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HELI G3 Series Operation & Service Manual
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HELI G3 Series Operation & Service Manual

Dual-drive lithium battery powered counterbalanced forklift trucks 2.5-3.5t
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OPERATION & SERVICE
MANUAL
G3 Series Dual-drive Lithium Battery
Powered Counterbalanced Forklift Trucks
2.5-3.5t

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Summary of Contents for HELI G3 Series

  • Page 1 OPERATION & SERVICE MANUAL G3 Series Dual-drive Lithium Battery Powered Counterbalanced Forklift Trucks 2.5-3.5t...
  • Page 2 G3 series dual-drive lithium battery powered forklift truck. They are particularly suitable for railway stations, ports, freight yard, warehouse and food, light textile industry, as well as general industrial goods loading and unloading, transporting, stacking, etc.
  • Page 3 precautions in this manual strictly. This manual is the description of standard and optional trucks. Non-standard trucks shall prevail in kind. If you have any technical questions, please consult the manufacturer. This manual content might not correspond with the actual condition because of the improving of our products.

  • Page 4: Table Of Contents

    8. Capacity chart ....................6 Ⅱ. Primary Parameters of Forklift Truck ............... 8 Ⅲ. The Structure, Principle, Adjustment and Maintenance of Forklift Truck .... 10 1. Transmission system(Heli bridge box) ............10 2. Braking system ....................20 3. Steering system ....................27 4.

  • Page 5: Ⅰ. Safety Regulations For Driving And Operation Of Forklift Truck

    Ⅰ. Safety regulations for driving and operation of forklift truck 1. Fundamental principle Drivers and superiors of the truck should always keep “SAFTY FIRST” in mind. Operate according to the OPERATION & SERVICE MANUAL and OPERATOR’S MANUAL. 2. The delivery of the truck Pay attention to the following items when delivering the forklift truck by car: (1) Pull up the hand brake;...

  • Page 6: Operation Of Forklift Truck

    (6) Complete the preparation work before starting; (7) Loose the parking brake; (8) Carry out the operation of mast lifting and lowering, forward and backward tilting, steering and braking. 5. Operation of forklift truck (1) Only trained and authorized operator shall be permitted to operate the truck; (2) Wear safety guards such as shoes, helmet, clothing and gloves while operating the truck;...

  • Page 7: Daily Maintenance Of Forklift Truck

    (13) Tilt the mast backward as possible if the lifting height is high. Load or unload with mast slightly forward or backward tilt; (14) Slow down and be more careful when travelling on dock or bridge plate; (15) When checking the battery or fuel tank level the driver should not be on the truck and make the truck shut down and stop steadily;...
  • Page 8 HD DRIVE AXLE OIL truck GL-5 HELI drive axle: Mobil ATF220 ● The oil adding volume is given based on standard mast. ● Apply lubricating grease NYOGEL 782G to the conductive plate on the steering wheel horn switch acted by the connecting point.
  • Page 9 (3) The figure of Lubrication System...

  • Page 10: The Frame Number Position

    7. The frame number position The unique series number (the same number as the product number) is marked on the frame of the forklift truck when leaving the factory, and it is permanently marked on the frame with steel marks, which can trace the production, sales, maintenance and other information of the truck.
  • Page 11 (2-stage mast) (3-stage mast) 2.5t 2.5t (2-stage mast) (3-stage mast) (2-stage mast) (3-stage mast) 3.5t 3.5t...

  • Page 12: Ⅱ. Primary Parameters Of Forklift Truck

    Ⅱ. Primary Parameters of Forklift Truck...
  • Page 13 Primary Parameters Model number CPD25 CPD30 CPD35 Configuration GE2DLI GE2DLI GE2DLI Rated load weight 2500 3000 3500 Load centre distance Power source Lithium Battery Operation type Sit-on truck Tyre type Super elastic solid tire Size of front tyre 23x9-10 23x10-12 23x10-12 200/50 200/50...

  • Page 14: Ⅲ. The Structure, Principle, Adjustment And Maintenance Of Forklift Truck

    1. Transmission system(Heli bridge box) 1.1 General description This part is about the introduction for Heli bridge box that adopted by this series battery truck. The transmission system with Heli bridge box is split type dual drive axle. The drive axle is mainly composed of left drive unit and right drive unit. Each drive unit consists of a single drive machine and a reduction box, wherein the reduction box is a wheel-side reduction and wet braking structure.
  • Page 15 transporting. The drive axle must be transported with care or it may injure the person or the axle itself. When slinging, special slinging equipment must be used to sling from the slinging area (note: the driving unit and oil weight of about 133kg); During transportation, the drive unit must be fixed on a special pallet for transportation.
  • Page 16 with the position of the oil port. The service cycle of lubricating oil is 1000 hours or one year (whichever comes first), that is, the forklift needs to change the lubricating oil after working for 1000 hours or one year, clean the lubricating oil in the gearbox, and add the specified lubricating oil.
  • Page 17 Figure 1-4 Positions of oil holes 2. oil filling hole 3.oil viewing hole 4. vent plug 1.3.4 Drive axle and frame, wheel installation Figure 1-5 Torque requirements for connecting drive axle with frame and rim When it is installed with the frame, check whether the surface of the frame connecting plate is flat or damaged.
  • Page 18 When installing the wheel, ensure that the corresponding mounting surface of the wheel hub and rim is clean, and check whether there is damage. Align the rim hole with the hub bolt on the hub, and push in the wheel to make the wheel rim coincide with the hub mating surface.
  • Page 19 Avoid splashing the cleanser on the skin while using. Do not drink or inhale the volatile gas. In case of accidental drinking of detergent, seek medical advice immediately. Keep motor output shaft and driving gear (part 3) clean. Load the driving gear (part 3) into the motor output shaft, and tighten the inner hexagon bolt (part 1) with the flat washer (Part 2).
  • Page 20 Figure 1-7 Disassembling of drive gear 1. Hexagon socket bolt M16×1.5×130 2. Flat gasket 3. Drive gear 4. Motor The driving gear (part 3) is mounted on the motor shaft through a cone limit, and the end face is fastened by a M16×1.5×130 hexagon socket bolt (Part 1) with a flat gasket (Part 2).
  • Page 21 Figure 1-8 Structure of the reduction gearbox (1) Figure 1-9 Structure of the reduction gearbox (2)
  • Page 22 Figure 1-10 Structure of a reduction gearbox (3) 1. Housing cover 2. Driving gear 3. Piston 4. Driven gear 6. Bearing 6209NR 7. apex pin 1 8. apex pin 2 9. apex pin 3 10. Oil seal 11. sliding bearing 12.
  • Page 23 Figure 1-11 Installation of brake cylinder (1) Figure 1-12 Installation of brake cylinder (2) 1. Brake cylinder assembly 2. check ring 3. Pin 4. housing cover 5. Oil seal 6. Top pin 7. Sliding bearing After installation, check and adjust the top pin in the brake cylinder (part 6, there are several different lengths and sizes for selection), install the bottom surface of the groove according to the sliding bearing (part 7) whose size does not exceed the cover plate (part 4), and select the top pin with appropriate length.

  • Page 24: Braking System

    installing the pin, and grease the lip of the oil seal gently. Wet multi-disc braking method is adopted for both service and parking braking, with oil consumption of 1.94cc for unilateral braking once, and 2.935cc after considering the maximum wear of friction disc. The tightening torque of the brake oil port and the hand brake cable is 25-30N.m, as shown in Figure 1-13.
  • Page 25 2.2 Parking Brake Operation The driving brake system mainly consists of brake pedal, main pump, sub-pump brake oilcan, pipeline and brake. The principle of service brake is shown in figure 2-1, and the structure of brake pedal is shown in figure 2-2, which is installed on the support assembly through pin shaft.
  • Page 26 Fig.2-2 Service brake device 2.3 Brake pedal adjustment (1) Shorten the push rod on the brake main pump; (2) Adjust the stop bolt. As shown in the figure below, adjust the pedal height, which is about 60-75-mm; After stepping the pedal, the gap between the pedal and the front bottom plate should be greater than 20 mm;...
  • Page 27 Fig.2-3 Brake pedal adjustment 2.4 Brake master pump The master pump consists of a seat, a one-way valve, a return spring, and a leather bowl, piston and auxiliary leather bowl. The ends are secured with stop washers and stop wire, the exterior is protected by a rubber dust cap, and the master pump piston is actuated by a push rod with the help of an operating brake pedal.
  • Page 28 (piston front chamber) through the one-way valve, and the piston returns to the original position.The brake fluid in the master pump flow back to the fuel tank through the oil return port, adjust the one-way valve pressure into a certain proportion with residual pressure in the brake pipe and brake sub-pump ,makes the brake fluid in the sub-pump flow back to the fuel tank through the oil return port, adjust the one-way valve pressure into a certain proportion with residual pressure in the brake...
  • Page 29 When the brake cylinder is in the release state, connect the brake rubber hose and the hand brake cable with the brake cylinder and tighten the torque according to the above requirements. Add brake fluid to the oil pot shown in Figure 2-2 and loosen the exhaust port shown in Figure 2-5.
  • Page 30 handle. After the truck stops, pull the brake handle, the brake is locked, and the truck is in the parking brake state. The brake can provide the different braking forces required for parking on ramps or ground. The braking force can be increased by turning the regulator clockwise. And turning the regulator counterclockwise could reduce braking force.

  • Page 31: Steering System

    Fig.2-5 Installation of brake switch 2.9 Fault diagnosis Problem Analysis of causes Troubleshooting Replenish brake fluid 1）insufficient brake fluid Check out and replace brake 2）Impurities are mixed into the brake fluid fluid Poor or Repair 3）Leakage of brake system braking Deflate 4）Air are mixed into the brake fluid Adjust...
  • Page 32 turning is often required at the minimum radius, so the steering system is required to work reliably and operate lightly. When the forklift is unloaded, the load of the steering bridge accounts for about 55-60% of the truck weight. Forklifts tend to use power steering (hydraulic power steering or full hydraulic steering) to reduce operator labor intensity.
  • Page 33 Fig.3-1 Steering control mechanism G3 series of 3~3.5t forklift steering mechanism is mainly composed of the steering wheel, pipe column, universal joint, steering and mounting bracket, etc (as shown in figure 3-1), they are made up of mounting bracket is fixed on the instrument...
  • Page 34 axle section for more information). 3.4 Steering axle The steering axle (as shown in figure 3-2) consists of steering axle body, steering cylinder, connecting rod, steering knuckle and other parts. The steering trapezoid adopts the slider-crank mechanism, and the oil cylinder piston rod pushes the steering knuckle through the connecting rod to make the steering wheel offset, thus realizing the steering.
  • Page 35 1) Steering axle body 2) connecting rod 3) steering cylinder 4) knuckle 5) Axle sleeve 6) Tapered Roller Bearings 7) Steering stub 8) Angle potentiometer 9) Tapered Roller Bearings 10) Tapered Roller Bearings 11) Locknut 12) Gasket 13) Lockpin 14) Wheel hub cover 15) Steering wheel hub 16) Oil seal 17) Oil seal 18) Connecting rod pin (1) Steering cylinder The steering cylinder is a double-acting piston cylinder.
  • Page 36 Fig.3-4 Wheel hub 3.5 Installation, commissioning and maintenance 3.5.1 Adjustment steps for pre-load on steering wheel bearings (1) As shown in figure 3-5, grease the inner cavity of the wheel hub, inner and outer bearings and the wheel hub cover, and grease the lip of the oil seal; (2) Fix the outer ring of the bearing onto the wheel hub and install the wheel hub onto the steering knuckle shaft;...
  • Page 37 Fig. 3-5 Add grease and adjust preload (6) Gently knock the wheel hub with a wooden hammer, turn the wheel hub 3 to 4 circles by hand to ensure smooth rotation, and measure the rotational torque of the wheel valley, whose value is 2.94~7.8N.m (0.3~0.8 kgm); (7) When the rotational torque is higher than the specified value, it can be returned 1/6 circle and then measured the rotational torque;...
  • Page 38 (3) Pay attention to check the working status of steering system during daily maintenance. When steering, the manual force acting on the steering wheel should be 6-20N; The difference of right and left steering force is no more than 5N; When the car travels in straight line at the maximum speed, there should be no obvious snake phenomenon.

  • Page 39: Electric System

    4. Electric system 4.1 General description The electric system of 2.5-3.5t dual-drive four-wheel balanced forklift trucks is an AC control system with high performance, which can realize a silent, high efficient, smooth and safe control of the truck. The electric system is mainly composed of smart instrument, control system, traction motor, pump motor, steering motor, battery, control switch, acousto-optic system, lighting device and connecting wire harness.
  • Page 40 Key sw. F3-10A NETWORKING DEVICE 80V-24V DC-DC 选项optional function 200R 420W WORK SIGNAL CANH CANL FUSE FUSE 250A 350A 钥匙 MC COIL 主接触器 1A26 脚刹 P.B. 1A13 3A1 KEY 前进 倾斜 FORWARD 后退 BACKWARD 倒车继电器 侧移 12VDC 使能开关 ENABLE 1A34 PENC_R 下降锁止电磁阀...
  • Page 41 Key sw. F3-10A NETWORKING DEVICE 80V-24V DC-DC 选项optional function 200R 420W WORK SIGNAL CANH CANL FUSE FUSE 300A 400A 钥匙 MC COIL 主接触器 1A26 脚刹 P.B. 1A13 3A1 KEY 前进 FORWARD 倾斜 后退 BACKWARD 倒车继电器 起升使能 使能开关 ENABLE 1A34 12VDC PENC_R 1A10 下降锁止电磁阀...
  • Page 42 4.2 Detailed description of electrical system 4.2.1 CAN bus network technology 2.5-3.5t dual-drive four-wheel counterbalanced forklift truck uses CAN bus network technology, and each module connected to CAN network (including traction control module/lift control module/ instrument display module) act as an "access point"...
  • Page 43 Fig.4-3 ZAPI smart instrument panel 1. JL-3 instrument is a smart instrument panel connected to the truck system through CAN bus. The smart instrument panel provides fault diagnosis and setup for the entire truck control system: smart displayer, traction controller, lift controller, valve controller.
  • Page 44 4.2.2.2 Instrument connector with 23 core Positive pole of the power supply The positive terminal of the power supply for digital input device -BATT Negative pole of the power supply -BATT Negative pole of the power supply digital input, -BATT/+BATT range voltage digital input, -BATT/+BATT range voltage CAN_L CAN low level signal...
  • Page 45 4.2.2.4 Instrument function diagram Start Battery level Without fault , With fault Then display Main interface Travelling hour with fault Or without Speed Click key 6 twice Display the node Steering angle number and the Input the password fault code value Working mode Parameter menu Use key 1 and 2 to choose different submenu,...
  • Page 46 appropriate photosensitive effect Power-on interface: the screen content displays during the instrument power-on initialization stage, which is divided into standard interface and neutral packaging interface. Password change: Enter the 6-digit password on the parameter setting screen Fault inquiry: find the record number and value of the faulty node on the CAN bus in history.
  • Page 47 trucks are equipped with three ZAPI motor controllers imported from Italy to control the traction and lifting systems of the forklift truck respectively. 4.2.3.2 Introduction to the control system The controller assembly includes motor controller, contactor, relay set, fuse, OPS warning buzzer and associated wiring harness.
  • Page 48 Fig.4-8 Assembly of control device(2.5t) （1）Model of controller(3-3.5t) Model of left/right traction controller: ZAPI DUAL ACE2 80V/350A (each for left and right) Model of oil pump controller: ZAPI ACE3 80V/450A （2）Model of controller(2.5t) Model of left/right traction controller: ZAPI DUAL ACE2 80V/300A (each for left and right) Model of oil pump controller: ZAPI ACE3 80V/350A...
  • Page 49 maximum allowable working temperature is 85º C. ●Protection functions of motor controller: a) Battery polarity protection b) Incorrect connection protection c) Over heat protection; overload protection; short circuit protection d) Protection class of controller 1P65 e）Out-of-control protection; f) Battery over discharging protection g）Mis-starting protection.
  • Page 50 4.2.5 Lithium battery 4.2.5.1 Lithium Battery specification Table 4-3 Lithium Battery specification Brand Capacity Specification 3-3.5T 2.5T Remark ● 271AH 1P5S Suitable for case ● ○ Pengcheng 404AH 1P5S 775*705*758 ○ 542AH 1P6S 4.2.5.2 Lithium battery usage The usage and routine maintenance of the lithium battery will influent lithium battery life and performance.
  • Page 51 be sufficient, but it is strictly prohibited to overcharge; (3) When the truck needs to be stored for a long time, it should be kept at 50% ~ 80% of the battery, and do not charge up full. Fill the battery before use and then use, which can effectively avoid the phenomenon of battery bloating;...
  • Page 52 ZAPI shall be notified immediately and the agent shall determine the safety of the truck. Note: After the chopper is installed, the truck wheels should be lifted (off the ground) for test, so that there will be no danger even if there is a connection error.
  • Page 53 is damage at battery monomer. 3.Test B+, B-, Whether Power cables on terminal posts such as the main contactor are secured. 4. Check whether the controller voltage calibration parameters are consistent with the actual voltage. The hardware circuit of the overvoltage protection on the logic card is fault.
  • Page 54 Troubleshooting: Reset the controller. If the fault persists after the reset, replace the controller. Fault description: Parameters have been restored to default parameters. This fault is a warning that the "CLEAR EEPROM" operation has been correctly completed before the "CLEAR EEPROM" operation is completed and the key is restarted.

  • Page 55: Analog Input

    Troubleshooting: 1. Check whether the type of controller and the parameters inside is right. 2. Replace the controller. Fault description: When the ANALOG signal in the A/D converter (A stands for ANALOG, D stands for DIGITAL) output A constant value for more than 400 milliseconds, the alarm will be reported.

  • Page 56: Hydraulic System

    5. Hydraulic system 5.1 General description The hydraulic system is composed of oil pump, multi-way valve, lifting oil cylinder, tilting oil cylinder, high and low pressure oil pipe, joint and other parts. The lifting motor drives the oil pump, which converts mechanical energy into hydraulic energy and supplies the system with oil, which is distributed to each cylinder through multiple valves.
  • Page 57 Fig.5-2 Hydraulic piping diagram 5.1.1 Oil pump The oil pump converts the mechanical energy of the motor into the hydraulic energy. The lifting pump is a single The oil pump used by forklift is external gear pump. pump (figure 5-3), and the steering braking system is a dual pump (Fig.5-4). Fig.5-3 lifting pump 5.1.2 Multiway valve The control valve adopted by this truck is the load sensing multiway valve,...
  • Page 58 Steering relief valve Main relief valve Fig.5-5 Outline drawing of multiple valve Multi-way valves are disc valves, adopts mechanical manipulation control to distribute high pressure oil to the lifting cylinder or tilting cylinder and make oil to flow back to the tank. Forward tilting self-locking valve is integrated in the tilting valve plate to prevent the tilting cylinder from tilting forward under the weight of the mast due to the misoperation of the handle in the condition of no power oil source.
  • Page 59 D) Tighten the nut at last. For electric forklift truck, each valve plate is equipped with a valve control switch for the electrical control system to control the motor speed according to different actions. A speed regulation sensor is installed below the lifting valve plate to control the motor speed accurately when lifting.
  • Page 60 23.The steel ball 24.Combination washer 25.Hexagon bolts Fig.5-7 Lifting cylinder 5.1.4 Pipeline explosion-proof valve (Stop valve) The pipeline explosion-proof valve is used to prevent the damage of personnel and goods caused by the collapse of the high pressure rubber hose. It is installed at the bottom of the oil cylinder.
  • Page 61 Fig.5-9 The speed limit valve Working principle, working flow direction is from B to F, the flow speed is limit. Fig. 5-10 Flow condition with speed limit Working flow direction is from F to B, flow freely. Fig. 5-11 Free flow condition 5.1.6 Tilting cylinder The tilting cylinder is a double-acting piston hydraulic cylinder mounted on both sides of the mast, and its piston rod end is connected with the mast.
  • Page 62 cylinder bottom, guide sleeve and sealing element. Piston and piston rod adopts welding structure, piston outer edge is equipped with a supporting ring and two Yx sealing rings, in the guide sleeve hole is equipped with Yx sealing ring, retaining ring and dust proof ring, the shaft sleeve supports the piston rod, sealing ring, retaining ring and dust proof ring can prevent oil leakage and dust, together with the "O"...
  • Page 63 and the lifting height of the mast. Refueling cover Return oil filter Oil suction filter Fig.5-13 Oil tank schematic 5.2 Maintenance, fault analysis and troubleshooting methods 5.2.1 Maintenance Before and after the shift, check whether there is leakage or serious oil leakage in the pipe joint, lifting cylinder, tilting cylinder, oil pump, full hydraulic steering gear and steering cylinder of the hydraulic transmission system;...
  • Page 64 multi-way reversing valve fails. 4) Multi-way valve reversing valve The clearance between the valve handle control handle and valve body wear, and the hole after chrome plating is excessive oil leakage 0.01~0.02. 5) Oil leakage between the body of the Replace the sealing ring and tighten the multi-way reversing valve.

  • Page 65: Lifting System

    sound. The steering wheel turns, and the oil cylinder sometimes moves and sometimes does not. Check for the presence of the ball and 3) The steel ball one-way valve in the for any dirt that may have stuck the ball. valve body fails, the fast and slow steering wheels are both heavy, and there is no pressure for steering.
  • Page 66 Fig.6-1 Inner and outer mast 6.1.2 Fork carrier The fork carrier rolls through the main roller inside the inner mast. The main roller is mounted on the main roller shaft and stuck with elastic retaining ring. The middle and bottom rollers adopt compound rollers; The main roller shaft is welded to the fork carrier, and the side roller of the plate is bolted to the fork carrier.
  • Page 67 1. Limit screw 2. Washer 3. Load-backrest 4. Washer 5. Bolt 6. Fork carrier 7. Main roller 8. Check ring 9. side roller 10. Adjusting gasket 11. Side roller 12. Washer 13. Bolt 14. Fork assembly Figure 6-2 Fork carrier 6.1.3 Adjustment method of roller 8 compound rollers, respectively installed on the upper end of the outer mast (2), the lower end of the inner mast (2), and both sides of the column plate of the fork...
  • Page 68 together to make the inner mast and fork carrier move freely. Fig.6-3 Roller layout Note :(a) Adjust the clearance of side rollers to be 0~0.5mm; (b) Butter the main roller surface and the contact surface of the mast. (Announcements: the maintenance of the upper compound roller of the inner and outer mast belongs to the high maintenance, and safety shall be paid attention to.
  • Page 69 roller is as shown in the figure. Special gaskets are added between the side roller and the roller shaft. 6.1.4 Repair （1）Adjusting of the lifting cylinder Readjust the stroke of the lift cylinder when the lift cylinder, the inner mast or the outer mast is replaced.
  • Page 70 upper end joint of the chain so that there is an A distance between the main roller and the mast channel, as shown in the Fig.6-5. (c) Make the fork carrier fall to the ground and tilt back in place, adjust the adjusting nut of the upper end joint of the chain, so that the tension of the two chains is the same.
  • Page 71 Fig. 6-6 （4）Replacing rollers of masts (a) Take apart the fork carrier from the inner mast, then replace the main roller follows the way as c. (b) Park the truck on the horizontal ground and lift up the front-wheel 250～ 300mm from the ground (c) Pull parking brake level fully, and use a wedge to make back-wheel stationary.
  • Page 72 (j) Assembly the lift cylinder and the fork carrier as disassembly contrarily. 6.2 Genneral description of two-stage full free lifting system The two-stage full free lifting system is a two-stage roller vertical lifting and shrinking system, which consists of two masts, two rear lifting cylinders, one front lifting cylinder and fork carrier.
  • Page 73 6.2.2 Fork carrier The fork carrier rolls through the compound roller, the main and side rollers inside the inner mast. The main roller at the upper end of the column plate is mounted on the main roller shaft and stuck with the elastic retaining ring. The main roller shaft is welded to the fork carrier, and the side roller of the column plate is bolted to the fork carrier.
  • Page 74 carrier (4); 2 main rollers are mounted on the upper end of the column plate of the fork carrier. 2 side rollers are mounted on the top of the column plate of the fork carrier. The compound rollers not only bear the load from the front and rear directions but also bear the lateral load.
  • Page 75 Note: the clearance adjustment method of the side roller of compound roller is as shown in the figure. Special gaskets are added between the side roller and the roller shaft. 6.2.4 Repair （1）Adjusting of the lifting cylinder When the lifting cylinder, inner mast or outer mast are disassembled and replaced, the stroke of the rear lifting cylinder shall be adjusted again (Note: there is no need to carry out the front lifting cylinder).
  • Page 76 two oil cylinders are in sync. You can refer to the adjustment method of synchronization method of lifting. (d) Adjust the tension of the chain. The adjustment of lifting cylinder also belongs to high maintenance, should pay attention to safety. Fig.
  • Page 77 Fig. 6-11 (3) Replace the roller of fork carrier (a) Hold a pallet on the fork and park on the level ground. (b) Drop forks and pallets to the ground. (c) Remove the upper end joint of the chain and remove the chain from chain wheel (Fig.
  • Page 78 (a) Remove the fork carrier from the inner mast in the same method of the replacement fork rack roller as described in the c. (b) Drive the forklift truck to the level ground and lift the front wheel 250 ~ 300mm.
  • Page 79 axle housing by the supporting shaft, and the middle of the outer mast is connected with the truck frame by the tilting cylinder, which can be tilted forward and backward under the action of the tilting cylinder. The channel steel of the outer mast is C-type, with the main roller and side roller mounted on the upper part;...
  • Page 80 fork carrier. The longitudinal load is borne by the main roller, which emerges from the top of the mast when the fork reaches the top, and the transverse load is borne by the compound roller. 1. Limit screw 2. Washer 3. Load-backrest 4. Washer 5. Bolt 6. Fork carrier 7.
  • Page 81 upper end of the column plate of the fork carrier only bears the load from the front and rear directions, while the side roller bears the lateral load in the left and right directions. Main roller and side roller are used together to make the inner mast and fork carrier move up and down freely.
  • Page 82 Fig. 6-16 The compound roller Note: the clearance adjustment method of the side roller of compound roller is as shown in the figure. Special gaskets are added between the side roller and the roller shaft. 6.3.4 Repair （1）Adjusting of the lifting cylinder When the lifting cylinder, inner mast or outer mast are removed and replaced, the stroke of the rear lifting cylinder shall be adjusted again (Note: there is no need to carry out the front lifting cylinder).
  • Page 83 two cylinders are in sync. Can refer to the adjustment method of lifting. (d) Adjust the tension of the chain. The adjustment of lifting cylinder also belongs to high maintenance, should pay attention to safety. Fig. 6-17 Adjust rear lifting cylinder synchronously (e) When the front cylinder needs to be replaced, it is necessary to remove the fork carrier.
  • Page 84 (c) Make the fork fall to the ground and tilt back into place, adjust the connection at the upper end of the chain, and adjust the nut so that the tension of the two chains is the same. (3) Replace the roller of fork carrier (a) hold a pallet on the fork and park on the level ground.

  • Page 85: Operating System

    (b) Drive the truck to the level ground and lift the front wheel 250~300mm. (c) Pull the hand braking and wedge the rear wheel. (d) Remove the upper end of the chain on the head of the rear cylinder and remove the chain from the chain wheel.
  • Page 86 Figure 7-1 Multi-way valve control device According to the arrow direction shown in Figure 7-2, count handles from the driver's side, pushing forward and pulling backward the first valve handle for several times can realize the lifting and lowering of the mast respectively. Pushing forward and pulling backward the second valve handle to achieve the mast tilting forward and backward respectively.
  • Page 87 Note: ● Operate the handle smoothly and do not pull and stop suddenly, otherwise it may be dangerous. 7.2 Fingertip control system (optional) The control system of this series electric forklift adopts the fingertip control system. The control system is integrated on the right armrest of the seat, as shown in Figure 7-3.
  • Page 88 the surrounding attention. When the " travelling direction switch" is in the neutral , the foot presses the accelerator pedal, and the truck is not moving. Note: ●When the car stops, the gear should be in the neutral （2）Fingertips switch The "fingertip switch"...

  • Page 89: Horn Button

    an alarm and informs the fault; After the joint operation is withdrawn, fingertip operation function returns to normal. ● While operating the fingertip switch, do not release it suddenly to cause a sudden stop. （3）Horn button The "horn button switch" is a circular button , that the horn will sound when pressed.

  • Page 90: Ⅵ. Lithium Battery Changing

    Ⅵ. Lithium Battery changing 1. General description Lithium Battery is the energy source of the truck. When the working intensity is high and the operation duration is long, the lithium battery needs to be replaced. The lithium battery can be changed from the right side of the truck body by forklift, pallet stacker and other tools.
  • Page 91 L2 + For example, when equipped with the 80V542Ah battery, it is estimated to use the HELI H3 series 1.5ton battery truck to pick up. Technical parameters of H3 series 1.5ton battery truck: Q=1500kg, fork length L4=920mm, front suspension L2=410mm, c=500mm.

  • Page 92: Steps To Change The Lithium Battery

    1500(500 + 410) ��2 = = 1179kg + （920 − 560） 410 + Through calculation, Q2 is 1179kg, which is larger than the lithium battery weight of 435kg, meeting the service requirements. 3. Steps to change the lithium battery Change the lithium battery according to the following steps: （1）Open the side door to the maximum Angle.
  • Page 93 （4）Adjust the fork spacing of the truck to a proper level. Put the truck directly facing the side of the lithium battery. Lower the fork horizontally and insert it into the bottom under the lithium battery. Pay attention to the fork carrier or any part of the truck body when the truck enters, otherwise it may cause damage to the side door.

  • Page 94: Steps To Install The Lithium Battery

    （6） When the truck is equipped with a cab, please pay attention to open the right door of cab before opening the side door, as shown in Figure (b) below; Then open the side door of the battery cabin, as shown in Figure (c). Figure（a）...
  • Page 95 lithium battery warehouse, adjust the height of the fork properly and enter the warehouse. Pay attention while the truck moving forward, the fork carrier or any part of the truck body should not hit the side door, otherwise the side door may be damaged.
  • Page 96 （5）Connect the lithium battery. （6）Close the side door.
  • Page 97 OPERATION & SERVICE MANUAL www.helichina.com Add/No.668, FangXing Road, Hefei, China Post Code/230000 Customer Service Hotline/4001-600761 Service Tel/+86-551-63648005,63689000 S370-2:2022 E-mail/heli@helichina.com All rights reserved...

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