9.

Forklift maintenance
Maintenance Schedule
These new series have a daily and a 1000 hours maintenance interval. If the truck is operated in a
dirtier (more dusty and wet condition), inspect and lubricate the truck more and frequent. For the actual
maintenance intervals, please consult de maintenance section in your workshop manual.

Major difference with the Former Product

 Hydraulic oil; change every 2000 hours or one year.
 Hydraulic oil type: ISO VG-46 = SAE15 W (instead of SAE 10W).
 Replace the oil tank filter/breather every 1000 hours.
 Steering actuator bolts: check torque every 2000 hours (270 N.m) .
 Steering plate bolts: check torque every 2000 hours (305 N.m).
 Break fluid: change every 2000 hours.
 Break fluid type: DOT 4.
 Master break cylinder reservoir: change with DOT 4 every 2000 hours (no break fluid!!)
 Transaxle: check every 2000 hours (Dexron 3)
Hydraulic Compartment Inspection
 Hydraulic components inspection
Check the condition of all hydraulic system components, hose, piping, and connections. Check for wear,
leakage, and damage.
 Hydraulic pump inspection
Check hydraulic pump motor fasteners, check hydraulic pump motor.
 Hydraulic Oil Tank Inspection
Check the hydraulic oil tank oil level. Correct oil level is important for proper hydraulic system
operation. Low oil level can cause pump damage. Overfilling can cause loss of oil or lift system
malfunction.
Hydraulic oil expands as its temperature rise. Check the oil level at operating temperature. After
approximately 30 minutes of truck operation. To check the oil level, park the truck on a level surface.
Put the mast in a vertical position and lower the fork carriage fully down. Remove the floorplate and
observe the fluid level marking on the oil tank. Do not overfill.
Check the condition of the hydraulic oil for color, clarity, and contamination. Change the hydraulic oil as
necessary.
 Hydraulic oil tank breather Inspection
Remove the oil tank filter/breather and inspect for excessive contamination and damage.
Changing the Hydraulic oil
The new type of the tank
1. Turn the key switch to the OFF position.
2. Remove the filter cover to allow for faster draining.
3. Remove the screw plug and allow oil to drain into container.
4. When the oil has drained, reinstall the plug into the drain port.

Fig 1 The module of oil tank(New type)

5. Fill the hydraulic tank to the proper level with new hydraulic oil. Do not overfill the hydraulic tank.
Note: Hydraulic oil must comply to ISO VG-46(SAE 15W)
6. Cover the filter.
7. Operate the lift pump for one to minutes to purge air from the hydraulic system.
8. Add oil as necessary. Check the oil level on the content gauge, make sure there is oil in it.

Fig 1 The module of content gauge

The old type of the tank
1. Turn the key switch to the OFF position.
2. Remove the air filter/ dipstick to allow for faster draining.
3. Remove the screw plug and allow oil to drain into container.
4. When the oil has drained, reinstall the plug into the drain port.

Fig 1 The module of oil tank

1—Drain plug 2—Drain port 3—Tank 4—Dipstick 5—Air filter 6—Filter

5. Fill the hydraulic tank to the proper level with new hydraulic oil. Do not overfill the hydraulic tank.
Note: Hydraulic oil must comply to ISO VG-46(SAE 15W)
6. Install the air filter/dipstick.
7. Operate the lift pump for one to minutes to purge air from the hydraulic system. Remove air
filter/dipstick and check the oil level on the dipstick as shown in figure 3.
8. Check oil level of oil tank again. Add oil as necessary.

Fig 2 model of dipstick

Changing the filter/element
BYD forklift has two types of return oil filter, one is can not be replaced (old type) and another one can
be replaced element (new type).
CHANGE THE NEW TYPE FILTER ELEMENT
Removing the element
1. Switch off hydraulic system and release filter pressure.
2. Unscrew cover plate
3. Pull out filter element (with contamination retainer, if present) by the handle. Examine element
surface for dirt residues and large particles since these can be an indication of damage to components.
Fitting the element
1. Lubricate the sealing surfaces on the filter housing and cover plate, as well as the O-ring, with clean
operating fluid.
2. When fitting a new filter element, check that the designation corresponds to that of the old
element.
3. If present, fit the contamination retainer onto the new or cleaned filter element by clockwise.
4. Place filter element carefully on to the element spigot in the housing.
5. Replace cover plate and tighten with appropriate tightening torque.
6. Switch on hydraulic system and vent filter at a suitable point in the system.
7. Check filter for leakage.

Fig model of return filter (new)

 New filter

CHANGE THE OLD TYPE FILTER ELEMENT

The filtering accuracy of former filter is 20μm. This element in the return oil filter cannot be replaced.
The whole filter needs to be replaced when fault occurs and every 1000 working hours it needs to be
replaced. To replace the return oil filter, first loosen the clamps on both sides of the filter, and then
unscrew the two screws on base of filter.

Fig 3 model of return filter （OLD）

1—Screw
2—Clamp
3—Filter
 Changing the High Pressure Filter
Any foreign particle/substance in the hydraulic oil might cause the failure to hydraulic components. To
better protect the hydraulic components which set higher standards on hydraulic oil (e-hydraulic
valves), the filtering element needs to be replaced/changed on the regular basis. The filter element
needs to be changed after the 1st 1000 operating hours. Afterwards, change the filter element every
2000 working hours.

Fig 4 model of high pressure filter

1—Screw plug 2—Profile seal ring 3—O-ring 4—O-ring (bowl) 5—Back-up ring (indicator)
6—Filter element 7—Oil drain plug 8—O-ring
Removing the element
1. Switch off hydraulic system and release filter pressure.
2. Remove oil drain plug. Drain oil into container.
3. Unscrew filer bowl (drain fluid into a suitable container and clean or dispose of it in accordance with
environment ).
4. Remove filter element from element spigot in filter head (check surface of element for contamination
residue and large particles; these can indicate damage to components).
5. Replace or clean filter element.
6. Clean filter bowl and filter head; particular attention must be given to the threads!
7. Examine filter, especially sealing surfaces, for mechanical damage.
8. Check O-rings and replace if necessary.
Fitting the element
1. Wet the sealing surfaces and thread on the filter head and bowl/end cover, as well as the O-ring, with
clean operating fluid.
2. When fitting a new filter element, check that the designation corresponds to that of the old element.
3. Place filter element carefully on to the element spigot.
4. Screw in filter bowl fully.
5. Screw in oil drain plug.
6. Unscrew filter bowl or end cover by one quarter-turn.
7. Switch on hydraulic system and vent filter at a suitable point in the system.
8. Check filter for leakage.
Changing Brake Fluid
The service brake system is a self-contained system filed with hydraulic oil and does not require frequent
service. However, normal operation does use a small amount of hydraulic fluid so the master cylinder
reservoir must be checked and refilled at the 1000-hr/6-month interval.
A float switch inside the reservoir an indicator light on the display panel if the hydraulic oil drops below the
minimum safe level between checks, as in the case of a leak.
The reservoir stores a small amount hydraulic oil (DOT 4) to compensate for normal loss.
Due to the long time use, brake fluid will turn bad and therefore need to be replaced in time. If foreign
article or water or precipitate gets into brake fluid, filter or replace the brake fluid immediately.
Otherwise it might cause insufficient pressure in the drive units and impair the braking effect.

Fig 5 The moudle of break system Fig 6 The moudle of drive bridge
1—Brake oil resorvoir 2—Brake oil hose 3—Brake Pedal 4—Master cylinder 5—Master
cylinder

1. Run the forklift till drive units get warmed up;

2. Park the forklift securely on the level ground so that brake fluid could be easily drained out;
3. Cleanse drain plug (2) and oil injection plug (1) and their neighboring area;
4. Place a reservoir under the drain plug (2);
5. Remove the drain plug (2) and oil injection plug (1);
6. Depress and release the braking pedal. Repeat this action several time till the brake fluid is drained
out;
7. Put on the drain plug with oil-ring and tighten it;
8. Torque on drain plug: 20Nm
9. Fill brake fluid into the brake fluid reservoir till the fluid reaches required level (a line marked in the
reservoir)
Note: brake fluid type: DOT4. Use brake fluid type other than PMP prescribed will directly impair the braking
performance of forklift and increase the risk of accidents.
 10. Tighten the injection fluid plug;
11. Torque on injection fluid plug: 20Nm;
12. Breath the air out of braking system. Depress and release the braking pedal for 4 to 5 times.
Depress the braking pedal fully and stay in that position. Meanwhile remove the drain plug (2), which
allows brake fluid and air to come out and then put on the drain plug (2);
13. Repeat the step 12 till no more air is breathed out through drain plug;
 Changing gearbox oil
ATTENTION: The oil type is Mobil 424
1. Operate the forklift until the gearbox fever。
2. In order to fully drain the gear oil, lift truck from both sides, and make sure the gearboxes are in the
horizontal position.
3. Remove the wheel.
4. Cleaning the oil level plug 3, the filler plug 1, drain plug 2 and the vicinity.
5. Place a container under the oil drain plug 2.
6. Remove all oil drain plugs, and drain the gear box oil completely.
7. Reinstall and tighten the drain plug 2 with torque 20Nm.
8. Add about 0.55-0.65L to gear box oil from the plug 1, until the oil start leaking off the plug 3.
9. Tighten the plug 3 and plug 1, torque is 20Nm.
10. Replace the other side of the gear box.

Lubricating
Lubrication site contains the following location：
1. Tilt cylinders eccentric shaft： EP2
2. Mast rotation base： EP2
3. Chain: 20# Machinery oil
4. Steering axle shaft pin： EP3

Tilt cylinders eccentric shaft Mast rotation base

Chain Steering axle shaft pin