HELI G3 Series Operation & Maintenance Manual
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HELI G3 Series Operation & Maintenance Manual

Rough terrain forklift with engine 5t
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HELI
OPERATION &
MAINTENANCE MANUAL
G3 Series Rough Terrain Forklift
with Engine
5t

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Summary of Contents for HELI G3 Series

  • Page 1 HELI OPERATION & MAINTENANCE MANUAL G3 Series Rough Terrain Forklift with Engine...

  • Page 3: Foreword

    Foreword 1.1 Application Scope and Instruction on the Manual • The manual contains the following contents: proper operation, easy maintenance and daily check; • Before operation, please read the manual thoroughly to guarantee safe and effective material handling through propeT operation and maintenance; •...

  • Page 4: Safety Signal, Expression And Mark

    1.2 Safety signal, expression and mark 1.2.1 DANGER It indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. You must observe this instruction. It indicates a potentially hazardous situation WARNING which, if not avoided, could result in death or serious injury.

  • Page 5: Applied Model

    1.3 Applied model The manual is suitable for the following models: ■CPCD50-CU1Y4G3 with Cummins QSF3.8 (55KW, EPA/CARBTier4(f)) engine...

  • Page 6: Truck General View

    Truck general view 1.4.1 1.4.2 Tuck application (1) Main use of forklift trucks The main use of forklift trucks is handle and stack the loads that on the pallets. When they are assembled with proper attachments, they also can handle and stack the loads that not on the pallets. (2) Prohibitive use The following prohibitive uses are not allow to use an^ay.
  • Page 7 1.4.3 Working environment and areas of forklift trucks (l)Ground condition Keep good condition of flat road surface and ventilation. Lift truck performance depends on the ground or floor conditions and travel speed should be adjusted properly. Use extreme care when operating on a ramp or rough ground or floor. ▲WARNING ■When crossing the railroad, be sure to once stop and make sure to be safe.
  • Page 8 B artery •In cold weather Under normal charged conditions, the freezing point of electrolyte is about -35?. Always keep the battery in a well-charged condition since there is danger of damaging the battery jar if electrolyte freezes. To prevent the freezing, charge at least 75% of the whole capacity. Also it is effective to keep the specified gravity up to 1.260, but not higher than this value.

  • Page 9: Measuring Unit

    •In environments where there is a risk of explosions due to suspended particulate matter or explosive gases, etc. •In cold regions, hot regions, or at high altitudes. ■In environments with exhaust emission standards. For engine-powered forklifts ■Do not use the forklift in bad weather conditions such as thunderstorms or high winds. Similarly, when dense fog arises, wait nutil visibility is good before using the forklift.

  • Page 10: Notes On New Truck Usage

    1.8.1 Parts changing at regular time Heli truck requires parts changing at regular time except for the legal rules. Parts which are important for safety will inescapably go bad if they exceed their service time, so whether the parts are damaged, change according to regulated time.

  • Page 11: Displaying Position Of The Truck Model And Number

    1.9.1 Ituck basic information table (complete by HELI dealer or agent) Model Truck number Engine series number Accessories, optional devices Dealer/agent Address Telephone number, fax number Service person Sales person 1.9.2 Displaying position of the truck model and number The truck model and number is displayed on the truck plate which is on the right side of the engine hood.
  • Page 12 Mast information Mast information consists the truck model assembled with the mast, mast type and height (M stands for two stage basic type mast, ZM standards for full-free two stage mast, ZSM stands for the full free three stage mast. The unit is cm.) Attachments consist types of side shifter, rotator, bale clamps and so on. Please refer to the attachments manual for more details such as model and function.
  • Page 13 1.9.3 Displaying position of the truck working hours It is in the middle of the meter.

  • Page 14: Table Of Contents

    1.7.2 Maintenance of the new truck ..................5 1.8 Quality guarantee and maintenance ..................5 1.8.1 Parts changing at regular time ..................5 1.8.2 Usage of HELI specified parts and oil ................5 1.9 Basic information of the truck ....................5 1.9.1 Truck basic information table ..................6 1.9.2 Displaying position of the truck model and number .............
  • Page 15 2.2.4 Protect against fire caused by wire fault ................22 2.2.5 Protect against fire caused by oil pipe fault ..............22 2.2.6 Cleaning after operation ....................23 2.2.7 If fire occurs ........................24 2.3 Basic notes ..........................24 2.3.1 Follow the rules ......................24 2.3.2 Do not operate fault truck ....................
  • Page 16 2.7.1 Be sure to carry out the starting check ................44 2.7.2 Place a warning sign around during check and maintenance ........44 2.7.3 Keep the working area clean and tidy ................45 2.7.4 Notes before check and maintenance ................45 2.7.5 Let the unauthorized people be away ................45 2.7.6 Proper using of the tools and devices ................45 2.7.7 Notes when working under the working devices ............46...
  • Page 18 3.1.2 Instrument and control devices ..................60 3.2 Parts instruction ........................61 3.2.1 Meter ..........................61 3.2.2 Operating devices ......................65 3.2.3 Assembly and disassembly of the attachments ............. 69 3.3 Operation ..........................71 3.3.1 Starting check .........................71 3.3.2 Getting on and off the truck and operation posture adjusting ........71 3.3.3 Starting, gear shifting and travelling ................
  • Page 19 4.4 Simple maintenance ......................108 4.4.1 Lubricating grease and fuel ..................108 4.4.1.1 Notes ........................108 4.4.1.2 Lubricating chart ....................110 4.4.2 Filter element cleaning ....................113 4.4.3 Water and gas exhausting of the fuel filter (diesel engine) ........113 4.4.4 Tyre changing ......................114 4.4.5 Parking brake shank operation force adjusting ............
  • Page 20 DESIGN DRAWINGS...
  • Page 22 The engine (or motor) drives the gear pump to produce high-pressure oil, which enters the multi way valve control valve and divides the oil into two parts. Part of the oil enters the lifting, tilting and attachment control valves, and controls the multi-way control valves through the joystick to realize the lifting, lowering, forward and backward tilting and attachment action functions of the mast;...
  • Page 26 The brake system is composed of service brake and parking brake. The service brake is installed in the driving wheel and generally consists of the brake device (brake pump or brake valve), brake pedal and brake. When the brake pedal is pressed, the brake medium in the brake device (brake pump or brake valve) will be filled into the brake, so that the brake will produce friction torque and prevent the wheel from rotating.
  • Page 27 Electric principle diagram...

  • Page 29: Safetynotes

    SAFETY NOTES When operating the truck, please follow the safety notes or serious injuries may be caused.

  • Page 30: Description Of The Safety Plate

    2.1 Description of the safety plate 2.1.1 Position of the safety plates Safety\ plate Position The rear side of the tilting cylinder mast pillar and top Mind your hands pillar (the middle cross beam of the extemal mast) Do not enter the space after the The rear side of the tilting cylinder mast pillar and top mast pillar (the middle cross beam of the extemal mast)
  • Page 31 Fan safety plate The top of the radiator s wind cover Aluminum radiator warning plate the radiator’s cover Usage note Right side of the engine hood Safety plate The right and left side of the extemal mast Safety belt The left side of the engine hood surface...

  • Page 32: Safety Plates

    2.1.2 Safety plates ■ (1) It is prohibited to stay at the area above or below the fork. •Do not enter the area below the fork. •Do not stay on the fork. ■ (2) Notes when slinging •Never sling the truck at the overhead guard . •...
  • Page 33 Split rim Cage protector ■(5) It is prohibited to enter the space between mast and frame. • It is prohibited to enter the space between mast and frame. ■(6) Caution: mind your hands • Do not put your hands where may be caught. ■(7) Truck washing note •Do not flush the electric parts such as electric cabinet, meters, sensors, connectors and so on.
  • Page 34 加注指定防冻液 注意高温烫伤 ■ (9) Use the radiator with care 1.Fill appointed antifreeze 2. High temperature attention •Rotate the radiator cap slowly until the coolant is cool. 严禁直接 加注自来水 、 河水、井 •Add designed anti-freeze liquid into Aluminum radiator. It is 水等硬 A Forbidden to fill hard water, such prohibited to add hard water such as tape water, river water and wall as tap water, river water, well...
  • Page 35 ■ (13) No jump starting •Start the engine only when the operator sit well on the seat; •Never try to make the engine starting circuit short circuit on purpose to start the engine, or serious injury or fire may be caused. ■...

  • Page 36: Protecting Against Fire

    Before starting the engine, check the following parts: if the battery terminal is loose, fix it. And if there is dirt such as smudginess, leaf or paper, remove it. It problems still exist, contact with HELI dealer for repair. ■ 1. Check around engine •...
  • Page 37 • Check if there are leaves or paper around fuel ■3. Check if oil or fuel leaks. • Check if there are dirt gathering under the truck tank or hydraulic oil tank; • Check if the pipes or fuel tank (1 shown in the chassis (engine transmission...

  • Page 38: Protecting Against Fite Caused By Fuel Or Oil

    • Check if the harness is loose, worn or damaged daily. Tighten the loose contactor and wire clamp. The damaged harness must be repaired or changed by HELI dealer. 2.2.5 Protect against fire caused by oil pipe fault ■ Be sure the snap clip, guard board and cushion pad are proper fixed. Loose pipe or hose may be damaged because of vibration or friction with other parts when operated and fire or injury may be caused by ejection of high pressure liquid.

  • Page 39: Cleaning After Operation

    2.2.6 Cleaning after operation ■ Remove the dirt, leaves papeT with fan after operation. • Around engine Clean around air exhausting manifold. • The bottom of the chassis Lay emphasis on the truck with bottom plate where dirt is easy to gather. •...

  • Page 40: If Fire Occurs

    2.2.7 If fire occurs ■ If fire occurs, turn the starting switch to OFF position to shut off engine. ■ Do not jump off the truck in a hurry. Support yourself with handle and pedal in order to leave safely. 2.3 Basic notes 2.3.1 Follow the rules ■...

  • Page 41: Proper Wearing When Operation

    • Do not disassemble the safety devices and make sure they are in good condition, • If there is damage or loose of overhead guard or back rest, do not operate the truck until HELI dealer agent fix it well.

  • Page 42: It Is Prohibited To Jump On And Off The Truck

    2.3.7 It is prohibited to jump on and off the truck • It is prohibited to jump on and off the truck. • Do not jump onto the truck to try to stop it when it moves accidentally without any operation.

  • Page 43: Beware Of Scalding

    2.3.10 Beware of scalding ■ Cooling liquid with high temperature • The cooling liquid is in high temperature if the truck is just stop. There is a danger of scalding caused by the ejecting of steam or boiling water if the radiator cap is removed at once.

  • Page 44: If Fire Occurs

    • Do not jump off the truck in a hurry. Support yourself with handle and pedal in order to leave safely. 2.3.13 Do not modify the truck • Contact with HELI sales and service agent before carrying out any modification (fix,...

  • Page 45: Ensure The Working Area Safety

    2.3.15 Ensure the working area safety • Ensure the flatness of the road and working area and clean the oil and grease on the working area avoiding injury caused by bump and slip. • When working in place that has a danger of falling such as dock,platform and so on, place blocks avoiding truck travelling surpassing boarder.

  • Page 46: Before Operation

    2.4 Before operatio 2.4.1 Starting check Carry out starting check every day in order to ensure truck safe operation. Refer to ^check and maintenance” for the detailed check item. 2.4.2 Check and adjust before starting ■ Check the following item before starting •...

  • Page 47: Travelling

    2.5 IVayelling 2.5.1 Preparation before travelling ■ Wear safety belt • Wear safety belt before operation; • Check if the safety belt is well; • Injury may occur if safety belt is improper fixed. ■ Proper seat posture • If you operate the truck with improper seat posture or away from the seat, accident may occur.

  • Page 48: Notes When Travelling

    2.5.2 Notes when travelling ■ Avoid sudden start, stop and direction change; • Stop truck (hydraulic-powered truck) before direction change; • Operate the operation lever (forward/backward lever, high speed/ low speed lever) after stepping on the clutch pedal fully only. (Mechanical truck) ■ Keep safety in mind during travelling •...
  • Page 49 ■ Do not stay your foot on the inching pedal (hydraulic-powered truck). • Keep foot away from the inching pedal during normal travelling or the untimely worn out of the clutch and overheat of transmission unit; • Brake unit will be ineffective if the pedal is pressed to haft engaged with the clutch.
  • Page 50 • Keep in mind that the truck with LPG container has poor backview which has a danger of collision of people around or goods. So make sure to check the back view; • Contact with HELI agent or dealer for detail when alarming devices such as backward flasher, backward sensor, backview mirror and so on are needed.
  • Page 51 ■ Bewaie of the rear part rotation; • The steeling wheel of the truck is its rear wheel which is different from the other kind of truck; • Keep a safe distance with the wall because the counter weight will rotate outside when steering. ■...
  • Page 52 compact force will cause body harm such as backpain.
  • Page 53 ■ Avoid travel on road shoulder. • Do not travel close to the road shoulder which may sink. • Keep a safe distance from the road shoulder or platform in preventing of truck falling. ■ Notes when travelling on a slope •...

  • Page 54: Notes On Truck Stopping And Parking

    ■ Notes when travel into railway lorry or container • Check the brake and block applying to the lorry, trailer and container and make sure they are well stopped; • Do not move the vehicles before the load carrying operation is finished; •...

  • Page 55: Notes On Towing

    2.5.4 Notes on towing ■ Proper using of traction pin • Traction pin is designed for the towing when it is sunk into channel or mud; • Do not use it for towing or lifting; ■ Use the traction pin as a fasten point when carrying by lorry.
  • Page 56 ■ Take care not to be caught by mast. • Do not put hand, feet or other parts of your body into mast; • There is a danger of being caught by moving parts and serious injury. • Do not stand between the mast and driver^ cab because serious injury or death may be caused by extruding.
  • Page 57 ■ Take care when carrying long and wide goods; • Take care when carrying long and wide goods. Lift the goods slowly so as not to collide anything around; • Keep the goods as low as possible and keep balance when changing direction. ■...
  • Page 58 ■ Do not carry goods with insecurity measure. ■ Make sure the goods center of gravity is in the same line with the trucks center of gravity. Do not carry unbalanced goods; • Fix the goods avoiding falling or collapse. Do not carry unstable goods;...
  • Page 59 ■ Do not push goods by the tip of fork. • Do not push goods by the tip of fork or the good may break away from the fork tip and be damaged. The reaction may cause the truck and goods to move accidentally and is dangerous.
  • Page 60 ■ Prohibition of prod goods horizontally with forks • Do not prod goods horizontally with forks or parts damage may be caused. ■ Prohibitions of carry goods with a single fork • When loading, two forks shall be loaded at the same time.

  • Page 61: Check And Maintenance Notes

    • Serious accident and adverse effect may be caused by improper check, maintenance and repair. For safety reason, contact with HELI dealer/agent for certain check, maintenance and repair. 2.7.2 Place a warning sign around during check and maintenance •...

  • Page 62: Keep The Working Area Clean And Tidy

    2.7.3 Keep the working area clean and tidy • Keep the working area clean and tidy. Remove the barriers, grease and oil. • The truck should work on flat ground with enough space. • Ensure good ventilation if the truck works inside a building. 2.7.4 Notes before check and maintenance •...

  • Page 63: Notes When Working Under The Working Devices

    2.7.7 Notes ^Yhen working under the working devices • Support fork and mast avoiding falling when working under the or serious accident will be 〇 caused. 2.7.8 Beware not to be caught by mast or falling ■ Do not put your hand, foot or other part into mast or there is a danger of being caught.

  • Page 64: Take Care Of The High Pressure Oil

    2.7.11 Beware of the rotating belt and fan ■ Do not remove the radiator’s cap as soon as the truck is stopped "because the cooling liquid has high temperature and pressure, or you may be scalded. ■ When removing the radiator’s cap ， rotate it slowly until the cooling liquid is cool to release inside pressure.

  • Page 65: Notes When Repairing Electric System

    2.7.9 Beware of the boiling cooling liquid ■ Keep your hand away from the rotating belt and fan. ■ Shut ofF the engine before open the engine hood which is only can be done by authorized person. 2.7.12 Notes when repairing electric system ■...

  • Page 66: Notes When Dealing With Battery

    2.7.14 Notes when dealing with battery The battery will produce hydrogen and oxygen during charging which may explode and electrolyte contains dilute sulphunc acid. Personal injury, explosion or fire may be caused if the battery is improper dealt. Please follow the rules below: ■...

  • Page 67: Note When Installing Or Removing The Battery

    Please refer to 4.4.4 TYRE CHANGING for tyre changing. ■ Please use the special tyre for HELI truck and follow the set inflation pressure. ■ Make sure there is no person around when inflating the tyre. Make sure the gas outlet port of the air pump is connected with tyre valve core tightly.

  • Page 68: Notes And Recommendations When Maintaining Oil Cylinders

    2.7.18 Notes and recommendations when maintaining oil cylinders As the executive element of the hydraulic system, the oil cylinder is mainly responsible for lifting, tilting, steering, side shifting and other actions on the forklift. It is characterized by precise structure, frequent actions and sensitive to the cleanliness of oil products.

  • Page 69: Note When Dealing With The Waste

    • Replace the key parts regularly. • If there is any abnormal, change the key part even it is undue. ■ Note • Check and change of the key parts and lubrication grease adding should be carried out by HELI dealer or agent.

  • Page 70: Transportation And Hanging Up

    ■ Do not stay under the lifted truck. ■ Use undamaged slings and steel rope with enough strength. ■ Please contact with HELI dealer or agent for special sling equipment if the truck has to be hung up frequently. 2.8.2 Notes when loading or unloading the truck...

  • Page 71: Truck Structure And Stability

    2.9 Tuck structure stability 2.9.1 Longitudinal stability ■ Load is balanced with the weight on the rear wheel with the front wheel as the supporting point so as to avoid truck tilting forward. ■ If the truck is overloaded, the rear wheel will lift away from the surface.

  • Page 72: Actual Loading Capacity

    • The rear wheel will be away from the ground if the truck is over loaded and thus the truck will be out of balance. Ensure the load capacity stays in the allowed range. • Series number plate on the truck shows the work in permit range. Contact with HELI dealer or agent to change the damaged or unclear plate.
  • Page 73 2.9.6Instruction on optional safety devices Safety devices are optional. Contact with HELI dealer or agent for detail. Devices and equipments listed below may not work in certain conditions. Install the devices according to the instructions for safety reason.

  • Page 75: Towing

    2.10 Towing ■ Fault truck towing Be care if there is any of the fault below when towing a truck: • Fault of brake • fault of steering • fault of tyre • fault of traction pin • Move the truck on a abrupt slope The truck is hard to control if the steering motor does not work, if theie is no power, there is no powered steering.

  • Page 76: Operaton

    OPERATION WARNING Please read the manual and safety notes carefully. When operating the truck, please follow the safety notes or serious injuries may be caused.

  • Page 77: General View

    3.1 General view 3.1.1 Ituck general view 1 • mast 11. counter weight 2. Lifting chain 12. Fuel adding port 3. Lifting cylinder 13. Rear wheel 4. Rear view mirror 14. Engine hood 5. Front lamp 15. tilt cylinder 6. Steering light and stopping light 16.

  • Page 78: Instrument And Control Devices

    3.1.2 Instrument and control devices ■ Cab...

  • Page 79: Parts Instruction

    3.2 Parts instruction ■ Devices necessary for the truck are described below. It is very important to be familiar with the devices in order to operate the truck properly. 3.2.1 Meter...
  • Page 80 ON position. Check if the bulbs are damaged if any of the indicator is off. It is abnormal when the alarming indicator is on during operation. Repair it and contact with HELI dealer or agent. ■ Fuel gauge Oil quantity is shown on the fuel gauge.
  • Page 81 The light will turn on when the starting switch is turned to ON position and it will turn off after the engine is started. During operation, stop the engine and check the engine lubricating system and engine oil level when it turns on.
  • Page 82 (truck with diesel engine). Important If the indicator lights on, stop working and report the fault to the manager or contact with HELI dealer or agent for check. ■ Preheating indicator (truck with diesel engine) The indicator means that the engine is preheating.

  • Page 83: Operating Devices

    3.2.2 Operating devices ■ Starting motor switch The switch is used to start shut off the engine. (1) [ ] position: on OFF position, you can insert or 〇 draw out the starting key. (2) [I] position: on ON position, the electric circuit has electricity.
  • Page 84 When the truck needs changing direction, push the direction switch forward or pull the direction switch backward. Important: 1. If the direction switch is not on neutral gear, engine can not start. The operator can select gear by rotating knob. ■...
  • Page 85 ■ Steering signal switch Left turning (L): push the knob forward Right turning (R): pull the knob backward When turn the steering hand wheel backward, the knob will go back to neutral position. ■ Parking brake handle The handle is used to operate parking brake. Pull the handle back completely (to lock position) and the parking brake is applied.
  • Page 86 ■ Clutch pedal (mechanical truck) When operating forward/backward lever or high speed/low speed lever, the pedal will be used. Before operating forward/backward lever or high speed/low speed lever, step on the pedal fully and release it slowly after operation. ■ Inching pedal (hydraulic-powered truck) When travelling with low speed (such as loads handing operation), the pedal is used to adjust the travelling speed.

  • Page 87: Assembly And Disassembly Of The Attachments

    ■ Steering hand wheel and knob Steering hand wheel is used to change the left- right direction. Operate the steering hand wheel with the knob. ■ Tiltable steering hand wheel lock lever The lever is used to adjust the steering hand wheel tilting angle (upward/downward).
  • Page 88 ■ Fork ■ Lower the fork bracket and until the fork contact with the ground and the lifting chain is under the tight condition. • Lose the fork stopper and move the to the 〇 middle position. Put the lower hook to the cut and disassemble the fork.

  • Page 89: Operation

    3.3 Operation 3.3.1 Starting check CAUTION Do not operate the truck until all checks are done. If there is any abnormal, report to the manager and do not operate the fault truck until it is repaired. Carry out the starting check for safety. Refer to 4.2 Starting check for detail. 3.3.2 Getting on and off the truck and operation posture adjusting ■...
  • Page 90 ■ Seat position adjusting CAUTION Adjust the seat position before getting on the truck or changing a driver. (Adjust only the truck is well stopped. Make sure you can step the brake pedal fully when you lay against the seat. 1.
  • Page 91 ■Fasten and lose the safety belt CAUTION WeaT safety belt during operation. 1. Insert the spring bolt on the left side belt to the lock on the right side. Safety belt is locked when you hear a click. 2. Hold the safety belt with left hand and press the red button on the lock with right hand when loose the belt.

  • Page 92: Starting, Gear Shifting And Travelling

    3.3.3 Starting, gear shifting and travelling ■ Engine starting CAUTION Never try to make the engine starting circuit short circuit on purpose to start the engine，or serious injury or fire may be caused. CAUTION Start the engine only when the driver sits on the seat. Before starting the engine, place the forward/backward operation lever and high speed/low speed lever on neutral position and push the parking brake backward.
  • Page 93 1. Place forward/backward operation lever and high speed/low speed operation lever on neutral position. Note: Engine can not be started unless the forward/backward operation leveT is placed on neutral position. 2. Releasing the parking brake When releasing parking brake, pull the handle back and press down the button on top of the handle at the same time.
  • Page 94 (4) The engine can only be started three times continually at most. If it can not be started in three times, check the track or contact with HELI dealer/agent for check. • If it is electric controlled engine, the interval between two consecutive stay on ON(I) position shall be more than 6s during switching key switch between OFF (0) position and ON (I) position.
  • Page 95 What is more, the brake function will be affected. Contact with HELI dealer or agent for check if the truck travels with parking brake applied for a long distance. 3. Check the safety around the truck and in the travelling direction.
  • Page 96 ■ OPS (optional) • If the seat does not bear your whole weight, for example stand or lean against forward, backward or side when operating, the safety device will prevent the truck from working. If you operate the truck with such posture, the OPS will be activated in5s and transmission box power will be cut.

  • Page 97: Start And Stop On A Slope

    ■ Direction changing 1. Release the acceleration pedal (1) and step on the brake pedal (2). Before stopping, step on the clutch pedal fully (3). 2. Before truck stopping completely, shift the forward/backward operation lever to (|)(R) position from (t)(F) position. For mechanical truck, shift the high speed/low speed operation lever to high speed or low speed position.

  • Page 98: Inching

    3.3.5 Inching CAUTION Do not make the truck inching through stepping on the acceleration pedal and adjusting brake pedal pressing distance. Make the truck inching through half engaging the clutch pedal or inching pedal. IMPORTANT • Long distance travelling with clutch engaged will damage the clutch.

  • Page 99: Operate On Snow Field And Icy Field

    3.3.7 Operate on snoiv field and icy field CAUTION Slipping can not be prevented completely even the truck is assembled with anti-slipping tyre or chain. Some model may not be suitable to assemble anti-slipping tyre or chain. • When travelling on snow or icy field, assemble anti-slipping tyre or chain. •...

  • Page 100: Load Handing Operation

    ■ Truck parking procedures 1. Park the truck on flat ground. 2. Apply parking brake. 3. Place the forward/backward operation lever and high speed/low speed operation lever on neutral position. 4. Tilt the mast forward and lower the fork to the ground.
  • Page 101 ■ Operation lever CAUTION Sit on seat properly and ensure the safety around when operating lifting operation lever. Improper operation and even serious injury may be occur if operating with improper posture or operating outside of the cab. Lifting operation lever Lifting: press the operation lever downward.

  • Page 102: Notes When The Truck Is Equipped With Solid Tyre

    Stacking 1. Make the mast be vertical and lift the fork to be 5-10cm higher than stacking position. And then move the truck forward slowly. 2. Put the truck on desired position. 3. Draw the fork out. 3.3.10 Notes when the truck is equipped with solid tyre When the truck is equipped with solid tyre, please pay attention to the following notes: 1) The truck with solid tyre is suitable for intermittent working condition and the working radius shall not exceed 2km.
  • Page 103 3.3.12.2 Opening of door After the key is opened, The left cab door assembly is a normal inlet and outlet, and the door is equipped with a key. lift and pull the unlocking buckle 7-1 to open the cab door. 3.3.12.3 Adjustment of view The cab is equipped with rear view mirrors 6 on both sides, which has a certain impact on the truck's vision.
  • Page 104 6 backview mirror 3.3.12.4 Accessories of cab Front window wiper cleaning After the truck starts, switch the rocker switch 1 to the "wiper gear", and the front window wiper acts; Switch the rocker switch 1 to the "washing gear", and the front window washing and wiper will act at the same time.

  • Page 105: Transporting

    3.4 Transporting Refer the technical parameter for truck size and weight. Refer to the following figure for truck center of gravity. For more information, please contact with HELI dealer. 3.4.1 Ituck fixing CAUTION Authorized transporting company is recommended to transport the truck through highway, railway and waterway.
  • Page 106 Forklift truck fixing method in a container: 1. For container space limit, trucks position is compact. The min. distance between the two trucks is 20-3Omm to ensure disconnecting with each one. 2. Protect the left and right sides of the frame and counter weight with felt pads before going to the container avoiding truck appearance damage.

  • Page 107: Mast Transporting And Reassembling

    3.4.2 Mast transporting and reassembling Some mast has to be disassembled during transporting for height limit. 1. Seal the hydraulic pipeline disassembling ends after disassembly. Fix the pipelines with belts. Wrap the connectors and transport with the whole truck. 2. Reassemble the mast after arriving by professionals. Main technical requirements are followed: (1) Mast assembly a.
  • Page 108 The lifting plate shown in the figure shows the proper lifting points. The points are on the mast and counter weight. For more information, contact with HELI dealer or agent. IMPORTANT Make sure all slings have the safe capacity to lift up the truck.

  • Page 109: Checking And Maintenance

    CHECKING AND MAINTENANCE Please read the manual and safety notes carefully. When checking and maintaining the truck, please follow the safety notes or serious injuries may be caused.

  • Page 110: About Checking And Maintenance

    4.1 About checking and maintenance Staring check, oil change, filter cleaning and other simple maintenance work are described below. For others that are not described, contact with HELI dealer or agent. Refer to the second chapter SAFETY NOTE for safe checking and maintenance.

  • Page 111: Check The Abnormal Found The Day Before

    Starting checking parts table Item Checking parts — Check the abnormal found the day before Leakage of oil and electrolyte Crack, damage and fixing condition (overhead guard, fork, backrest and so on) Tightness of the locking nut of the tilting cylinder piston rod Check if the light and glass cover are clean damaged.

  • Page 112: Forklift Truck

    Item Checking parts Mast operation condition Load handling Tightness of lifting chain; check if it is damaged or rust. OPS (hydraulic-poweied truck) Safety function check Parking brake 4.2.1 Check the abnormal found the day before Check the abnormal found the day before. Make sure there is no fault.
  • Page 113 ■ Crack, damage and fixing condition check Check if there is any damage, cracks, loose and clearance through visual check. Check the following parts preferentially: • Overhead guard • Fork • Backrest •Fork bracket •Mast • Fuel tank • Hydraulic oil tank ■...
  • Page 114 ■ Check if the rim nut is loose. Check if there is loose nut by wrench. IMPORTANT Tighten the rim nut to the regulated torque. tighten refer to 4.16 REPAIR proper Tque, 〇 PARAMETER. ■ Tyre and rim checking • Check if the tyres are worn, damaged. Check if there is any adhered nail and other foreign matters.

  • Page 115: Open The Engine Hood To Check

    Draw out the oil dipstick and check if the adhered oil is in normal range. Add oil if oil level is low; if oil run out, clean it. IMPORTANT • Only pure HELI hydraulic oil or recommended oil can be used.
  • Page 116 IMPORTANT If the engine oil is polluted or goes color, change the engine oil. Only pure HELI engine oil or recommended oil can be used. ■ Electrolyte level check Flammable hydrogen produced by the battery is explosive. Dilute sulphuric acid is also contained in the electrolyte.
  • Page 117 For the V belt tension check, press the middle of the belt with 98N. The belt deflation should be 10-13mm. NOTE: Change the belt if it is stretched and there is no adjusting possibility or it is damaged. Please contact with HELI dealer or agent for belt change.
  • Page 118 ■ Safety belt check Check the safety belt first. Check if the belt and connectors are damaged. Check if the belt can be pulled out and withdrawn smoothly; check if the connector can be locked ot loosen normally. Check if the belt can be locked when pulling suddenly. ■...
  • Page 119 ■ Brake pedal check Check if the brake pedal operation force and pedal distance are correct. Refer to 4.16 REPAIR PARAMETER for clearance standard value (SI) and pedal height (H) during brake. ■ Inching pedal check (hydraulic-powered truck) Check the inching pedal operation force, clearance and interlocking distance.

  • Page 120: Check When The Starting Key Switch Is On On Position

    ■ Horn check Check if the horn can sound normally. ■ Rear mirror check Check if the driver can see the rear view easily from the rear mirror. Check if it is dirty or damaged. 4.2.4 Check when the starting key switch is on OlV position ■...
  • Page 121 when the parking brake is released, it means the indicator is OK ■ Engine coolant temperature meter When the engine is cold, the pointer points to the left side and when the engine is preheated, the pointer points to the white range. ■...
  • Page 122 ■ Lights check • Check if the front lamp, contour light, steering signal, brake light and reversing light are normal. ■ Fuel level check and adding Before fuel adding, shut off the engine and be away from the open flame. Do not let the fuel run out when adding fuel, or fire may be caused.
  • Page 123 The table below lists the corresponding oil level: Truck model Full (L) CAUTION 5-7t Back buzzer check ■ Check if the back buzzer sounds when the operation lever is placed on backward position. Take care of the ventilation condition when starting engine indoor or in poor ventilated place because •...
  • Page 124 Alarm indicator on the meter ■ Check if the alarm indicator on the meter turns off as soon as the engine is started. Engine pressure alarm indicator may turns off a little later. But that does not mean the indicator has fault. If it is electric controlled engine, please stop for a check or contact with local dealer if fault indicator turns on or there is fault code, it is suggested not to staTt the engine until the fault is removed.

  • Page 125: Check When Travelling Slowly

    CAUTION ■ Inching pedal check (hydraulic powered truck) Check its function through stepping on the inching pedal when driving slowly. Check if travelling speed can be adjusted according to pressure applied on the inching pedal. Check if the truck can be stopped completely when the inching pedal is pressed down fully. ■...

  • Page 126: Check Through Operating The Working Devices Operation Lever

    • Make sure there is no abnormal noise and smell when travelling slowly. CAUTION 4.2.8 Check through operating the working devices operation lever ■ Mast, abnormal noise and smell check Check if the fork can be lifted or lowered smoothly and mast can tilt forward and backward smoothly when operating the levers.
  • Page 127 If the lifting chain is broken, the goods may fall down or truck may tip over. If there is any fault with the chain, contact with HELI dealer/agent to replace the lifting chain. Rust on the chain is the main cause of chain damage, so keep the chain from rusting in early stage.

  • Page 128: Safety Function Check

    4.2.9 Safety function check CAUTION Park the truck on a flat ground before carrying out the check. Make sure there are no people and barriers around and there is enough driving space. ■ OPS (travelling function) check (hydraulic-powered truck) The truck is not allowed to move by the OPS system when the driver goes away from the seat Check the safety function.
  • Page 129 The function is used to avoid truck moving suddenly when starting the engine as the forward/backward operation lever is placed on forward or backward position. CAUTION...

  • Page 130: Check After Operation And Report

    Checking steps 1.Park the truck on a flat and solid ground and apply parking brake. 2.Place the forward^ackward operation lever on neutral position and shut off the engine. 3.Make sure the starting motor and engine do not work even starting switch is turned to starting position when the forward/backward operation lever is placed on forward or backward position.

  • Page 131: Simple Maintenance

    OIL AND GREASE and LUBRICATING CHART. 7 Change the oil in regulated time even it does not go bad. Be sure to use HELI specified engine oil. Oil listed in the OIL TYPE TABLE is filled in the truck • before delivery.
  • Page 132 Fuel ■ Only HELI specified fuel is allowed to be used or the cleanness of the exhausting air can not meet the standard requirement. For your health and environment, use HELI specified fuel. Add the fuel to the full level after one day*s work. Reducing the air in the tank is helpful to reduce the possibility of moisture mixed into the fuel.
  • Page 133 Before assembly, do not open the new filter’s package too early • NOTE Only HELI pure filter is to be used. Filter with poor quality may affect truck performance and durability. Quality assurance is invalid.

  • Page 134: Lubricating Chart

    4.4.1.2 Lubricating chart Oil and grease adding chart (oil and grease adding position and maintenance interval)
  • Page 135 The diesel, gasoline and engine oil shall meet relative quality requirements and please refer to relevant engine operation mamials or consult the dealer / agent of HELI; Liquefied petroleum gas for vehicles (GB 19159) shall be used for LPG trucks.

  • Page 136: Filter Element Cleaning

    4.4.2 Filter element cleaning CAUTION When the engine is working, serious injury may be caused by fun or belt. Shut off the • engine before disassemble or clean filter element. When cleaning filter element, dust on it may get into eye or be breathed inside. Wear •...
  • Page 137 When the oil-water separator alarm indicator flickers, water subsided on the bottom of the filter exceeds the regulated limit. Drain out the water according to the following steps: 1.Loose the exhausting plug at the bottom of the fuel filter, (it is also used as sensor)(l) and drain out the water.
  • Page 138 1.Unload the goods on truck and park the truck on flat and solid ground. Apply parking brake 2.Lift the truck at the required position. (1)Replace the front tyre: (A) under the outer mast (2)Replace the rear tyre: (B) under the counter weight 3.Lift the truck to the position where the tyre connects with the ground a little and place a...
  • Page 139 4.Disassembling the tyre CAUTION Do not loose the rim connecting bolt (special bolt)(2) and nut for the tyre assembled with separated type rim. ■ After pressure releasing, loose the hub nut for the tyre assembled with separated type rim. For your safety, when changing or inflating the tyre, stay right before the tyre surface as shown in the figure.

  • Page 140: Parking Brake Shank Operation Force Adjusting

    4.4.5 Parking brake shank operation force adjusting CAUTION • Wedge the front and rear tyre before adjusting. Press the button (1) and release the parking brake (2) to position B. Adjust the nut (3) until the operation force of the parking brake is reached. The operation force is 250Nm before delivery.
  • Page 141 Before changing the fuse, turn off the power, (turn the starting switch to OFF position) Change the fuse with the same standard and capability. If the replaced fuse is bum again, it may be caused by the abnormal electric system, please contact with HELI dealer or agent. Diesel engine and gasoline engine ■...
  • Page 142 Number Capability Color Corresponding electric parts Note I 7.5A Brown Meter 7.5A Brown Steering light 7.5A Brown Horn 7.5A Brown Shutting off valve F or hydraulic 7.5A Brown Commutator powered truck 7.5A Brown Lifting valve For OPS Width lamp, brake lamp Reversing light Spare Blue...
  • Page 143 Controller (for hydraulic powered truck) The controller has OPS function. •OPS (driving function) If the condition that the seat switch is open or driver goes away from the seat or sits on the seat with improper posture is detected by controller for 5s, the controller will disconnect the power of transmission commutator and thus driving power will be disconnected.

  • Page 144: Bulbs Changing

    Change the bulb with the same standard. If the bulb still does not light on, it may be caused by the abnormal system. Please contact with HELI dealer or agent. 1.Switch the starting key and light switch to the OFF position.

  • Page 145: Steps Of Dealing With The Fault Battery

    4.5 Steps of dealing with the fault battery If a battery has fault, start the truck with jumper cable to use other truck5s battery. ■ Notes when disconnecting and connecting jumper cable CAUTION Never connect the positive(+) and negative (-) terminal when connecting he jumper cable.
  • Page 146 on neutral position. Check if the parking brake is applied. Connect the cables referring to the figure. Connect the clamp of jumper cable A to the positive terminal of the fault truck; Connect the other clamp of jumper cable A to the positive terminal of the normal truck; Connect the clamp of jumper cable B to the negative terminal of the normal truck;...
  • Page 147 Engine starting ■ CAUTION Check if the forward/backward operation levers of two trucks are placed on neutral position and if parking brakes are applied. 1.Make sure clamps are connected to battery terminal firmly. 2.Start the normal truck’s engine and make it run at highest speed. 3.Turn the starting key switch on the fault truck to the STARTING position to start the engine.

  • Page 148: Working In Cold Weather

    Coolant is poison and take care not to get in touch with your skin. If so, wash with lots of clean water and see a doctor. Contact professional company or HELI dealer or agent to deal with the drained coolant. Never pour it onto ground or drainage ditch because it is poison.
  • Page 149 Drain out the water in fuel pipeline in preventing of freezing. Please refer to the WATER AND GAS EXHAUSTING OF THE WATER-OIL SEPERATOR for oil- water separator water draining of the diesel engine. When the cold weather is over ■ Do the following as the weather gets warm.

  • Page 150: Measures For Engine Overheating

    If waterlogging or rust is produced in the cooling system, it means the cooling system efficient is poor and it causes overheat. Please contact with HELI dealer or agent for maintenance because the cooling system needs periodical check and cleaning with radiator washing solution.

  • Page 151: Operate Truck In Special Environment Or With Force

    Applications prohibited in this manual; Others. IMPORTANT HELI will not bear the responsibility if the truck is used under the special environment or with force. Technology may not involve in certain condition. The truck can not be used where has a danger of explosive.

  • Page 152: Measures If The Fork Can Not Be Lowered

    Do not touch mast, fork, chain or other working devices or truck may move accidently and serious accident may be caused. Contact with HELI dealer or agent for repairing. 1.Stop working at once if the fork can not be lowered during operation.

  • Page 153: Truck Cleaning

    4.10 Truck cleaning CAUTION There is a danger of truck being out of work or mis-moving if water entering into electric system (controller, sensor, contactor and so on). Do not clean the electric system with water or air with high pressure. Cleaning steps Turn the starting key switch to the OFF position and draw out the key.

  • Page 154: Storing For A Long Time

    Check the engine oil before and after engine starting. If the engine oil is mixed with moistme, change the engine oil. IMPORTANT Please contact with HELI dealer or agent before operation when using the truck without anti-rust maintenance once a month.

  • Page 155: Slinging The Truck

    4.12 slinging the truck CAUTION Put the sling into the specified holes on top of the overhead guard and counter weight. Never sling the truck at the over head guard and cab base (if cab is assembled), or there is a danger of falling down.

  • Page 156: Loading And Unloading The Truck

    4.13 Loading and unloading the truck CAUTION There is a danger of tipping over and falling when loading or unloading the forklift truck. So follow the rules below: Park the trailer on a flat road. Apply parking brake and wedge the wheels. Use connection board with proper length, width and strength.

  • Page 157: Check And Maintenance Time Table

    4.14 Check and maintenance time table Please contact HELI dealer or agent for check and maintenance items not described in the manual. Serious accident may be caused or truck service life may be affected if the truck is not checked or maintained improperly. For safety reason, please contact HELI dealer or agent for check, maintenance and repair.
  • Page 158 Check and maintenance interval Note: this table is only for reference. The information of engine is subject to the maintenance schedule of the engine manuals.
  • Page 159 Check and maintenance interval...
  • Page 160 Check and maintenance interval...
  • Page 161 Check and maintenance interval...
  • Page 162 Check and maintenance interval...
  • Page 163 Check and maintenance interval...
  • Page 164 Check and maintenance interval...

  • Page 165: Change The Safety Key Parts Regularly

    4.15 Change the safety key parts regularly Safety parts listed in the table below should be changed regularly for safety reason. If the parts exceed their service life, they may be aging and go bad. Their condition is hard to be known through Tegular maintenance.

  • Page 166: Repair Parameter (Gasoline Engine)

    4.16 Repair parameter Parts Checks Unit Front tyre Tyre Tyre inflation pressure Driving Rear tyre 520-560 system Front tyre Hub nut Tighten torque 520-560 Rear tyre Steering hand wheel 3-10。 Clearance (when pump is working) Clearance Inching pedal Inching travel Steering The initial height of the front floor board...
  • Page 167 Parameters and Configuration Truck Parameters (Note: the parameters are for trucks with standard configuration.) CPCD50 Parameters Rated capacity (kg) 5000 Load center (mm) Lifting height (mm) 3000 Free lift (mm) Mast tilt (Fwd/Bwd) (°) 15/15 Overall length (without fork) (mm) 4960 Overall width (mm) 2130...
  • Page 168 Horn Charging indicator Oil pressure alarm Wide view mast Control valve Air intaking device Wholly hydraulic-powered steering Durable tire with decorative pattern Rubber pad Lifting and tilting operating handles Backrest Traction pin Rear view mirror Full suspension seat Front combined lamp (LED light) Hydraulic oil dipstick Transmission oil filter Overhead guard rain cover...

  • Page 169: Optional

    Optional Optional item Optional details Transmission model Hydraulic-powered transmission Normal Mast type Pull free -stage mast Full free 3-stage mast Direction changing way Electro-hydraulic direction changing Vacuum tire tyre(front/rear wheel tyre) Tyre choice Single normal solid tyre (firont/rear tyre) °- °...
  • Page 170 Optional item Optional details Two throw Three throw Number of throw Four throw Five throw Overload choice Overload protection (the third throw) Exhausting way High air exhausting Normal air cleaner Air cleaner Dry type double air cleaner Wet type double air cleaner Metric thread Thread American thread...
  • Page 171 Optional item Optional details Warmer Warmer &Air conditioner Air conditioner Non-universal key Universal key Front windshield glass Rear windshield glass Wind shield and ceiling Iron sheet ceiling OPS (driving function) OPS system OPS (whole set) Fire extinguisher Fire extinguisher Additional choice Sling Power switch Power switch...
  • Page 172 If the users have the requirements on corrosion prevention, the following protection level can be chosen according to particular case. The instructions on the plates of protection on corrosion are following: rotection level and instruction Plates Protection level I (protected during transportation): The whole truck has been processed with protective wax (pay attention to...
  • Page 173 Annex New standard operation instruction for Australia customer’s requirements 1.Starting: the truck can be started when the direction switch is on neutral gear, the hand brake switch is closed,the seat switch is closed, the seat belt switch is close and the starting voltage signal of key switch is normal.
  • Page 174 Instructions for Trucks Meeting China IV and EU V or Higher Emission Limits Stage Application engine model EU V: Cummins F3.8(EU Stage V/EPA T4F) Instruction of indicators and switches DPF regeneration remind/DPF regeneration state indicator, it is yellow when it is DPF regeneration inhibit, it is yellow when it is on.
  • Page 175 When to regenerate Requirements for some power source are listed below, and others can be referred to. Cummins F 3,8(EU Stage V/EPA T4F) The high exhaust temperature indicator is on and active regeneration is in progress. At this time, the exhaust temperature is higher than the normal temperature.
  • Page 176 Notes 1) When the DPF regeneration switch is in the regeneration inhibit position ,t h e truck will not actively carry out the regeneration mode, which is easy to cause congestion and shorten the maintenance cycle after treatment. 2) Active regeneration: the truck can regenerate automatically during operation, which can produce high exhaust temperature.

  • Page 177: Capacity Chart

    Capacity Chart The capacity chart is the load (kg) of the truck when the mast is vertical without attachment. The load center distance (mm), lifting height (mm), and the corresponding maximum load (kg) of the truck are shown in the form of a curve，and they are pasted on the whole truck.
  • Page 178 CPCD50 CPCD60 CPCD70...
  • Page 179 OPERATION & MAINTENANCE MANUAL HELI A N H U I H E L I C O • ， L T D Add/No.668, FangXing Road, Hefei, China Post Code/230000 Customer Service Hotline/4001-600761 Service Tel/+86-551-63648005,63689000 S0925-2023 All rights reserved...

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