

3.

I nspect the cylinder tube and bore for cracks, pining, scoring, or other irregularities that may require replacement of the cylinder.

4.

Inspect the check valves.

Main Lift Cylinder Reassembly 1.

oat all o-rings, seals, bushings, back-up rings, the rod and piston, valves, and the inner wall of the gland and the cylinder C 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 into the cylinder without damaging cylinder tube threads and inner wall.

4.

Lubricate cylinder threads and carefully screw gland onto the cylinder fully without damaging o-rings and seals.

5.

Check and ensure the piston slides freely, and then tighten the gland.

6.

Install the valve on the cylinder bottom side.

SERVICE MANUAL

62

ECB30 ECB35

Free Lift Cylinder Removal and Installation Removal 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

se a reliable hoisting strap to the hang the upper beam of the inner mast(2-stage mast) or the middle mast(3-stage mast), U and secure the strap with a safety hook.

3.

Remove screw and the protection on the free lift chain.

4.

Slowly lift the hoisting strap to release the chain, and then move it away from the sheave.

5.

Loosen bolts to remove the cylinder with the support and sheave.

6.

Remove the sheave, and then loosen the cylinder rod bolt to release the cylinder. <1>

<2>

11

13

17

12

11 13

18 19 17 21

14 20

15

22 16

15

16

23

24

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

11

HEXAGON SCREW M6×12

2

19

PIN

1

12

PROTECTION

1

20

CIRCLIP

1

13

HOSE

2

21

BOLT ASSY M12×40

1

14

FREE LIFT CHAIN

1

22

SUPPORT

1

15

HEXAGON FLANGE BOLT M8×30

2

23

SUPPORT

1

16

FREE LIFT CYLINDER AND SUPPORT ASSY

1

24

FREE LIFT CYLINDER

1

17

RING

2

18

CHAIN SHEAVE

1

INFORMATION

Installation Follow the removal steps in reverse to install free lift cylinders.

63

SM-ECB302016001-EN

MAST Free Lift Cylinder Overhaul Free Lift Cylinder Explosive View

12 13 14 15 17 83 84

18

20 10 19 21 22 23 24 25 26 27 85 28

82

CODE

INFORMATION

PART NAME

QTY

CODE

PART NAME

QTY

10

FREE LIFT CYLINDER (3-STAGE FREE LIFT MAST 4.5M 4.8M)

2

26

CHECK VALVE

1

12

DUST WIPER

1

27

WASHER

1

13

SEAL

1

28

VALVE ASSY

1

14

GLAND

1

82

PIN

1

15

O-RING

1

83

SCREW M5×5

1

17

BUSHING

1

84

WASHER

1

20

SEAL KIT

1

85

CIRCLIP

1

21

RETAINER RING

1

22

BACK-UP RING

1

23

PISTON

1

24

RETAINER RING

1

25

SEAL

1

INFORMATION

Free Lift Cylinder Disassembly 1.

Clean rod tops and gland thoroughly to prevent contamination.

2.

emove the gland (with O-rings and seals), and then carefully take the rod and piston (with O-rings and seals) out of the R cylinder tube and place them in a clean area.

3.

Remove the valve on the cylinder bottom side, and then cover the cylinder to prevent contamination.

4.

Remove all O-rings and seals from the gland and the piston.

5.

Remove the snap ring from the piston bore to release the check valve.

SERVICE MANUAL

64

ECB30 ECB35 Parts Inspection 1.

Clean all parts completely in a suitable solvent. Dry all parts with a soft clean cloth.

2.

I nspect dust wipers, o-rings, seals, bushings, back-up rings of the gland or the rod and piston. And inspect all O-rings and seals grooves for nicks, burrs, and scratches that can damage components during reinstallation.

3.

I nspect the cylinder tube and bore for cracks, pining, scoring, or other irregularities that may require replacement of the cylinder.

4.

Inspect the check valves.

Free Lift Cylinder Reassembly 1.

oat all o-rings, seals, bushings, back-up rings, the rod and piston, valves, and the inner wall of the gland and the cylinder C 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 into the cylinder without damaging cylinder tube threads and inner wall.

4.

Lubricate cylinder threads and carefully screw gland onto the cylinder fully without damaging o-rings and seals.

5.

Check and ensure the piston slides freely, and then tighten the gland.

6.

Install the valve on the cylinder bottom side.

65

SM-ECB302016001-EN

MAST Mast and Carriage Roller and Clearance Adjustment 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 stub and secured by a secure pin.

86

82

83

81 85 84

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

81

MAST ROLLER

1

85

SECURE PIN

1

82

BEARING

1

86

CIRCLIP

1

83

DUST PROTECTION

1

84

ADJUSTING SCREW

1

SERVICE MANUAL

66

INFORMATION

ECB30 ECB35 2-Stage Mast And Carriage Roller Description In the 2-stage mast, 2 mast rollers are installed on the top side of the outer mast, 2 mast rollers are installed on the bottom side of the inner mast, and 6 mast rollers are installed on the carriage. Being different from others, the upper 2 mast rollers of the carriage are installed by roller protections and bolts. <A>

81

84 82 83

86

85

<A>

<A> 81

12

88

81 88

<A>

12

<A> <A>

<A>

87

<A>

<A>

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

12

PROTECTION

2

84

ADJUST SCREW

8

81

MAST ROLLER

10

85

SECURE PIN

8

82

BEARING

8

86

CIRCLIP

8

83

DUST PROTECTION

8

88

BOLT ASSY M8×16

2

67

INFORMATION

SM-ECB302016001-EN

MAST 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 rollers are installed on both sides of the middle mast, 2 mast rollers are installed on the bottom side of the inner mast, and 6 mast rollers are installed on the carriage. Being different from others, the upper 2 mast rollers of the carriage are installed by roller protections and bolts. <A>

81

84 82 86

83

<A>

<A>

85 <A>

81

81

<A>

88 12

<A>

12 88 <A>

<A>

<A>

<A>

<A>

<A> <A>

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

12

PROTECTION

2

84

ADJUST SCREW

12

81

MAST ROLLER-119.2MM

14

85

SECURE PIN

12

82

BEARING

12

86

CIRCLIP

12

83

DUST PROTECTION

12

88

BOLT ASSY M8×16

2

SERVICE MANUAL

68

INFORMATION

ECB30 ECB35 General Carriage 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.

After adjustment, bend the secure pin to secure the adjustment screw. <1>

<2>

Adjustment Order Order of adjusting 2-stage mast and carriage clearance: 1.

Clearance between the outer mast and the inner mast.

2.

Clearance between the inner mast and the carriage.

Order of adjusting 3-stage mast and carriage clearance: 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.

69

SM-ECB302016001-EN

MAST Mast Removal and Installation Removal 1.

Tilt the mast to be on the vertical position, and then fully lower the mast.

2.

Remove forks or the attachment.

3.

Use a reliable hoisting strap to the hang the upper beam of the mast, and secure the strap with a safety hook.

4.

isconnect the fittings and hoses of the main lift cylinders, and disconnect the fittings and hoses of the attachment if it is D equipped .

5.

Remove bolts, bushings and pins connecting the tilt cylinder and the mast.

6.

Remove bolts, bushings and pins connecting the frame and the mast.

7.

Slowly set the mast down on the flat floor or sturdy pallets.

83

14 13

12

11 16

81 14 13 14

83

13

83 83

13

11

12

14

82 82 16 81

82 82

CODE

PART NAME

QTY

CODE

INFORMATION

PART NAME

QTY

11

BUSHING

2

82

BOLT ASSY M14×60

4

12

MAST MOUNTING

2

83

BOLT ASSY M10×25

4

13

MOUNTING PIN (MAST)

4

14

BUSHING DRY

4

16

GREASE NIPPLE CAP

2

81

GREASE NIPPLE

2

INFORMATION

Installation Follow the removal steps in reverse to install the mast. And adjust mast and carriage clearance by rollers after installation.

SERVICE MANUAL

70

ECB30 ECB35

Carriage Removal and Installation Carriage Removal 1.

Remove the mast, slowly set the mast down on the flat floor or sturdy pallets

2.

Loosen chain nuts to release the carriage.

3.

Remove the carriage by sliding it out from the bottom of the mast.

Carriage Installation Follow the removal steps in reverse to install the carriage. After installation, adjust the clearance between the carriage and the mast.

71

SM-ECB302016001-EN

MAST Carriage and Mast Roller Replacement Carriage Roller Replacement 1.

Check the adjusting screws and secure pins, replace them if necessary.

2.

Replace carriage rollers. <A>

81

88 12

81 84 82

86

83

81

85 88

<A>

12 <A>

<A> <A>

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

12

PROTECTION

2

86

CIRCLIP

4

81

MAST ROLLER

6

88

BOLT ASSY M8×16

2

82

BEARING

4

83

DUST PROTECTION

4

84

ADJUST SCREW

4

85

SECURE PIN

4

SERVICE MANUAL

72

INFORMATION

ECB30 ECB35 Mast Roller Replacement Before mast roller replacement, remove the mast, slowly set the mast down on the flat floor or sturdy pallets, and then remove the carriage and cylinders away from the mast.

1.

Slide the mast in the direction of bottom side of the mast, and then replace mast rollers.

2.

lide the mast in the direction of top side of the mast, and then check the adjusting screws and secure pins, replace them if S necessary.

After replacement, adjust the clearance of the mast. <1>

81

82 86

83

<2>

84

CODE

PART NAME

85

QTY

INFORMATION

CODE

PART NAME

QTY

81

MAST ROLLER

8

85

SECURE PIN

8

82

BEARING

8

86

CIRCLIP

8

83

DUST PROTECTION

8

84

ADJUST SCREW

8

73

INFORMATION

SM-ECB302016001-EN

INTEGRAL SIDESHIFT

ECB30 ECB35

Descriptions CYZ Type Integral Sideshift CYZ xxx-xxxx-xxxx-xxx

xxxxx

xxxxxxxxxx

xxxxx

xxxxxx

xxxxx

ISS Type Integral Sideshift XXX: xxxxx

XXX: xxxxx

MODEL: ISS-xxx-xxx

XXX: xxxxx

XXX: xxxxx

XXX: xxxxx

XXX: xxxxx

XXX: xxxxx

75

SM-ECB302016001-EN

INTEGRAL SIDESHIFT Integral Sideshift Gliding Strip Replacement CYZ Type Integral Sideshift Gliding Strip Replacement 1.

ilt the mast to be on the vertical position, operate the sideshift to the initial position, and then fully lower the sideshift. Remove T the load backrest.

2.

Remove grease nipples, loosen screws and remove lower hooks, and then remove the outer carriage.

3.

Replace the upper and lower gliding strips.

12

12

91

87

22

87

91

23 87 87

24

23

88 88

24 88 88

CODE

PART NAME

QTY

12

UPPER GLIDING STRIP

2

22

SIDESHIFT OUTER CARRIAGE

1

23

LOWER GLIDING STRIP

2

24

LOWER HOOK

2

87

HEXAGON SCREW M6×12

4

88

SCREW M16×40

4

SERVICE MANUAL

CODE

INFORMATION

91

76

PART NAME GREASE NIPPLE

QTY

2

INFORMATION

ECB30 ECB35 ISS Type Integral Sideshift Gliding Strip Replacement 1.

ilt the mast to be on the vertical position, operate the sideshift to the initial position, and then fully lower the sideshift. Remove T the load backrest.

2.

Remove grease nipples, loosen screws and remove lower hooks, and then remove the outer carriage.

3.

Replace the upper and lower gliding strips.

91

91

91

22 12

91 12

12

91

12

23

91

88

23

88 91 23 88 88

89

89

89 24

89

24

CODE

PART NAME

QTY

12

UPPER GLIDING STRIP

4

22

SIDESHIFT OUTER CARRIAGE

1

23

LOWER GLIDING STRIP

3

24

LOWER HOOK

2

88

SCREW

4

89

SPRING WASHER

4

CODE

INFORMATION

91

77

PART NAME GREASE NIPPLE

QTY

INFORMATION

7

SM-ECB302016001-EN

INTEGRAL SIDESHIFT Integral Sideshift Cylinder Overhaul CYZ Type Integral Sideshift Cylinder Disassembly 1.

Remove the outer carriage and lower hooks. Disconnect the fitting and the hose, and collect the oil.

2.

Loosen screws to remove the gland with the dust wiper, and then Pull out the cylinder rod.

3.

Remove the retainer ring, seal, and then remove the steel retainer ring and the bushing if it is loose.

15

16

17 18 92

13 92 92

92 93

93

93 14

93 92

14

93

19 93

92

93

92 93 13

92

19 18 17 21

CODE

PART NAME

QTY

INFORMATION

CODE

16

15

PART NAME

QTY

13

DUST WIPER

2

19

FITTING

2

14

GLAND

2

21

SIDESHIFT INNER CARRIAGE

1

15

RETAINER RING

2

92

SCREW M8×20

8

16

SEAL

2

93

SPRING WASHER M8

8

17

BUSHING

2

18

CYLINDER ROD

2

INFORMATION

CYZ Type Integral Sideshift Cylinder Inspection 1.

Clean all parts and the the interior area of the cylinder completely in a suitable solvent. Dry all parts with a soft clean cloth.

2.

I nspect the dust wiper, the retainer ring, the seal and the bushing. And inspect the seal groove for nicks, burrs, and scratches that can damage components during reinstallation.

3.

The dust wiper, the retainer ring and the seal should be replaced as a set.

4.

Inspect the cylinder rod and bore for cracks, pining, scoring, or other irregularities that may require replacement

CYZ Type Integral Sideshift Cylinder Reassembly 1.

I f the bushing is needed to be replaced, lubricate it and install it, clear debris produced by installation, and then install the steel retainer ring.

2.

Lubricate and install the seal and the retainer ring. Lubricate the cylinder rod and install it.

3.

Install the dust wiper on the gland plate, and then install the gland plate and screws.

4.

einstall the the outer carriage and lower hooks. Connect the fitting and the hose, and then operate the sideshift to check if it R works well.

SERVICE MANUAL

78

ECB30 ECB35 ISS Type Integral Sideshift Cylinder Disassembly 1.

Remove the outer carriage and lower hooks. Disconnect the fitting and the hose, and collect the oil.

2.

Remove the end cushion, and then pull out the cylinder rod.

3.

Carefully use the copper hammer to take out the gland plate with the dust wiper.

4.

Remove the retainer ring, seal, and then remove the bushing if it is loose.

15

16

17

18

14

13

25 19

25 14 13 18 19

21 17

CODE

PART NAME

QTY

INFORMATION

16

15

CODE

PART NAME

QTY

13

DUST WIPER

2

19

FITTING

2

14

GLAND PLATE

2

21

SIDESHIFT INNER CARRIAGE

1

15

RETAINER RING

2

25

END CUSHION

2

16

SEAL

2

17

BUSHING

2

18

CYLINDER ROD

2

INFORMATION

ISS Type Integral Sideshift Cylinder Inspection 1.

Clean all parts and the the interior area of the cylinder completely in a suitable solvent. Dry all parts with a soft clean cloth.

2.

I nspect the dust wiper, the retainer ring, the seal and the bushing. And inspect the seal groove for nicks, burrs, and scratches that can damage components during reinstallation.

3.

The dust wiper, the retainer ring and the seal should be replaced as a set.

4.

Inspect the cylinder rod and bore for cracks, pining, scoring, or other irregularities that may require replacement

ISS Type Integral Sideshift Cylinder Reassembly 1.

If the bushing is needed to be replaced, lubricate it and install it, and then clear debris produced by installation.

2.

Lubricate and install the seal and the retainer ring.

3.

Install the dust wiper on the gland plate, and then install the gland plate. Lubricate the cylinder rod and install it.

4.

einstall the the outer carriage and lower hooks. Connect the fitting and the hose, and then operate the sideshift to check if it R works well.

79

SM-ECB302016001-EN

STEERING CONTROL UNIT

ECB30 ECB35

Steering Control Unit Removal and Installation Removal 1.

Disconnect hoses from the steering control unit, and then remove screws to release the steering control unit.

2.

Clamp the steering control unit in a vise and do not overtighten, and then remove fittings from the steering control unit.

85 98

<1>

<2>

85 98 85 98 85 98

18 18 14 14

15 16

17

11 12

CODE

PART NAME

13

QTY

INFORMATION

CODE

PART NAME

QTY

11

RETURN HOSE

1

17

FITTING

2

12

PRESSURE HOSE

1

85

SCREW M10×35

4

13

PRESSURE HOSE

1

98

SPRING WASHER M10

4

14

PRESSURE HOSE

2

15

FITTING

1

16

FITTING

2

INFORMATION

Installation Follow the removal steps in reverse to install the steering control unit.

81

SM-ECB302016001-EN

HYDRAULIC OIL TANK AND FILTER

ECB30 ECB35

Hydraulic Oil Tank Descriptions Item

Needed

Volume Needed

Type

Oil Tank

Hydraulic Oil

40 L

ISO VG46, ISO VG68

Hydraulic Oil Level Check Park the truck on a level ground and fully lower the mast and apply the parking brake. Switch off the truck, take off the key and press down the emergency disconnect switch.

Open the battery hood to check the gauge. If there is no oil in the gauge, unscrew the cover plate of the return fillter, and then fill oil into the oil tank until it appears in the gauge.

Hydraulic Oil Replacement 1.

rive the truck to the maintenance ditch, fully lower the forks, apply the hand brake, switch off the truck, remove the key and D press down the emergency disconnect switch.

2.

Place a container below the drain plug of the oil tank, and then unscrew the drain plug to drain the hydraulic oil.

3.

Check if the seal ring of the drain plug is in good condition, replace the drain plug if necessary.

4.

crew the drain plug, and add a small amount of hydraulic oil first to check if there is any leakage, replace the drain plug if S necessary.

5.

Tighten the plug, and then add hydraulic oil into the oil tank until the oil appears in the gauge.

6.

Remove the residual oil spill on the oil tank, truck bottom and working area.

11

CODE

11

PART NAME PLUG

QTY

INFORMATION

1

45 N-m

CODE

83

PART NAME

QTY

INFORMATION

SM-ECB302016001-EN

HYDRAULIC OIL TANK AND FILTER Return Filter Descriptions Return Filter Element State Indicator The indicator of the return filter indicates the state of the filter element.

(1) Green area: the element is in good condition.

(2) Yellow area: the element's performance drops and it's better to be replaced within a short time.

(3) Red area: the element is invalid, and it must be replaced immediately.

1 2 3

Return Filter Element Replacement 1.

Put the clean cloth around the return filter.

2.

Unscrew the cover plate with the seal, and then pull the out filter element.

3.

Clean the cover plate and check if the o-ring is in good condition, replace it if necessary.

4.

Check if the spread and the o-ring of the new element are in good condition, replace them if necessary.

5.

Use clean hydraulic oil to lubricate the the o-ring of the new element, fit the new element carefully and screw the cover plate.

6.

After replacement, operate the hydraulic system to check if there is any leakage.

11 12 13 14

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

11

COVER PLATE

1

13

FILTER ELEMENT

1

12

SEAL

1

14

O-RING

1

SERVICE MANUAL

84

INFORMATION

ECB30 ECB35 Air Filter Replacement Unscrew the cap of the air filter, check the air filter, replace it if necessary.

11

CODE

11

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

INFORMATION

1

AIR FILTER ELEMENT

Return Filter Removal 1.

Disconnect the return hose from the return filter.

2.

Remove screws to release the return filter, and then pull out the return filter with the fitting and the lower hose.

3.

Remove the clamp and the hose.

4.

Remove the fitting.

14 11

14 12 13

15

16

17

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

11

RETURN HOSE

1

15

RETURN FILTER

1

12

RETURN HOSE

1

16

CLAMP

1

13

T-FITTING

1

17

RETURN HOSE

1

14

HEXAGON FLANGE BOLT M10×30

2

85

INFORMATION

SM-ECB302016001-EN

HYDRAULIC OIL TANK AND FILTER Return Filter Installation Follow the removal steps in reverse to install the return filter.

Return Filter Parts Inspection Remove the return filter from the oil tank, and then disassemble the return filter, and then check o-rings and seals, replace them if necessary.

19

20 21 13

13

22 24

23 25

CODE

PART NAME

QTY

13

RETURN FILTER

1

19

SEAL

20 21

INFORMATION

CODE

PART NAME

QTY

22

O-RING

1

1

23

AIR FILTER ELEMENT

1

FILTER ELEMENT

1

24

INDICATOR

1

O-RING

1

25

TANK SEAL

1

SERVICE MANUAL

86

INFORMATION

ECB30 ECB35

High Pressure Filter Descriptions High Pressure Filter Element Replacement 1.

Put the clean cloth around the return filter.

2.

Unscrew the filter bowl and pull the out filter element.

3.

Clean the filter bowl and check if the o-ring is in good condition, replace it if necessary.

4.

Check if the spread and the o-ring of the new element are in good condition, replace them if necessary.

5.

Use clean hydraulic oil to lubricate the the o-ring of the new element, fit the new element carefully.

6.

Screw in the filter bowl fully and then unscrew by one quarter-turn.

7.

After replacement, operate the hydraulic system to check if there is any leakage.

11

11

12 13

14 15

16

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

11

HEXAGON FLANGE BOLT M10×12

2

15

RETAINER RING

1

12

O-RING

1

16

FILTER BOWL

1

13

FILTER ELEMENT

1

14

O-RING

1

87

INFORMATION

SM-ECB302016001-EN

HYDRAULIC OIL TANK AND FILTER High Pressure Filter Removal 1.

Disconnect the return hose from the high pressure filter.

2.

Remove screws to release the high pressure filter with the mounting plate and fittings.

3.

Remove bolts and the mounting plate.

4.

Clamp the filter in a vise and do not overtighten, and then remove fittings. <1>

<2>

17

87 87

14

<4>

<3> 86

86

86

86 15

19

16 10

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

10

PRESSURE FILTER

1

17

PRESSURE HOSE

1

14

PRESSURE HOSE

1

19

MOUNTING PLATE

1

15

FITTING

1

86

HEXAGON FLANGE BOLT M6×12

4

16

FITTING

1

87

HEXAGON FLANGE BOLT M10×12

2

High Pressure Filter Installation Follow the removal steps in reverse to install the high pressure filter.

SERVICE MANUAL

88

INFORMATION

ECB30 ECB35

89

SM-ECB302016001-EN

HYDRAULIC OIL PUMP

ECB30 ECB35

Descriptions

91

SM-ECB302016001-EN

HYDRAULIC OIL PUMP Removal and Installation Removal 1.

Disconnect the outlet pressure hose.

2.

Use a straight screwdriver to loosen the clamp on the return hose, and compress the hose to avoid oil leakage.

3.

Pull out the hose, bend the hose upward, and the use a tie wrap to fix it.

4.

Loosen the oil pump mounting bolts to remove the pump with fittings.

5.

Remove fittings and screws. <1>

<2>

14

11 81

<4>

<3>

91 91 81

81

11

<5>

83

85 13

12

10

84 82

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

10

HYDRAULIC PUMP

1

82

HEXAGON SCREW M8×55

4

11

SUCTION HOSE

1

83

SCREW M6×20

4

12

PUMP INLET SECTION

1

84

SPRING WASHER M8

4

13

PUMP OUTLET SECTION

1

85

SPRING WASHER M6

4

14

PRESSURE HOSE

1

91

BOLT ASSY M10×30

2

81

CLAMP

2

Installation Follow the removal steps in reverse to install the oil pump.

SERVICE MANUAL

92

INFORMATION

ECB30 ECB35

93

SM-ECB302016001-EN

MAIN VALVE

ECB30 ECB35

Manual Main Valve Descriptions Manual Main Valve Cover Removal and Installation 1.

Loosen and remove the hand lever knobs, and then remove rubber boots.

2.

Loosen and remove screws to release the cover.

3.

Move the cover upward and forward for some distance to expose some space, and then disconnect the emergency button.

4.

Remove the cover upward. <1>

16

<2>

17

15 18

14

18 18

18

12

82

82

11

82

CODE

PART NAME

QTY

11

LEVER COVER

1

12

EMERGENCY SWITCH

14 15

INFORMATION

CODE

PART NAME

QTY

16

KNOB SIDESHIFT

1

1

17

KNOB

1

KNOB LIFT

1

18

RUBBER BOOT

4

KNOB TILT

1

82

SCREW M6×20

3

INFORMATION

Follow the removal steps in reverse to install the cover.

95

SM-ECB302016001-EN

MAIN VALVE Manual Main Valve Hand Levers Disassembly and Reassembly 1.

Remove switches.

2.

Remove split pins and pins to release hand levers from the manual main valve.

3.

Loosen and remove the bolt, remove the rotating shaft and hand levers.

4.

Remove screws, brackets and plates from the manual main valve. <A>

<B> 30

17 16 81 15

14

26

25

29 21

24

18

23

13

27

18

13 <B>

18

12 11

19 18

<A>

28

<A>

28 <A> 28 27

<A> <B> 22 82 83

CODE

PART NAME

QTY

CODE

INFORMATION

PART NAME

QTY

11

BRACKET (LH)

1

24

LEVER TILT

1

12

BRACKET (RH)

1

25

LEVER SIDESHIFT

1

13

BRACKET

4

26

LEVER

1

14

KNOB LIFT

1

27

BUSHING

2

15

KNOB TILT

1

28

BUSHING

3

16

KNOB SIDESHIFT

1

29

PLATE

2

17

KNOB

2

30

SWITCH

4

18

RUBBER BOOT

4

81

HEXAGON SCREW M5×10

8

19

BUSHING

4

82

SPLIT PIN

4

21

PIN

4

83

HEXAGON FLANGE BOLT M6×10

1

22

ROTATING SHAFT

1

23

LEVER LIFT

1

Follow the disassembly steps in reverse to reassemble hand levers.

SERVICE MANUAL

96

INFORMATION

ECB30 ECB35 Manual Main Valve Removal and Installation Before the manual main valve removal, remove the cover and hand lever, and then follow steps below: 1.

Disconnect the lift motion sensor below the manual main valve, and then disconnect hoses from the manual main valve.

2.

oosen lower 2 mounting bolts of the lower plate, and then remove the manual main valve, with fittings and the lower plate, L from the upper plate which it hangs on.

3.

Remove upper bolts, rubbers, inserts and the lower plate from the manual main valve.

4.

Clamp the manual main valve in a vise and do not overtighten, and then remove fittings. <1>

<2>

25 82 23

26 26 26

20

22

24

82

21

26 <4>

<3>

13

14

81 15

35

34 10

35 35

12

CODE

PART NAME

QTY

35

INFORMATION

33

CODE

31 32

PART NAME

31

QTY

10

MAIN VALVE MANUAL (4 FUNCTIONS)

1

31

FITTING

2

12

LOWER PLATE (VALVE)

1

32

FITTING

1

13

RUBBER

4

33

FITTING

1

14

RUBBER

4

34

FITTING

1

15

INSERT

4

35

FITTING

4

20

LIFT MOTION SENSOR

1

81

HEXAGON FLANGE BOLT M10×30

4

21

PRESSURE HOSE

1

82

HEXAGON FLANGE BOLT M10×16

2

22

PRESSURE HOSE

1

23

PRESSURE HOSE

1

24

RETURN HOSE

1

25

PRESSURE HOSE

1

26

PRESSURE HOSE

4

INFORMATION

Follow the removal steps in reverse to install the manual main valve.

97

SM-ECB302016001-EN

MAIN VALVE Electric Main Valve Descriptions Electric Main Valve Removal and Installation Before the electric main valve removal, remove the floor plate, and then follow steps below: 1.

Disconnect the dataline, and then disconnect hoses from the electric main valve.

2.

Loosen bolts of the mounting plate, and then remove the electric main valve with fittings and the mounting plate.

3.

Remove bolts and the mounting plate.

4.

Clamp the electric main valve in a vise and do not overtighten, and then remove fittings. <1>

<2>

82

21 22

24 24

82

23

25

25

25

25 <4>

<3> 11 13 13

81 81 32

13

31

81

33 33

CODE

PART NAME

QTY

INFORMATION

CODE

10

32 33

33

33 33

PART NAME

QTY

10

MAIN VALVE MANUAL (4 FUNCTIONS)

1

31

FITTING

2

12

LOWER PLATE (VALVE)

1

32

FITTING

1

13

RUBBER

4

33

FITTING

1

14

RUBBER

4

34

FITTING

1

15

INSERT

4

35

FITTING

4

20

LIFT MOTION SENSOR

1

81

HEXAGON FLANGE BOLT M10×30

4

21

PRESSURE HOSE

1

82

HEXAGON FLANGE BOLT M10×16

2

22

PRESSURE HOSE

1

23

PRESSURE HOSE

1

24

RETURN HOSE

1

25

PRESSURE HOSE

1

26

PRESSURE HOSE

4

Follow the removal steps in reverse to install the manual main valve.

SERVICE MANUAL

98

INFORMATION

ECB30 ECB35

99

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TILT CYLINDER

ECB30 ECB35

Descriptions

101

SM-ECB302016001-EN

TILT CYLINDER Tilt Cylinder Unequal Stroke Adjustment Descriptions

Forward Adjustment 1.

Slowly tilt the mast forward to the end of the cylinder stroke, and watch the mast be twisted by unequal stroke of tilt cylinders.

2.

o adjust, loosen the cylinder yoke locking nut on the tilt cylinder which extends longer, use a wrench on the wrench flat to turn T the piston rod into the yoke until tilt cylinder strokes are equal, and then tighten the cylinder yoke locking nut. <1>

<2>

SERVICE MANUAL

102

ECB30 ECB35

Tilt Cylinder Removal and Installation Removal 1.

ark the truck on a level ground, tilt the mast to be on the vertical position and fully lower the mast. Apply the parking brake, P switch off the truck, take off the key and press down the emergency disconnect switch.

2.

se a reliable hoisting strap to the hang the upper beam of the carriage, and secure the strap with a safety hook. Slowly lift the U carriage to make chains slack, and then block it.

3.

Remove the mounting pin13, the bolt83 and the bushing14 of the tilt cylinder upper side.

4.

Remove the mounting pin13, the bolt83 and the bushing14 of the tilt cylinder lower side.

5.

Remove the tilt cylinder.

83

14 13

14 13 14

83

13

83 83

13 14

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

INFORMATION

11

BUSHING

2

11177089-00

16

GREASE NIPPLE CAP

2

11316427-00

12

MAST MOUNTING

2

11266984-00

81

GREASE NIPPLE

2

10151745-00

13

MOUNTING PIN

4

11167445-00

82

BOLT ASSY M14×60

4

11176435-00

14

BUSHING DRY

4

11004276-00

83

BOLT ASSY M10×25

4

11096508-00

Installation Follow the removal steps in reverse to install the tilt cylinder. After installation, adjust the tilt cylinder racking.

103

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TILT CYLINDER Tilt Cylinder Overhaul Tilt Cylinder Explosive View

10

11

12 14 10

15

13

16

18

19

20

23 17

25

21 22 24

28 27 15

28 19 20

26

28 27

17 28

22

29

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

INFORMATION

10

TILT CYLINDER

2

11355756-00

22

O-RING

2

11407570-00

11

YOKE

2

11413452-00

23

GLAND

2

11413454-00

12

NUT M14

2

11595295-00

24

BUSHING

2

11407008-00

13

BOLT M14×70

2

11400995-00

25

TILT CYLINDER ROD

2

11413455-00

14

SPRING WASHER M14

2

10623044-00

26

TILT CYLINDER BARREL

2

11413456-00

15

DUST WIPER

2

11413435-00

27

SEAL

2

11464543-00

16

CIRCLIP

2

11407004-00

28

BACK-UP RING

4

11413428-00

17

O-RING

2

11407574-00

29

SEAL KIT

2

11439747-00

18

RETAINER RING

2

11415389-00

19

WASHER

2

11407575-00

20

SEAL

2

11413904-00

21

WASHER

2

11407573-00

Tilt Cylinder Disassembly 1.

Unscrew the nut to remove the yoke.

2.

Clean rod tops and gland thoroughly to prevent contamination.

3.

Remove the gland, and then carefully take the rod and piston out of the cylinder tube and place them in a clean area.

4.

emove the dust wiper, and then remove the circlip to remove the retainer ring, washer and the seal in the gland. Remove all R o-rings on the gland.

5.

Remove seals and the back-up ring on the piston.

SERVICE MANUAL

104

ECB30 ECB35 Parts Inspection 1.

Clean all parts completely in a suitable solvent. Dry all parts with a soft clean cloth.

2.

I nspect dust wipers, o-rings, seals, back-up rings of the gland or the rod and piston. And inspect all O-rings and seals grooves for nicks, burrs, and scratches that can damage components during reinstallation.

3.

I nspect the cylinder tube and bore for cracks, pining, scoring, or other irregularities that may require replacement of the cylinder.

Tilt Cylinder Reassembly 1.

oat all o-rings, seals, back-up rings, the rod and piston, valves, and the inner wall of the gland and the cylinder tube in clean C 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 into the cylinder without damaging cylinder tube threads and inner wall.

4.

Lubricate cylinder threads and carefully screw gland onto the cylinder fully without damaging o-rings and seals.

5.

Check and ensure the piston slides freely, and then tighten the gland.

105

SM-ECB302016001-EN

MAIN CONTROLLER

ECB30 ECB35

Main Controller Assembly Removal and Installation Removal 1.

Disconnect all lines and cables on the controller panel assembly10.

2.

Unscrew screws81 to remove the controller panel assembly10.

81

81

81

11

81

10

81

11

81

CODE

PART NAME

QTY

10

CONTROLLER PANEL ASSY

1

11

CLAMP

3

81

HEXAGON SCREW M6×80

6

INFORMATION

CODE

11

PART NAME

QTY

INFORMATION

Installation Use the picture as a guide to install the controller panel assembly10.

107

SM-ECB302016001-EN

MAIN CONTROLLER Main Controller Assembly Disassembly and Reassembly Explosive View <A>

85 83 82

84

90 86 87 88 <B>

<A>

<A> 13 24

25

25 24

25

90

91

92 93 29

92

90

93

15

16 87

27

87 89

13

25

25

82 83 84 91

28

89 25

17

19

<B> 20

21

25 26

18

25 22

12 25

23 <A> <B>

CODE

PART NAME

QTY

INFORMATION

CODE

PART NAME

QTY

12

HYDRAULIC CONTROLLER

1

84

WASHER M8

19

13

TRACTION CONTROLLER

2

85

BOLT ASSY

12

15

MAIN CONTACTOR

1

86

SCREW M4×30

32

16

PRE-CHARGER

1

87

SPRING WASHER M4

34

17

FAN

8

88

WASHER M4

32

18

CONNECTION BAR ASSY

1

89

SCREW M4×25

2

19

CONNECTION BAR

1

90

SCREW M5×10

6

20

CONNECTION BAR

1

91

SCREW M6×12

2

21

CONNECTION BAR

1

92

SPRING WASHER M6

2

22

CONNECTION BAR

1

93

WASHER M6

2

23

CONNECTION BAR

1

24

FUSE 250A

2

25

SHIM

9

26

FUSE 425A

1

27

HEATSINK

1

28

MOUNTING PLATE

1

29

BRACKET

1

82

NUT M8

19

83

SPRING WASHER M8

19

SERVICE MANUAL

108

INFORMATION

ECB30 ECB35 Disassembly Use the picture of the explosive view as the guide to disassemble the controller panel assembly.

Reassembly Use the picture of the explosive view as the guide to reassemble the controller panel assembly.

109

SM-ECB302016001-EN

MAIN CONTROLLER PROGRAMMING

ECB30 ECB35

Descriptions Dataline

111

SM-ECB302016001-EN

MAIN CONTROLLER PROGRAMMING Software Interface

1

2

3 4

5

6

7

8

9

SERVICE MANUAL

No.

Name

No.

Name

1

MenuBar

7

Path Textbox

2

Baudrate Textbox

8

Status Textbox

3

"Scan units" Button

9

"Download Switch" Button

4

"Scan boot" Button

5

Nodes Drop-down List

6

"Fw version" Textbox

112

ECB30 ECB35 Program File Descriptions

69G2132XC01x XX _Node X 1

2

69G2132XC01x XXX _Node X 1

1.

2

Version Code

The code "XX" or "XXX" after "C01x" is the file version code. It contains 2 or 3 characters, for example, "03" or "03b".

2.

Node Name

The number after the word "Node" is the name of the node. Each node is corresponding to a main controller.

Node

EPF file

Controller

6

69G21321C01x02_Node6

Left Drive Motor Controller

7

69G21320C01x02_Node7

Pump Motor Controller

8

69G21322C01x03_Node8

Right Drive Motor Controller

113

SM-ECB302016001-EN

Programming Programming Procedure 1.

Dataline Connecting

Use the dataline to connect the truck and the computer.

2.

Program Opening

Open the programm.

3.

Baudrate Setting

Set the baudrate at 125.

4.

Nodes Scanning and Choosing

Click "Scan units" button to scan nodes named "6","7" and "8". If it fails to scan nodes, click the "Scan boot" button, restart the truck and click "Scan units" button to scan nodes again.

Click "Talk to node" drop-down list to choose the node. Follow the order of "8", "6", "7" to choose the node.

5.

Program Downloading

Click "Download SW" button, chose the right file, wait for software file downloading. If "Switch version read" appears in the status textbox, the program downloading succeeds.

Use the same procedure to program other nodes, exit the program, turn off the truck and restart it after 10 seconds. If the main contactor close if normal, programming succeeds.

SERVICE MANUAL

114

ECB30 ECB35 <1>

<2>

<3>

<4>

Failure of Programming Solutions 1.

Check if the dataline is connected well. Restart the computer and restart the truck, and then program again.

2.

Disconnect the dataline on other main controllers when downloading one program into the current main controller module.

115

SM-ECB302016001-EN

SENSOR MONITORING AND ADJUSTMENT

ECB30 ECB35

Descriptions Software Interface

1 2

3

No.

Name

No.

1

Menu Bar

2

"Start Comm" Button

3

Parameter Information Window

Name

Parameter Name and Index

ADConverterValues (2005h) 1

2

Accelerator Pedal Analog (2005h:9) 3

2

No.

Name

No.

Name

1

Parameter Group Name

3

Parameter Name

2

Parameter Index Group

4

Parameter Sub Index

117

4

SM-ECB302016001-EN

SENSOR MONITORING AND ADJUSTMENT General Using Load Files The settings file and the EPF file are needed to be loaded before monitoring and adjustment.

Correspondence list: Node

Setting file

EPF file

Controller

6

GEN6 F6DM Left Traction

69G21321C01x02_Node6

Left Drive Motor Controller

7

GEN6 F6DM PUMP

69G21320C01x02_Node7

Pump Motor Controller

8

GEN6 F6DM Right Traction

69G21322C01x03_Node8

Right Drive Motor Controller

File loading procedure: 1.

Choose the setting file to load settings.

2.

Choose the right setting file to load settings.

Note The version of EPF file should be the same with the EPF file downloaded in the controller.

SERVICE MANUAL

118

ECB30 ECB35 Start Software Click "Start Comm" Button to run the software, and then the interface color will change to blue.

Single Parameter Monitoring and Modification After the "Start Comm" Button is clicked, double-click the parameter group in the parameter listbox, select the parameter, and the current parameter will appear in the parameter textbox.

Write the new parameter in the parameter modification textbox, and click the "write" button to modify the parameter.

After all necessary parameters' modification, click "store par to eeprom" button to write parameters into the main controller.

1

6

2

3 4 5

No.

Name

No.

Name

1

Parameter List Page

5

Write Button

2

Parameter ListBox

6

"Store par to EEPROM" Button

3

Parameter Textbox

4

Parameter Modified Textbox

119

SM-ECB302016001-EN

SENSOR MONITORING AND ADJUSTMENT User-defined Parameters Monitoring and Modification 1.

User-Defined Parameters Interface

In the user-defined parameters interface, parameters' values can be selected to read or write.

Click parsetting button3 in the parameter reading area2 or parameters writing area5 to open the parsetting window and select userdefined parameters.

Write the new parameter value in the parameter value writing textbox.

After all necessary parameters' values being writed, return to the Par list page, and click "Store par to EEPROM" button to write parameters into the main controller 1

2 3 4

5 6

SERVICE MANUAL

No.

Name

No.

Name

1

User-defined Parameter List Page A, B, C

5

Parameters Writing Area

2

Parameter Reading Area

6

Parameter Value Writing Textbox

3

ParSetting Button

4

Parameter Value Reading Textbox

120

ECB30 ECB35 2.

Cutom Parameters Selection

Click parsetting button in the parameter reading area or parameters writing area to open the parsetting window and select userdefined parameters.

Select the parameter group in the parameters selection list1, and change the sub index4. For example, to select the Accelerator Pedal Analog (2005h:9), select "2005h ADConverterValues AD", and then change the sub index to 9.

The parameter alias2 can be changed in different languages by user.

Click “Remove“ button to remove or click "OK" button to add the parameter in the parameter reading area or parameters writing area.

1

2

3

4

5

No.

Name

No.

Name

1

Parameter Selection List

5

Remove Button

2

Parameter Alias

6

Cancel Button

3

Parameter Name

7

OK Button

4

Parameter Sub Index

121

6

7

SM-ECB302016001-EN

SENSOR MONITORING AND ADJUSTMENT Save Parameters File for Analysis Click "Upload par from drive" button, save the parameters file, and then give it to the technical support personnel for analysis.

SERVICE MANUAL

122

ECB30 ECB35

Accelerator Sensor Monitoring and Adjustment Parameter Check Release the accelerator pedel, and check the value of the parameter below: Node

Read or Write

Name

Index

Value

8

Read

Accelerator Pedal Analog

2005h:9

About 220

Parameter Adjustment 1.

elease the accelerator pedal. Read the value of Accelerator Pedal Analog(2005h:9), add 50, and then write it into R TractPotActiveLow(2024h:10).

2.

tep on the accelerator fully. Read the value of Accelerator Pedal Analog(2005h:9), subtract 50, and then write it into S TractPotActiveHigh(2024h:9).

Node

Read or Write

Name

Index

Value

8

Write

TractPotActiveHigh

2024h:9

-

8

Write

TractPotActiveLow

2024h:10

-

123

SM-ECB302016001-EN

SENSOR MONITORING AND ADJUSTMENT Steering Axle Sensor Monitoring and Adjustment Parameter Adjustment 1.

urn the steering wheel to the left fully. Read the value of Steering Sensor Analog(2005h:10), add 50, and then write it into T SteerPotActiveHigh(2022h:2).

2.

urn the steering wheel to the right fully. Read the value of Steering Sensor Analog(2005h:10), subtract 50, and then write it T into SteerPotActiveLow(2022h:3).

3.

urn the steering wheel to the initial position fully. Read the value of Steering Sensor Analog(2005h:10), and then write it into T SteerPotMiddle_U16(2022h:7).

SERVICE MANUAL

Node

Read or Write

Name

Index

Value

8

Read

Steering Sensor Analog

2005h:10

-

Node

Read or Write

Name

Index

Value

8

Write

SteerPotActiveHigh

2022h:2

-

8

Write

SteerPotActiveLow

2022h:3

-

8

Write

SteerPotMiddle_U16

2022h:7

-

124

ECB30 ECB35

Main Manual Valve Monitoring and Adjustment Parameter Adjustment 1.

elease the lift lever to the initial position. Read the value of PLiftPotSignal(2021h:11), add 30, and then write it into R LiftPotActiveLow(2029h:12).

2.

ush the lift lever forward fully. Read the value of PLiftPotSignal(2021h:11), subtract 30, and then write it into P LiftPotActiveHigh(2029h:11).

Node

Read or Write

Name

Index

Value

8

Read

PLiftPotSignal

2021h:11

-

Node

Read or Write

Name

Index

Value

8

Write

LiftPotActiveHigh

2029h:11

-

8

Write

LiftPotActiveLow

2029h:12

-

125

SM-ECB302016001-EN

OTHER INFORMATION

Importer: BYD Europe B.V. Address: Vareseweg 53,3047 AT,Rotterdam,Netherlands Tel:+31-10-2070888 Fax:+31-10-2070880

Importer: BYD Motors Inc. Address: 1800 South Figueroa Street, Los Angeles, CA, 90015 Tel: 213-748-3980 Fax: 213-748-3945 E-mail: FORKLIFTSERVICE@BYD.COM

Importer: BYD do Brasil Address: Av. Antonio Boscato, 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, Kanagawa-ku, Yokohama-shi,Kanagawa-ken,2210835,Janpan 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

126