To correctly check the oil level in the automatic transmission of the HELI CPCD 35 G3 Series:

1. Wipe off the hydraulic oil on the dipstick with a clean rag.
2. Insert the dipstick into the fuel tank fully.
3. Pull out the dipstick and check the oil level.
4. Ensure the oil level is between the "H" (high) and "L" (low) marks on the correct side of the dipstick:
- Use side A if the lifting height is below 4700mm and there are no accessories.
- Use side B for all other cases.
5. If the oil level is low, add Heli's pure or recommended hydraulic oil.
6. Wipe off any spilled oil.

This answer is automatically generated

Summary of Contents for HELI G3 Series

Page 1 OPERATION & SERVICE MANUAL G3 Series Internal Combustion Counterbalanced Forklift Truck (Standard) 2-3.5t...
Page 2: Foreword
Foreword 1.1 Scope of application and description of the Manual ● The content of this Manual includes correct operation, simple maintenance, and daily inspection. ●Before operation, please read this Manual carefully to ensure safe and effective material handling through proper travelling and maintenance. ●...
Page 3: Safety Signals, Terms And Indicators
1.2 Safety signals, terms and indicators This indicates an upcoming dangerous situation that, if left avoided, will result in death or serious injury, and you must follow this instruction. This indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury, and you must follow this instruction.
Page 4: Applicable Truck Model
1.3 Applicable truck model 1.3.1 List of applicable models The Manual is mainly applicable to the following models: Model configuration Engine Emission CPQYD20~35-KU1HG3 Equipped with Kubota WG2503 engine Euro V/CARB IV/EPA (Tier 2) CPYD20~35-KU1HG3 Equipped with Kubota WG2503 engine Euro V/CARB IV/EPA (Tier 2) CPCD20~35-Q17HG3 Equipped with Quanchai V32-50C42 engine China IV...
Page 5: Forklift Truck Overview
1.4 Forklift truck overview 1.4.1 Purpose of forklift truck (1) Main purpose of forklift truck The forklift truck is mainly used to carry goods placed on pallets and stack them at a certain height. In addition, after the forklift truck is equipped with suitable attachments, it can also be used to carry and stack goods that are not placed on pallets.
Page 6: Operation Site And Working Environment Of Forklift Truck
1.4.3 Operation site and working environment of forklift truck (1) Ground conditions • The forklift truck shall be used on a flat and solid road or ground with sufficient bearing capacity. • Do not exceed the allowable area and point load of the travelling road. •...
Page 7 (2) Climatic conditions • The basic climatic conditions include the following requirements: Average ambient temperature under continuous operation: +25℃ • Maximum ambient temperature in a short time (not more than 1h): +40℃ • • Minimum ambient temperature when the truck is operating under general indoor conditions: +5℃...
Page 8 Since the battery has high efficiency at high temperatures, no other maintenance is required. The gas generated by the battery will explode. Do not smoke or use open flames, and do not generate arcs and sparks near the battery. Store or charge the battery in a closed space with good ventilation.
Page 9: Measurement Units
• Environment where a certain amount of hazardous substances are discharged. Do not operate the forklift truck reluctantly under severe weather conditions such as thunderstorm or strong wind. For example, when dense fog occurs, the forklift truck can only be operated after the fog dissipates to provide a good visibility. Exhaust gases (carbon monoxide) can be a hazard when the forklift truck is used indoors.
Page 10: Precautions For Use Of New Forklift Truck
The forklift truck shall be maintained by the dealer of Heli Forklift truck. 1.8 Warranty and maintenance 1.8.1 Regular replacement of parts Heli Forklift truck designates "regular replacement of parts" except as required by law.
Page 11: Use Of Original Heli Parts And Oil
No., product No. (VIN), engine serial number, mast model, attachments and required accessory No. 1.9.1 Basic information form of forklift truck The form is filled in by the dealer/agent of Heli Forklift truck. Its information may be updated, so please refer to the actual information. Model Configuration No.
Page 12: Nameplate Information Of Forklift Truck
1.9.2 Nameplate information of forklift truck The model and product No. (VIN) of the forklift truck are printed on the truck nameplate, which is located on the right side of the driver. The nameplate style can be selected according to different regions. The Manual only shows examples of Chinese and English styles.
Page 13 Lifting system information ● "Model description" indicates the classification of this industrial truck and its brand trademark; ● "Truck information" includes forklift truck model, product No., configuration No., VIN, rated capacity, No. of manufacture license, equipment code, manufacture date and mechanical environmental protection code. Some nameplates include load center distance and engine power.
Page 14: Vin And Position Of Forklift Truck
includes the form and height of the mast (M represents two basic sections, ZM represents two full free sections, and ZSM represents three full free sections; digits after letters are in centimeters). Attachments include side shifter, rotator, soft clamp, etc. Please refer to the attachment drawing album for model functional parameters.
Page 15: Installation Position Of Truck License Plate
1.10 Installation position of truck license plate The truck is equipped with a forklift truck license plate mounting bracket, which is located behind the top of the overhead guard and can be installed by users as required. Drawing of license plate mounting bracket: Schematic diagram for installation of license plate:...
Page 16: Table Of Contents
1.8 Warranty and maintenance ................9 1.8.1 Regular replacement of parts ..............9 1.8.2 Use of original Heli parts and oil ............10 1.9 Basic information of forklift truck ..............10 1.9.1 Basic information form of forklift truck ..........10 1.9.2 Nameplate information of forklift truck ..........
Page 17 2.2.3 Prevention of fire caused by attached or adhered flammables ... 34 2.2.4 Prevention of fire caused by wire failure ..........35 2.2.5 Prevention of fire caused by oil pipe failure ........35 2.2.6 Cleaning after operation ..............35 2.2.7 In case of fire ..................36 2.3 Basic precautions ...................
Page 18 2.7.16 Precautions for removal and installation of battery ......62 2.7.17 Precautions for handling tires ............62 2.7.18 Precautions for oil cylinder maintenance .......... 63 2.7.19 Precautions for waste disposal ............64 2.7.20 Precautions after inspection and repair ..........64 2.7.21 Regular inspection of safety critical parts .........
Page 19 4.2 Startup inspection..................119 4.2.1 Inspection of abnormalities found the previous day ......121 4.2.2 Peripheral inspection of forklift truck ..........121 4.2.3 Open the hood for inspection ............123 4.2.4 Inspection from seat position ............126 4.2.5 Turn the Start switch to [I] (ON) position for inspection ....128 4.2.6 Inspection after starting the engine ...........
Page 20 5.2.5 Forklift truck (load) curve ..............188 5.3 List of optional configuration ..............189 Operation and Maintenance of Diesel Particulate Filter (DPF) ......192 6.1 Description ....................193 6.2 Regenerate DPF ................... 193 6.3 Non-regenerate DPF ..................196...
Page 21: Safety Precautions
Safety Precautions Be sure to fully understand the precautions related to forklift truck safety in this Manual. When operating the forklift truck, strictly observe these precautions. Failure to pay attention to this warning may result in serious injury.
Page 22: Labels And Signs On Truck
2.1 Labels and signs on truck 2.1.1 Location plan of labels and signs Note: The styles and pasting positions of labels and stickers are for reference only, which may be updated in real time. Please refer to the actual truck.
Page 23: Main Safety Labels
2.1.2 Main safety labels Name of safety label Position Safety labels and signs (Caution! Hand Rear side of inclined mast struts and top struts injury) (outer mast middle crossbeam) Safety labels and signs (No entry into the Rear side of inclined mast struts and top struts space behind mast) (outer mast middle crossbeam) Precautions label for use and maintenance of...
Page 24 (2) Safety labels and signs (No entry into the space behind mast) It is forbidden to enter the space behind the mast for any activities. (3) Precautions label for use and maintenance of battery Describe the precautions for use and maintenance of battery. (4) Tire safety label •...
Page 25 (5) Instructions label Precautions before start-up and during start-up, loading and unloading, travelling and parking of forklift truck. (6) Lifting label Never lift the forklift truck at the top of the overhead guard. The forklift truck must be lifted through the lifting position indicated on the truck, and a lifting label is affixed to the lifting position.
Page 26 (8) No flushing ● Do not flush electrical boxes, instruments, sensors, connectors and other electrical parts. ● It is strictly prohibited to flush water at the intake hood of forklift truck overhead guard to prevent water from entering the engine. (9) Fan safety label Keep your hand away from the rotating fan.
Page 27: Other Labels
(11) Safety signs (No standing on fork; No standing under fork) ● Do not enter the area under fork. ● Do not stand on the fork. (12) Fasten seat belt Be sure to fasten the seat belt during operation. 2.1.2 Other labels No.
Page 28 Hydraulic Fill hydraulic oil here. refueling label Maximum filling Capacity label 2-3.5t amount of hydraulic oil and fuel. Gasoline refueling Type of fuel filled label diesel here. refueling label Antifreeze refueling Fill antifreeze here. label It is forbidden to adjust No on-load distance the fork spacing when adjustment label...
Page 29 WeChat QR code Relevant information sticker "Heli can be queried after Forklift truck" scanning the QR code. The load curve of the truck shows capacity at different Load curve label heights, loads, tire forms center distances. Parking brake Adjustment method of adjustment label parking brake device.
Page 30 Brake fluid filling Fill the brake fluid label here. some models. Precautions label for Precautions operation operation Mitsubishi diesel Mitsubishi diesel engine engine. interface interface warning label information. some models. Rear window Steps for opening the opening label rear window of LPG truck.
Page 31 some models. Warning label Illustration of warning (picture), the latest label, used together PI, PVC plastic with 46. For some models. Text Warning label (text), description of warning the latest PI, PVC label, used together plastic with 45. LPG truck sign, PVC For some models.
Page 32: Forklift Truck Load Curve Label
some models. Euro fuel Description fuel 2△ requirement label requirements for Euro (diesel), the latest PI V engines. regeneration some models. operation instruction Regeneration 3△ sticker, the latest PI instructions for Euro V (Kubota engine, in engines. English) regeneration some models.
Page 33 To replace damaged or unclear labels, please contact the dealer/agent of Heli Forklift truck. ● When the load capacity exceeds the requirements of the load curve, there is a risk that the rear wheels may be lifted. In this severe case, the forklift truck may fail to turn and tip over, resulting in serious accidents.
Page 34: Fire Prevention
In addition, if any condition is found, such as dirt, leaves or waste paper, it should be removed. If the problem still exists, please contact the dealer of Heli Forklift truck for repair. 1. Check the surroundings of engine ●...
Page 35: Prevention Of Fire Caused By Fuel Or Oil
4. Check the cab interior ● For trucks with a cab, check the cab interior for accumulation of flammable and explosive materials. 2.2.2 Prevention of fire caused by fuel or oil Since fuel, oil, coolant and window washer fluid are flammable, they should be kept away from open flames.
Page 36: Prevention Of Fire Caused By Wire Failure
Check the wiring harness for looseness, wear or damage every day. Tighten loose connectors and clamps. ● Damaged wiring harnesses must be repaired or replaced by a HELI dealer. 2.2.5 Prevention of fire caused by oil pipe failure ● Make sure that the clamps, fixing plates and cushions of hoses and pipes are firmly installed.
Page 37: In Case Of Fire
2.2.7 In case of fire ■ In case of fire, turn the Start switch to [0] (OFF) position to shut down the engine, and press the master power switch button (equipped for some models) to turn off the power supply. ■...
Page 38: Do Not Operate A Faulty Forklift Truck
2.3.2 Do not operate a faulty forklift truck ● In case of any abnormality (noise, vibration, smell, malfunctioning instrument, smoking, oil leak, error indication of warning device or monitor) during the starting inspection or operation, report to the management personnel immediately and take proper corrective actions.
Page 39: Confirmation Of Safety Devices
Do not disassemble the safety devices and always maintain their full functionality. ● If the overhead guard and load backrest have been damaged and loosened, do not operate the forklift truck until they are repaired by the designated Heli dealer/agent. 2.3.6 Full practice before operation ●...
Page 40: Keep The Cab And Platforms Clean And Tidy
● Do not hold the joystick or steering wheel when getting on or off the forklift truck. 2.3.8 Keep the cab and platforms clean and tidy ■ Keep the cab and platforms (handrails, steps, and floors) clean and tidy. Oil, mud, or dust attached around the cab and scattered spare parts or tools will cause slipping or the fabric to be caught, resulting in accidental falling or...
Page 41: Do Not Modify The Forklift Truck
● Heli forklift truck will not be liable for any personal injury, damage, or accident caused by changes made without our permission. 2.3.12 Do not remove the overhead guard and load backrest ●...
Page 42: Toxic Exhaust Of Engine
2.3.16 No welding ● It is forbidden to weld the truck. If welding is necessary, please contact the agent/dealer of Heli Forklift truck for relevant operations. Before welding the electronically-controlled engine, be sure to remove the engine ECU.
Page 43: Before Starting Operation
2.4 Before starting operation 2.4.1 Startup inspection For the safe operation of the forklift truck, a startup inspection shall be carried out at the beginning of each day. See "Inspection and Maintenance" for detailed inspection items. 2.4.2 Inspection and adjustment before starting the engine ■...
Page 44: Forklift Truck Travelling
light up. After 3 seconds, each indicator will light up or go out according to the actual signal. ● Make sure that the travelling interlock function (optional) can be realized. ● If any faults (noise, vibration, heating, odor, improper adjustment of instrument, engine oil leakage or fuel leakage) are found, they must be eliminated before starting operation.
Page 45: Precautions For Forklift Truck Travelling
surrounding area, such as pedestrians, other forklift trucks, and loads. ● Be sure to lift the forklift truck 15~20cm above the ground and tilt the mast backward. ● Be careful to honk when necessary. 2.5.2 Precautions for forklift truck travelling ■...
Page 46 ■ No one is allowed to take the forklift truck. ● No one shall be allowed to ride in the truck for any reason. ● Under no circumstances is it allowed to use people as counterweights. ■ Do not turn off the Start switch during travelling. ●...
Page 47 ● When installing optional alarm devices (such as reversing alarm flasher, reversing sensor, reversing auxiliary rearview mirror), contact the agent/dealer of Heli Forklift truck for details. ■ Do not drive the forklift truck when the fork is raised ●...
Page 48 Operation and Maintenance Manual carefully and carry out the operation, inspection, and maintenance correctly. ● Do not jump off the forklift truck when the forklift truck tips over, otherwise, serious personal injury will be caused. ● Make yourself lean toward the opposite direction of the forklift truck tipping. ●...
Page 49 ● Keep a distance from doors, wiring harnesses and pipelines. ● When the forks are raised, pay attention to the height of the mast and the load backrest. ■ Do not drive on uneven or slippery ground. ● Do not drive on bumpy or soft ground. When you lose control of the steering or the tire gets stuck in the mud, it will cause serious accidents.
Page 50 the ground. Make the bottom of the forks or pallet off the ground to prevent the fork ends from inserting into the ground during travelling. ● Travelling safely on the slope should: Loaded: forward uphill, backward downhill Unloaded: backward uphill, forward downhill ●...
Page 51: Forklift Truck Stopping And Precautions For Stopping
2.5.3 Forklift truck stopping and precautions for stopping ■ Stop or park according to the correct steps ● Park the forklift truck on solid and flat ground. ● Apply the parking brake to prevent the forklift truck from moving. ● The gearshift lever shall be placed in the neutral position.
Page 52: Load Handling
■ Do not use it to tow a faulty forklift truck. ● If there is a problem with the brake or steering system of the forklift truck, do not use another forklift truck to tow the faulty forklift truck, because the faulty forklift truck will cause unexpected danger when travelling.
Page 53 ■ Be careful not to get stuck in the mast ● Do not put hands, feet or other parts of body into the mast. ● There is a danger of being stuck by moving parts and causing serious injury. ● Do not stand between the mast and the cab, because you may be squeezed and suffer serious or fatal injury.
Page 54 ■ Note the mast height ● The height of the mast will also increase when the forks rises. Pay attention to this situation during operation. ● Pay attention that the mast cannot touch wires, pipelines, sprinkler heads, and ceiling beams. In case of such collision, the load on the forks will fall or the forklift truck will tip over.
Page 55 ● Make sure that the center of gravity of the load is in line with the center of gravity of the forklift truck. Do not transport the load that is not balanced. ● Fix the load in place to prevent collapse or falling. Do not transport the load that is not unstable.
Page 56 ■ Do not push or pull loads with the forks ● The loads may be damaged or dropped ■ Do not use the forklift truck for other purposes ● Do not use the forklift truck for other purposes than transporting loads with forks or accessories. ●...
Page 57: Precautions For Inspection And Maintenance
For inspection and maintenance that needs to be carried out by trained, skilled and qualified personnel, please contact the dealer/agent of Heli Forklift truck. ● Do not operate the forklift truck until the starting inspection is completed.
Page 58: Warning Signs For Inspection And Maintenance
Improper inspection, maintenance and repair can cause serious accidents and shorten the service life of the machine. For safe operation of relevant inspection, maintenance and repair, please contact the dealer/agent of Heli Forklift truck. 2.7.2 Warning signs for inspection and maintenance ●...
Page 59: Precautions Before Inspection And Maintenance
2.7.4 Precautions before inspection and maintenance ● Place the fire extinguisher and know its location and how to use it. ● During operation, any person wearing loose clothes or long fluffy hair shall not appear near the mast. ● Wear appropriate work clothes and protective articles (safety helmet, safety shoes, goggles and gloves).
Page 60: Avoid Being Stuck By Or Falling From The Mast
2.7.8 Avoid being stuck by or falling from the mast ● Do not put hands, feet or other parts of body into the mast, otherwise they will get stuck in the mast components. ● Do not stand between the mast and the cab, because you may be squeezed and suffer serious or fatal injury.
Page 61: Attention To High-Pressure Oil
2.7.10 Attention to high-pressure oil Remember that the hydraulic system is always under pressure. Before checking or replacing the pipeline or hose, check whether there is no pressure in the hydraulic system, otherwise serious accidents will occur. Please observe the following instructions: ■...
Page 62: Precautions For Cleaning With Compressed Air
2.7.13 Precautions for cleaning with compressed air ■ If compressed air is used for cleaning, dust will cause serious injury to the body. ■ Be sure to wear protective equipment, such as goggles, dust cover and gloves. 2.7.14 Precautions when handling the battery ■...
Page 63: Strictly Observe The Following Provisions To Avoid Sparks
Do not loosen the bolts (irregular shape) (2) of tires with divided rims. For tire replacement, see "4.4.4 Tire replacement". ■ Be sure to use the specified tires of the Heli forklift truck and observe the specified inflation pressure.
Page 64: Precautions For Oil Cylinder Maintenance
If the tire or rim is defective or improperly assembled, the rim will not "fit" the tire. In order to fit, the rim must be in uniform contact with the tire around the circumference. If necessary, please contact the dealer of Heli Forklift truck. 2.7.18 Precautions for oil cylinder maintenance As the actuators of the hydraulic system, the oil cylinder mainly deals with lifting, tilting, steering, lateral movement and other actions on the forklift truck.
Page 65: Precautions For Waste Disposal
the tilt cylinder or standing on it. It is strictly prohibited for users to adjust the pitch of the earring threads of the tilt cylinder without permission to adjust the tilt angle. ■ Regularly check the cylinder head with the hook wrench in the tool kit to prevent looseness.
Page 66: Lifting And Transportation Of Forklift Truck
Note: The inspection and replacement of safety critical parts and the filling of grease must be carried out by the dealer/agent of Heli Forklift truck. 2.8 Lifting and transportation of forklift truck 2.8.1 Precautions for lifting forklift truck...
Page 67: Precautions For Loading And Unloading Forklift Truck
2.8.2 Precautions for loading and unloading forklift truck When the forklift truck is loaded on the trailer or unloaded from the trailer, misoperation will cause forklift truck tipping over. Observe the following instructions: ■ Park the trailer on a flat road. Be sure to apply parking brake and put wedges behind the tires.
Page 68: Structure And Stability Of Forklift Truck
2.9 Structure and stability of forklift truck 2.9.1 Longitudinal stability ■ When the forklift truck is working, the front wheel of the forklift truck is used as a fulcrum to keep the load weight and the weight on the rear wheel in balance, so as to prevent the forklift truck from tilting forward.
Page 69: Actual Bearing Capacity
composite center of gravity for the forklift truck and loads. When a load is lifted, its center of gravity will be raised, and therefore the composite center of gravity will also be raised. ■ Composite center of gravity and stability ●...
Page 70: Wind Load
■ The actual bearing capacity label and load curve provided by the truck label show the relationship between the actual bearing capacity and the load center. ■ When the load center moves towards the fork ends, the weight (mass) of the loads shall be reduced to maintain balance.
Page 71: Introduction To Truck Safety Device
The devices listed below are only examples. For more information, please contact the dealer/agent of Heli Forklift truck. ●...
Page 72 Due to the different needs of each area, Heli's driver sitting (standing) posture state sensing system is subdivided into 4 OPS systems:...
Page 73: Operation Instructions And Requirements
Operation Instructions & Requirements Be sure to fully understand the precautions related to forklift truck safety in this Manual. When operating the forklift truck, strictly observe these precautions. Failure to pay attention to this warning may result in serious injury.
Page 74: Drawings
3.1 Drawings 3.1.1 General view of forklift truck 1. Mast 12. Frame 2. Chain 13. Engine hood 3. Lifting cylinder 14. Get-on handle 4. Wide-angle rearview mirror 15. Parking brake handle 5. Headlamp 16. Dashboard 6. Overhead guard 17. Tilt cylinder 7.
Page 75: Instruments And Control Devices
3.1.2 Instruments and control devices 1. Brake fluid filler 11. Attachment action valve stem (non-standard configuration) 2. Parking brake handle 12. LCD instrument 3. Forward/backward control handle 13. Attachment action valve stem (non-standard configuration) 4. Spherical handle of steering wheel 14.
Page 76: Description Of Components
3.2 Description of components ■ The main devices for operating the forklift truck are described below. To operate the forklift truck correctly and safely, it is important to fully understand the operating methods of the devices and the meaning of each instrument display. 3.2.1 Truck instrument...
Page 77 Pattern Description Function Fuel gauge Indicating fuel quantity Left turn signal Indicating left turn signal Charging state Indicating battery charging state Indicating engine preheating (diesel Preheating indicator truck) Engine oil pressure Low engine oil pressure warning indicator Indicating engine running time (unit: Stopwatch hour).
Page 78 If any alarm lamp does not light on, check whether the bulb is burnt out. If the alarm lamp lights on during operation, it indicates abnormality, and take corrective measures. Please contact the agent/dealer of Heli Forklift truck. ■ Fuel gauge (for CPCD, CPQYD and CPQD models) The fuel gauge indicates the approximate remaining quantity of fuel.
Page 79 ■ Left/right turn signal This indicator is used to indicate the steering of forklift truck. ● Turn left: The left turn signal lights on. ● Turn right: The right turn signal lights on. ■ Charging state When the engine is running, this alarm lamp indicates that the alternator charging system is abnormal.
Page 80 ■ Voltage display This indicator indicates the battery voltage. ■ Neutral position lamp The neutral position lamp indicates that the forward/reverse control lever is in the neutral position. When the Start switch is at [I] (ON) position, if the forward/reverse control lever is in neutral position, this lamp will light on, and if it is in forward or reverse position, this lamp will go out.
Page 81 ■ Parking brake lamp It is used to indicate that the parking brake of the forklift truck is locked. ■ Seat belt warning lamp When the Start switch is at [I] (ON) position, if the driver sits correctly on the seat and fastens the seat belt, this lamp will go out;...
Page 82 ● Operating parameters It displays some system operating parameters of the forklift truck, such as current remaining fuel, coolant temperature, speed, battery voltage, engine speed, engine oil pressure, urea level, and DPF blockage. ● Display settings It displays the brightness of display, current real-time clock adjustment, and language settings.
Page 83 ● Alarm record The alarm record is used to record the faults that have occurred during the operation of the forklift truck, which is convenient for the user and maintenance personnel to view when maintaining the machine. The instrument saves 6 alarm records, including low system voltage, high system voltage, high water temperature, high transmission oil temperature, low engine oil pressure and air filter blockage.
Page 84 ● ECU DTC (electronic control engine or electronic control transmission) In case of any relevant fault of the machine equipped with China III or above configuration, the truck controller will inform you of the specific fault of the machine by sending a DTC to the CAN bus, so that the fault can be quickly located and eliminated and the normal operation of the forklift truck can be restored.
Page 85: Control Devices
3.2.2 Control devices ■ Start switch This switch is for engine ON and OFF. (1) [O] position: For insert and pull out the Start switch key; (2) [I] position: For power-up the circuit; For diesel engine trucks, preheating starts automatically at this position.
Page 86 ■ Lamp switch/turn signal switch (lighting switch/turn signal witch) This handle is equipped with a lighting switch and a turn signal switch. ■ Lighting switch When the switch is turned to the arrow mark, the lamps will illuminate and go out in the order shown in the table below.
Page 87 ■ Accelerator pedal This pedal is used to adjust the travelling speed. The engine speed increases according to the amount of pedal being depressed. After the pedal is released, it will automatically bounce back. ■ Brake pedal This pedal is used to stop or slow down the speed of the forklift truck.
Page 88: Removal And Installation Of Accessories
■ Steering wheel and steering wheel ball handle The steering wheel is used to change the direction of the forklift truck to the left and right. Hold the steering wheel ball handle with your left hand for operation. ■ Tiltable lock lever of steering wheel This lever is used to adjust the tilting angle (up/down) of the steering wheel.
Page 89 ● Release the fork stopper, move the fork to the center, install the lower hook into the cutout and remove the fork ● The replacement steps are opposite to the removal order. Apply grease on the fork hook and adjust the width of the fork properly. ●...
Page 90: Operation
3.3 Operation 3.3.1 Inspection before startup 3.3.2 Getting on/off forklift truck and operation adjustment ■ Getting on/off forklift truck ■ Adjustment of seat position...
Page 91 1. For parking details of forklift trucks, see "3.3.8 Temporary Stopping and Parking". 2. Sit on the seat and pull the handle (1) to the right. (In this position, the operator seat can slide forward and backward.) 3. Adjust the seat to its optimal position and release the handle (1).
Page 92: Starting, Shifting And Travelling
3. The seat belt is automatically drawn into the seat. When the seat belt is being drawn in, hold the lock tongue (1) to slowly draw the seat belt in. ■ Adjustment of steering wheel position 1. Park the forklift truck. See "3.3.8 Stopping and Parking of Forklift truck"...
Page 93 ● The engine can only be started after the operator is seated. ● Before starting the engine, the forward/reverse control lever shall be moved to the neutral position. The parking brake shall be locked. ● Exhaust gas is toxic. Pay special attention to ventilation when starting the engine indoors or in poorly ventilated places.
Page 94 ● Diesel engine Turn the Start switch key to [I] (ON) position. The preheating indicator on the dashboard illuminates to indicate that engine preheating has started. Only after the preheating indicator is off can the Start switch key be turned to [II] (start) position to start the engine.
Page 95 5. Fuel switching (for CPQYD model) The dual-fuel (CPQYD) truck is equipped with gasoline and LPG fuels, and a fuel switching button is installed on the dashboard: ● Gear 1 is the gasoline fuel gear. When the button is switched to Gear 1, the truck will use gasoline as fuel ●...
Page 96 3. Check whether the travelling direction and the area around the forklift truck are safe. 4. Gently depress the accelerator pedal (3) and slowly release the inching pedal (4), then the forklift truck will start. After the forklift truck starts to move, keep your foot completely away from the inching pedal (4).
Page 97: Starting And Stopping On Slopes
2. After the forklift truck is completely stopped, move the forward/reverse control handle from the forward [F] position to the reverse [P] position or vice versa. The direction can only be changed after the forklift truck has been completely stopped. 3.3.4 Starting and stopping on slopes 1.
Page 98: Inching Travelling
3.3.5 Inching travelling Do not perform inching travelling by depressing the accelerator pedal (1) and adjusting the amount of brake pedal (2) being depressed. Operate the inching pedal (3) to keep the forklift truck at crawling speed. Caution ● When the clutch is engaged halfway, long-distance travelling will cause damage to the clutch.
Page 99: Operation On Snow And Icy Roads
3.3.7 Operation on snow and icy roads Even if the tires are equipped with tire chains or snow tires are used, skidding cannot be completely prevented. Some forklift trucks may not be suitable for installing tire chains or snow tires. ●...
Page 100: Load Handling
3. After it is completely stopped, move the forward/reverse control handle (1) from (F) position or (R) position to N (neutral) position. 4. Tilt the mast forward and lower the fork to the ground, and then flatten the fork tip. 5.
Page 101 1. Move the forklift truck to the front of the load and then stop it. 2. Place the gantry vertically and lift the fork about 10cm from the ground. 3. Tilt the mast forward. 4. Move the fork stop block knob upward and rotate it by 90° to the release position. (In this case, the fork can move leftward or rightward).
Page 102 Tilting of control valve lever Tilting forward: Push the control valve lever upward Tilting backward: Press the control valve lever downward Note: The speed of forward and backward tilting of the fork can be adjusted by controlling the tilting degree of control valve lever and the degree to which the accelerator pedal is pressed.
Page 103: Precautions For Selecting Solid Tires For Forklift Trucks
● If the driver does not sit on the seat correctly, such as sitting in a standing or forward-leaning or sideway-leaning posture, this safety control system will control the loading and unloading of forklift truck. ● If the driver suddenly leaves the seat during loading and unloading, this safety control system will be activated within approximately 1.5s to cut off the mast power, and then the mast will slowly stop.
Page 104 ● The windshield is a patch-type windshield, that is, the front windshield assembly 5, rear windshield assembly 3 and top windshield assembly 2 are mounted in the front, rear, top, "and" or "or" of the forklift truck overhead guard. For CPQYD or CPYD models, if equipped with non-standard configurations such as a cab or rear windshield, it is necessary to remove the high-pressure gas tube of the LPG tank in advance when opening the rear window, and rotate the LPG steel cylinder bracket outward in place before opening the rear window.
Page 105 ■ Opening of the cab door ● Opening of cab door from outside: The left door assembly of the cab is a normal entrance and exit, and the door is equipped with a key. After unlocking the door lock 7 with the key, pull the lock handle 7-1 outward to open the cab door. 7: Door lock 7-1: Lock handle ●...
Page 106 driver shall adjust the angle of the rearview mirror at the correct operating position and adjust the field of view to the optimal position. ■ Operation of accessory equipment After the cab or windshield is equipped, accessories such as front window wiper washer, rear window wiper washer (optional for the cab), heater (optional for the cab), rear window glass heating device (optional for the cab) and A/C (optional for cab) can also be installed.
Page 107 ● Front window wiper washer After the truck is started, switch the rocker switch 1 to the "Wiper" to activate the rear window wiper; switch the rocker switch 1 to "Washing" to spray detergent and scrap the front window. The "Washing" is a self-resetting mode, and when the Stop button is activated, it will automatically bounce back.
Page 108: Inspection After Operation
● Operation of A/C (optional for the cab) The control button of A/C is located on the top of the cab. Rotate switch 1 clockwise to activate the A/C fan, then the blower speed will gradually increase. Rotate switch 2 clockwise to adjust the cab temperature, then the temperature will gradually decrease.
Page 109: Transportation And Storage Of Forklift Truck
For the size and weight of forklift truck, refer to the technical parameters of forklift truck. The approximate position of the center of gravity of the forklift truck is shown in the figure below. For more information about the center of gravity, please contact the dealer of Heli.
Page 110: Transportation Of Forklift Truck
3.4.1. Transportation of forklift truck It is recommended that forklift trucks only be transported by an authoritatively approved transportation company through road, rail or waterway. All forklift trucks transported by road, rail, or waterway have a common fixing method that can reduce the possibility of damage to forklift truck and paint. ■...
Page 111 6. When the forklift truck is fixed on the truck, it shall be fixed according to its fixing position. In order to reduce the tension force, the truck can be fixed according to the schematic diagram (attached hereinafter). 7. In principle, the goods are required to be placed upside down when loading. Because if the goods (forklift trucks) are placed in sequence, the center of gravity will be inclined backward, and the carrier truck will be prone to "drift"...
Page 112 5. The operation shall be standardized to prevent damage to the appearance quality of the forklift truck paint during bundling. 6. Fastening points of bundling: For the front end of the forklift truck, it is selected at the lifting hole on the upper end of the mast. The outer side shall be tightened with iron wires and the upper hook of the container.
Page 114: Transportation Of Mast
3.4.2 Transportation of mast During the shipment of forklift trucks, some high masts shall be removed due to the specified requirements of "height limit" for transportation. 1. After the removing the mast, it is necessary to seal the to seal the hydraulic pipeline end at the removal position, fix the pipeline with straps, and package the connectors for shipment with the truck.
Page 115 Some suitable lifting points for the forklift truck are indicated in the lifting hook label diagram, which are located on the mast and counterweight. For more information or advice on suitable lifting for forklift trucks, please contact the dealer/agent of Heli Forklift truck.
Page 116: Lifting Forklift Truck
Caution Ensure that all lifting appliances have a safe working load suitable for the suspended weight of the forklift truck. Check that the mast is in a vertical position before making any lifting attempts. 3.4.3 Lifting forklift truck To attach a suitable lifting device to the lifting point of the forklift truck, you shall, 1.
Page 117: Storage Of Forklift Truck
Disconnect the battery negative pole (-) terminal, then cover it or remove it from the forklift truck and place it indoors. ● Add the coolant recommended by Heli to the engine coolant to prevent freezing. ● For LPG trucks (CPQYD and CPYD models), remove the LPG tank and seal the high-pressure gas tube structure.
Page 118 Before starting the engine, check the oil in all parts. If there is water mixed in the oil, replace the oil thoroughly. Caution When using forklift trucks that have not been subjected to a monthly rust prevention operation, please contact the dealer/agent of Heli Forklift truck before operation.
Page 119: Maintenance Instructions And Requirements
Maintenance Instructions & Requirements Be sure to fully understand the precautions related to forklift truck safety in this Manual. When operating the forklift truck, strictly observe these precautions. Failure to pay attention to this warning may result in serious injury.
Page 120: Relevant Inspection And Maintenance
"Safety" to carry out inspection and maintenance with caution. ● Improper maintenance and repair will cause dangerous accidents and shorten the service life of the machine. Please contact the dealer/agent of Heli Forklift truck for maintenance and repair. 4.2 Startup inspection Do not operate the forklift truck until the startup inspection is completed.
Page 121 Tire inflation pressure Brake fluid level Whether the air pipe of LPG truck is worn (CPQYD and CPYD models) Whether the LPG tank is damaged (CPQYD and CPYD models) Hydraulic oil level Whether the oil level is contaminated Open the hood for inspection Fastening of battery connecting wire Inspection of coolant level Deflection inspection of engine belt...
Page 122: Inspection Of Abnormalities Found The Previous Day
4.2.1 Inspection of abnormalities found the previous day Recheck the abnormalities found during the inspection at the end of the previous day. Check twice to ensure there are no abnormalities. 4.2.2 Peripheral inspection of forklift truck ■ Check whether the oil and battery electrolyte leak ●...
Page 123 ■ Dirt or damage of lamps Check all lamps, lenses etc. for damage or dirt. ■ Dirt or damage of reversing mirror and license plate Visually check the reversing rearview mirror for and the license plate for damage or dirt. ■...
Page 124: Open The Hood For Inspection
■ Brake fluid level 1.Open the brake fluid filler (1) on the dashboard and check the brake fluid level. 2.Check whether the fluid level is between MAX and MIN. If the brake fluid level is low, remove the cover and add brake fluid to the upper limit of normal range.
Page 125 4. Replenish hydraulic oil in case of low oil level. If the oil spills, wipe it clean. Important ● Be sure to use Heli's pure or recommended hydraulic oil. ● Instructions for use of forklift truck hydraulic oil dipstick: For different lifting systems, the reference scale lines are different.
Page 126 4. When the oil level is low, replenish it. If the oil spills, wipe it clean. Caution When the engine oil is seriously polluted or has changed color, be sure to replace it with new oil using pure or recommended HELI engine oil. ■ Fastening of battery connecting wire The battery will produce flammable hydrogen and may explode.
Page 127: Inspection From Seat Position
Important: If the belt is elongated and there is no allowance for adjustment or if the belt is cut or broken, replace it. Please contact the dealer/agent of Heli Forklift truck for replacement of the belt. 4.2.4 Inspection from seat position ■...
Page 128 ■ Whether the seat and handle are adjusted normally ● Check whether the seat is normally connected ● Check whether the seat can be adjusted forward and backward normally. ● Check whether the steering wheel can be adjusted forward and backward normally. ●...
Page 129: Turn The Start Switch To [I] (On) Position For Inspection
■ Dirt, damage and angle of rearview mirror ● Check the rearview mirror surface for dirt. ● Check the rearview mirror surface for damage. ● Check if the angle of the rearview mirror is appropriate. If not, adjust it to a position where the rear can be easily seen.
Page 130 ● Check the parking brake warning lamp If the Start switch lights up when it is set to the [I](ON) position, and the indicator goes out when the parking brake handle is in the unlocked position and functions normally. ● Coolant temperature gauge When the engine is in cold state, the pointer points to the left side.
Page 131 ■ Fuel level (for CPCD and CPQYD models) ● Check the fuel gauge to see if there is enough fuel in the fuel tank for one day's operation. ● When the fuel level gauge pointer points to F, it indicates that the fuel tank is full. ●...
Page 132: Inspection After Starting The Engine
In case of an electronically-controlled engine, if the fault indicator lights up or a DTC is displayed, please stop the engine for inspection or contact the local supplier of Heli. It is recommended not to start the engine before the DTC is found out. ■...
Page 133: Slow Travelling Inspection
4.2.7 Slow travelling inspection ■ Inspection of steering wheel clearance ● Check the clearance of steering wheel by turning it. If the clearance is within 3-10° , it is normal. ● Check for looseness by shaking it vertically or longitudinally. ■...
Page 134: Inspection Of Working Load During Handling
4.2.8 Inspection of working load during handling ■ Operation status of mast ● When the operator operates the working device on the seat and controls the valve lever, check whether the fork lifts and descends smoothly, whether the mast leans forward or backward smoothly, and whether the accessories can move smoothly.
Page 135: Inspection Of Safety Functions
If the lifting chain breaks, the load may fall down, or the forklift truck may tip over. When the lifting chain is found to be damaged and cracked, please contact the distributor/agent of Heli Forklift truck to replace the lifting chain. Rust on the hoisting chain is the cause of damage and crack, and rust prevention measures should be taken at an early stage to keep it from rusting.
Page 136 6. In this state, release the parking hand brake. 7. Depress the accelerator pedal with your hips lifted from the seat and confirm that the forklift truck does not move. 8. Sit back on the seat correctly, check whether the warning lamp of the seat switch on the dashboard is off, and make sure that the forklift truck will move only when the valve lever of the forward/backward operation is turned back to the [N] position, and then to the [F] (forward) or [R] (backward) position from the middle position.
Page 137: Inspection And Reporting After Operation
Steps 1.Park the forklift truck on a flat and hard ground and lock the parking brake. 2. Set the forward/reverse control lever to N (neutral) position and shut down the engine. 3. Check whether the starter motor runs when starting the engine when the forward/reverse control valve lever is not in the neutral position.
Page 138: Simple Maintenance
Oils must be changed within the specified time even if they are not deteriorated. ● Be sure to use the engine oil specified by Heli. Forklift trucks are filled with the oil listed in the "List of oil products" at the time of delivery from factory.
Page 139 Filters should be changed regularly. Please contact the dealer/agent of Heli Forklift truck. The following are precautions for changing filters by yourself or the dealer of Heli Forklift truck: ●...
Page 140: Lubrication Form And List Of Oil Products
To ensure good operation of the engine and its cooling system, the special coolant produced by Heli must be always used. It should be replaced every year. If it has deteriorated within one year, it should be replaced immediately. Before replacement, the inside of the whole cooling system should be cleaned.
Page 141 Diesel, gasoline and engine oil must be selected in accordance with quality indicator requirements. Please refer to the relevant engine operation instructions or consult the dealer/agent of Heli Forklift truck. For liquefied petroleum gas (LPG) the liquefied petroleum gas for trucks must be used (GB 19159).
Page 142: Fuel And Liquefied Petroleum Gas (Lpg)
When the diesel engine runs out of fuel or its filter is replaced, the fuel line must be cleaned. Unless the fuel specified by Heli is used, exhaust cleanliness cannot be guaranteed to be within the required environmental standards. To protect the environment and your health, be sure to use the specified fuel.
Page 143 ● The use of LPG equipment must comply with the legal provisions and technical requirements on the use of LPG. ● The operator shall comply with the current local regulations, and check whether all components of LPG equipment function normally before the forklift truck is put into use.
Page 144 1. Completely close the air outlet valve (1) (turn it to the right) and let the engine continue running at idle speed until the fuel in the pipe is burnt out. 2. Loosen the connecting screw (2) of LPG tank and remove the high-pressure gas pipe (3) connected to the engine.
Page 145: Cleaning Of Air Filter Element
6. Tighten the connecting screw (2) of LPG cylinder and connect the high-pressure gas pipe (3) to the cylinder. 7. Fully open the air outlet valve (1) (turn it to the left), and check for LPG leakage at the high-pressure rubber hose (3) joint.
Page 146: Drainage And Exhaust Of Fuel Filter (Cpcd Model)
compressed air (not more than 0.68 MPa) without damage to the sealing surface, and clean its entire periphery. 3. After cleaning, visually check the filter element. If the filter element is still contaminated or damaged, replace it with a new one. Caution When the engine is running, inspection, cleaning or maintenance of the air filter element may cause dust to enter the engine and damage it.
Page 147: Tire Replacement
4.4.6 Tire replacement Note: The truck can be equipped with pneumatic tires or solid tires. They are replaced and used in the same way, but have a certain impact on comfort, maintenance convenience and performance. Customers can consult our customer service department according to their own needs for the specific choice of pneumatic tires or solid tires.
Page 148 (2) Replacement of rear tires: (B) Under the counterweight. 3. Jack up the forklift truck to the extent that the tires slightly touch the ground, and place wedges under the frame to prevent falling. ● Place wedges in the front when replacing front tires. ●...
Page 149: Replacement Of Fuse
The fuse must be replaced with one having the same capacity and specification. ● If the replaced fuse is burned out again, it may be caused by the fault of electrical system. Please contact the dealer/agent of Heli Forklift truck. ■ Forklift truck with diesel engine, forklift truck with gasoline engine 1.
Page 150 3. Remove the fuse box cover and then the puller installed inside the fuse box. 4. Clamp the fuse by the puller and remove the fuse. Visually check whether it is burnt out. 5. If the fuse is burnt out, replace it with one of the same capacity and specification. ■...
Page 151 See the following table for relay capacity and relevant electrical components: Capacity Acting electrical components Remarks Power supply relay Light relay Preheating relay Start relay Forward relay Reverse relay Lifting/tilting relay For OPS Flasher Timer ■ Introduction to controller There are two types of controllers, both of which have the function of driver sitting (standing) posture state sensing system (OPS system).
Page 152: Replacement Of Bulb
OFF position and pull out the Start key) and turn off the lamp switch. ● If the replaced lamp still does not work, it may be caused by abnormal electrical system. Please contact the dealer/agent of Heli Forklift truck immediately 4.4.9 Adjustment of parking brake handle ●...
Page 153: Steps To Deal With Faulty Battery
1. Press the button (1) and set the parking brake handle (2) to the release position (B). 2. Turn the adjusting bolt (3) with a wrench through the window marked with arrow to adjust the operating force of the parking brake handle to the specified value.
Page 154 turned on, the forklift truck may move suddenly. ● Do not connect jumper cables incorrectly, and start from the positive (+) terminal. On the contrary, start from the negative (-) terminal (ground side) for disconnection. When connecting, connect the last cable to the engine block of the sparking faulty forklift truck.
Page 155: Operation In Cold Weather
● Check whether the forward/reverse control lever of the normal forklift truck and the faulty forklift truck is set to the neutral position and whether the parking brake works. 1. Confirm that the clip is securely connected to the battery terminal. 2.
Page 156 For the treatment of waste water with coolant (discharged during coolant replacement and radiator repair), please contact a professional treatment institution or the dealer/agent of Heli Forklift truck. The coolant is toxic, so it must not be discharged into drainage ditches or on the ground.
Page 157: Engine Overheating Treatment
● The battery performance will greatly decrease with the temperature drop, so the battery should be removed from the forklift truck, placed in a warm place overnight and installed the next morning. (especially when the temperature is low or the forklift truck will not be used for a period of time) ■...
Page 158 Water pressure: below 0.49 MPa (5 kgf/cm ■ Check the tension of the fan belt. If the fan belt is loose, adjust it to the specified tension. For adjustment of fan belt tension, please contact the dealer of Heli Forklift truck.
Page 159: Operation Of Forklift Truck In Special Environment Or In A Forced Manner
When the forklift truck is used in a special environment or in a forced manner, it needs to receive maintenance and various measures suitable for withstanding such harsh and difficult operating conditions. For details, please contact the dealer/agent of Heli Forklift truck.
Page 160: Measures For Fork Lowering Failure
(do not vibrate, touch or pry with sticks or tools). ● Contact the management personnel or the dealer/agent of Heli Forklift truck for repair immediately. 1. During operation, if the fork stops lowering, stop working immediately.
Page 161: Cleaning Forklift Truck
4.10 Cleaning forklift truck ● If water enters the electrical system (controller, sensor, connector, etc.), there is a risk of failure or mis-movement. Do not use water or high-pressure air flow to clean the electrical system. Cleaning steps: 1. Turn the Start switch key to [O] (OFF) position, and then remove the key. 2.
Page 162: Loading And Unloading Of Forklift Truck
External parts other Clean with high-pressure airflow or water sprayed from the than the above hose 1. Never clean the inside of instrument panel. 2. When using high-pressure airflow or water sprayed from the hose to clean the lower part of the engine compartment and Other precautions bottom plate (transmission system), cover the engine, transmission and their wires, as well as connector, fuse box and...
Page 163 ● When the forklift truck is on the gangway, do not correct the direction of the forklift truck. If it is necessary to change the direction, remove the gangway and correct the direction. 1. Arrange a trailer with sufficient load capacity for the weight and size of the forklift truck for transportation.
Page 164: Forklift Truck Maintenance Data
4.12 Forklift truck maintenance data Parts Inspection item Unit 2-2.5t 3-3.5t Front wheel kPa 860 Tire inflation Tire pressure Rear wheel kPa 860 Travelling system Front wheel Nm 480~560 480~560 Tightening Hub nut torque Rear wheel Nm 130-195 130-195 Connecting bolt between Nm ≥500...
Page 165: Inspection And Maintenance Interval Table
The replacement cycle of engine oil and oil filter element can also be implemented according to the maintenance instructions of the engine manufacturer. ■ Inspection and maintenance interval table Determine the interval and time of inspection and maintenance according to the recommendations of Heli. Table 4 shows the regular maintenance schedule of Heli...
Page 166 diesel forklift truck. Regular maintenance can be divided into monthly inspection (or every 200 h), quarterly inspection (or every 600 h), semi-annual inspection (or every 1200 h) and annual inspection (or every 2400 h), whichever comes first. See 1.4.3 for normal operating conditions.
Page 167 Table 4 Regular Maintenance Schedule of Diesel Forklift truck Periodic cycle Daily Item Inspection method, content and requirements Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection inspection Check whether the main design drawings, product quality Accompanying Rectify and ○...
Page 168 Periodic cycle Daily Item Inspection method, content and requirements Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection inspection Visually check whether the valve clearance meets the use ○ Adjust/repair Power requirements. system Gasoline ○ Visually check whether the cylinder head bolts are loose. Tighten engine ○...
Page 169 Periodic cycle Daily Item Inspection method, content and requirements Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection inspection Visually check the fuel pipe, fuel pump and fuel ○ Repair tank for leakage. ○ Diesel engine Visually check whether the fuel filter is blocked. Replace ○...
Page 170 Periodic cycle Item Inspection method, content and requirements Daily inspection Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection Check whether the idle stroke of clutch pedal and the clearance ○ between pedal surface and bottom plate when the clutch is Maintain/repair disengaged meet the use requirements through functional test.
Page 171 Periodic cycle Item Inspection method, content and requirements Daily inspection Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection ○ Visually check the bearing for abnormal sound. Lubricate/replace Visually check the axle body for deformation, crack, damage, ○ Repair etc.
Page 172 Periodic cycle Daily Item Inspection method, content and requirements Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection inspection Check whether the brake is safe and reliable, whether there is sufficient ○ Service brake Adjust/repair travel and whether the operation is normal through functional test. ○...
Page 173 Periodic cycle Daily Item Inspection method, content and requirements Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection inspection ○ Visually check whether the installation of locating pin is loose. Repair ○ Visually check the locating pin for damage and wear. Repair Visually check the welds of mast, fork arm carrier, load backrest and roller ○...
Page 174 Periodic cycle Daily Item Inspection method, content and requirements Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection inspection ○ Hydraulic pump Visually check the hydraulic oil pump for leakage or abnormal sound. Repair ○ Visually check the oil quantity and cleanliness of the oil tank. Refuel/clean/replace ○...
Page 175 Periodic cycle Daily Item Inspection method, content and requirements Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection inspection accessories Visually check the safety belt and seat fasteners for damage or ○ Seat looseness, and check whether the seat switch and seat adjustment Repair function are normal.
Page 176 Periodic cycle Daily Item Inspection method, content and requirements Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection inspection Visually check the pressure vessel for obvious dents, ○ Repair scratches and grooves. Visually check whether the pressure vessel is within the ○...
Page 177 Periodic cycle Daily Item Inspection method, content and requirements Monthly Quarterly Semi-annual Annual Disposal method Remarks inspection inspection inspection inspection inspection connection of extra and the truck. holes on the shell ○ Fork cladding Visually check the fork cladding for damage or wear. Repair Intake flame retardant Check whether the intake flame retardant disc is blocked...
Page 178: Main Parameters And Design Drawings
Main Parameters & Design Drawings Be sure to fully understand the precautions related to forklift truck safety in this Manual. When operating the forklift truck, strictly observe these precautions. Failure to pay attention to this warning may result in serious injury.
Page 179: Main Parameters
5.1 Main parameters 5.1.1 General drawing...
Page 180: Main Technical Parameters
5.1.2 Main technical parameters Description Unit Main technical parameters CPCD20 CPCD25 CPCD30 CPCD35 Model CPYD20 CPYD25 CPYD30 CPYD35 CPQYD20 CPQYD25 CPQYD30 CPQYD35 Diesel Diesel Diesel Diesel Power type LPG/gasoline LPG/gasoline LPG/gasoline LPG/gasoline Travelling mode Sit-down type Sit-down type Sit-down type Sit-down type Q （kg）...
Page 181: Main Parameters Of Tires
Fork arm carrier ISO2328 IIIA IIIA installation grade Minimum ground m1（mm） clearance (at mast) Minimum ground m2（mm） clearance (at frame) Minimum outside Wa (mm) 2220 2300 2400 2475 turning radius Distance from truck b13（mm） 639 body center slewing center Note: The data given in the table are standard configuration data. 5.1.3 Main parameters of tires CPCD20 CPCD25...
Page 182: Main Technical Parameters Of Engine
5.1.4 Main technical parameters of engine Engine Kubota Quanchai Kubota WG2503 manufacturer/model V2403 V32-50C42 GAS：42.8 Rated power 42.6 36.8 LPG：43.5 Rated speed min–1 2600 2400 2500 Number of （‒）/ cylinders/displacemen 4/2.491 4/2.43 4/2.54 （cm ） Euro V/CARB Euro Emission China IV IV/EPA (Tier 2) V/T4F Engine...
Page 183: Basic Parameters Of Mast
5.1.5 Basic parameters of mast Full height of mast h (mm) Free lifting height h (mm) Maximum Front/rear Mast lifting inclination angle α-β type height h CPCD20~25 CPCD30 CPCD35 CPCD20~25 CPCD30 CPCD35 (mm) of mast (° ) CPYD20~25 CPYD30 CPYD35 CPYD20~25 CPYD30 CPYD35...
Page 184: Main Design Drawings
5.2 Main design drawings 5.2.1 Diagram of main stressed structural members The main stressed structural members of the truck include frame, mast, fork arm carrier and fork. Their drawings are as follows: Note: The following figures are schematic diagrams of standard configuration, and do not contain non-standard or special manufacturing information.
Page 185: Schematic Diagram Of Brake
● Fork arm carrier ● Fork 5.2.2 Schematic diagram of brake The brake system is divided into service brake and parking brake, both of which are of a front double-wheel brake type. The service brake consists of brake master cylinder, brake and brake pedal mechanism.
Page 186: Hydraulic Schematic Diagram
The parking brake is of mechanical type. It is of a mechanical, internal-expansion type, and built in the wheel brake. It shares the brake shoe and brake drum with the foot brake. When the parking brake handle is pulled, the brake handle drives the pull rod through the brake cable.
Page 187: Electrical Schematic Diagram
5.2.4. Electrical schematic diagram The electrical system of forklift truck is an important part of the forklift truck, and the electrical equipment of diesel forklift truck is responsible for starting, charging, ignition, lighting, and signal monitoring. The performance of forklift truck electrical equipment directly affects the power, economy, reliability and safety of forklift truck.
Page 188 Fig. 1: Electrical Schematic Diagram of WG2503 (KU1HG3) Fig. 2: Electrical Schematic Diagram of Quanchai 498 (Q17HG3)
Page 189: Forklift Truck (Load) Curve
5.2.5 Forklift truck (load) curve The load curve of the forklift truck is the load (kg) of the forklift truck when the mast is in a vertical state without attachments. The maximum load (kg) corresponding to the forklift truck when the load center distance (mm) and lifting height (mm) are listed in the form of a curve and pasted on the truck.
Page 190: List Of Optional Configuration
CPCD30/CP（Q）（Y）D30 CPCD35/CP（Q）（Y）D35 5.3 List of optional configuration Standard configuration Optional configuration Stopwatch Wide-vision mast Electric horn Intake device Fork extension sleeve Oil pressure alarm Treaded durable tire Heater Two-piece multi-way Lifting tilting valve control lever Double air filters (some models) Full hydraulic power steering Traction pin...
Page 191 Transmission oil filter Fire extinguisher Engine flameout device Rear work lamp Coolant temperature gauge A/C (some models) On-board tools Service control system Rear combination lamp (LED) Torque converter oil thermometer Reversing buzzer User-specified color Self-locking valve of tilt cylinder Selected attachments Tilt-adjustable steering column Lifting appliance...
Page 192 If the user's truck has anti-corrosion requirements, the following levels of anti-corrosion treatment can be selected. The anti-corrosion stickers affixed to the truck are described as follows:...
Page 193: Operation And Maintenance Of Diesel Particulate Filter (Dpf)
Operation & Maintenance Diesel Particulate Filter (DPF) Be sure to fully understand the precautions related to forklift truck safety in this Manual. When operating the forklift truck, strictly observe these precautions. Failure to pay attention to this warning may result in serious injury.
Page 194: Description
6.1 Description Some diesel engine models (CPCD model) are equipped with a diesel particulate filter (DPF) in the exhaust system, which is divided into regenerate and non-regenerate versions. Regeneration is the process of burning the dust particles (PM) in tail gas in DPF.
Page 195 exhaust temperature warning (as shown below), please pay attention to avoiding surrounding personnel and flammable and explosive articles from approaching the exhaust pipe. During truck regeneration, high exhaust temperature will be generated. Pay attention to it when the air circulation is poor and there are flammable and explosive articles around! ■...
Page 196 ● When the truck is in parked regeneration request, if the driver does not park for regeneration, the truck will be subject to torque limit control. ● When the truck is in the process of parked regeneration, no operation can be carried out;...
Page 197: Non-Regenerate Dpf
2) Way of active regeneration Switch the rocker switch to the active regeneration state. When the truck meets the conditions for active regeneration during operation, it will automatically undergo regeneration. During active regeneration, and indicators illuminate. In this process, the truck can continue to be operated (such as travelling and loading/unloading), but attention shall be paid to ventilation and keeping away from flammable and explosive articles.
Page 198 Step 2: Sleeve the air inlet end of DPF assembly taken out on the dust collection bag, tie the bag mouth tightly, and clean it hole by hole from the safety valve end (air outlet end of DPF carrier) with a high-pressure blower gun with a pressure of not less than 16 kg for 20-30 minutes.
Page 199 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 S414-1:2024 E-mail/heli@helichina.com All rights reserved...

HELI G3 Series Operation & Service Manual

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