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HELI G2 Series Operation & Service Manual

Lithium battery powered counterbalanced forklift trucks
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OPERATION & SERVICE
MANUAL
G2 series lithium battery powered
counterbalanced forklift trucks
6-10t

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Summary of Contents for HELI G2 Series

  • Page 1 OPERATION & SERVICE MANUAL G2 series lithium battery powered counterbalanced forklift trucks 6-10t...
  • Page 2 FOREWORD This manual mainly introduces the performance, structure, safe operation and regular preventive maintenance of G2 series 6-10t lithium battery powered forklift truck in order to help operators operate and maintain the truck properly. Operators and equipment supervisors should read the manual carefully and operate and maintain according to the relative requirements and regulations during the usage in order to keep the truck in good working condition.

  • Page 3: Table Of Contents

    CONTENTS Ι. Safety Rules for Operation and Daily Maintenance of Forklift Truck ........1 1. Truck application scope ..................... 1 2. Truck operation area and condition ................... 1 3.Delivery of Forklift Truck ....................1 4. Storage of Forklift Truck ....................1 5.

  • Page 4: Ι. Safety Rules For Operation And Daily Maintenance Of Forklift Truck

    Ι. Safety Rules for Operation and Daily Maintenance of Forklift Truck It is important that driver and manager for forklift trucks remember the principle of the “first safety” and ensure the safety operation as the description in 《OPERATION AND SERVICE MANUAL》&《OPERATION MANUAL》. 1.

  • Page 5: Precautions Before Operation

    (5) Apply grease to the exposed piston rod of the hydraulic oil cylinder. 5. Precautions Before Operation (1) Don’t check fuel leakage and level or instruments at the place where there is open flame; (2) Check the level of hydraulic oil; (2) Check the tire inflation pressure.

  • Page 6: Accessories And Parts Of The Truck

    (20) Be familiar with and pay attention to the functions of the decals on the forklift trucks. 7. Accessories and parts of the truck (1) The safe operation of the truck may be badly affected if non-genuine parts are used; (2) When changing parts, it is recommended to use HELI genuine parts sold by HELI...

  • Page 7: Plates For The Truck

    (3) HELI will not bear the responsibility for the fault with the quality guarantee period caused by the using of non-genuine parts. 8. Plates for the truck The plates stuck on the truck are used to instruct the usage and notes. This is not only good for you but also for the truck.

  • Page 8: After-Sale Service For The Truck

    (2) See Figure 1.1 for Lubrication chart. Lubrication Chart 10. After-sale service for the truck Refer to the after-sale service of G3 series electric truck. 11. The frame number position The unique series number (the same number as the product number) is marked on the...

  • Page 9: Capacity Chart

    frame of the forklift truck when leaving the factory, and it is permanently marked on the frame with steel marks, which can trace the production, sales, maintenance and other information of the truck. The series number of the truck is located in the fender , and its position is shown in the figure below.
  • Page 10 （2）The rated capacity chart of forklift trucks 6t (2-stage mast) 6t (3-stage mast) 7t (2-stage mast) 7t (3-stage mast) 8.5t (2-stage mast) 8.5t (3-stage mast) 10t (2-stage mast) 10t (3-stage mast)

  • Page 11: Main Components And Parameters Of The Truck

    II. Main components and parameters of the truck 1. Brief instruction of the truck G2 series 6-10t lithium battery powered counterweight forklift is a new product built by Anhui HELI based on G3 series internal combustion large-tonnage platform. The appearance of the truck is basically the same as that of G3 series internal combustion trucks,...

  • Page 12: Main Parts

    2. Main parts See table 2.1 for main parts of the truck. Table 2.1 Main parts No. Name Contents Drive axle It mainly includes wheel reductor, reduction gearbox, brake and so on. Steering system It mainly includes steering wheel, hydraulic steering unit and so on. Steering axle It mainly includes steering axle, steering cylinder and so on.

  • Page 13: Main Parameters

    4. Main parameters Table 2.2 Main parameters Truck model Item Unit CPD60-A11LI CPD70-A11LI CPD85-A11LI CPD100-A11LI G2-H G2-H G2-M G2-M Rated capacity 6000 7000 8500 10000 Load center Power Electric Driving mode Driver seated Lifting height 3000 Free lift Mast tilt angle（fwd/bwd） deg.

  • Page 14: Main Parts Introduction, Troubleshooting And Maintenance

    III. Main parts introduction, troubleshooting and maintenance 1. Body system 1.1 General description The body system is the main part of a truck and the carrier for other system. It plays an important role. It mainly includes frame, dash board, hood, balance weight, seat and so on. Its disassembly, installation and maintenance must be carried out when the power of the truck is cut off.
  • Page 15 Rear Fixed Bolt Front Fixed Bolt Figure 3.1.2 (5) Lift the overhead guard through slings. 1.3 Dash board Steering column assembly, parking brake handle instrument assembly, control valve and windshield screen and so on are assembled on the dash board. Before disassembling the dash board, the accessories and the parts connected with the truck shall be disassembled first.
  • Page 16 Bolt Figure 3.1.3 1.4 Hood When removing the hood: (1) Remove the mounting bolts of the cover plate on the frame and remove the cover plate and counterweight cover from the truck body, as shown in figure 3.1.4; (2) Remove the fixing bolts of the cover rotary hinge on the frame, and take out the cover upward to complete the removal.

  • Page 17: Transmission System

    2. Transmission system 2.1 Transmission system-WEIDE 2.1.1 Overview The drive axle mainly includes the axle body, axle shaft, wheel hub reducer, brake and front wheel. See Fig. 3.2.1.1 for the detailed structure of the 6-7t drive axle and Fig. 3.2.1.2 for that of the 8.5-10t drive axle.
  • Page 18 Fig. 3.2.1.1 6-10t Drive Axle 1. Axle housing 2. Axle shaft 3. Brake 4. Brake drum 5. Oil seal 6. Conical roller bearing 7. Hub 8. Conical roller bearing 9. Adjusting nut 10. Lock nut 11. Planetary gear carrier 12. End cover 13.
  • Page 19 Fig. 3.2.1.2 8.5-10t Drive Axle 1. Axle housing 2. Axle shaft 3. Brake 4. Brake drum 5. Oil seal 6. Conical roller bearing 7. Hub 8. Conical roller bearing 9. Adjusting nut 10. Lock nut 11. Planetary gear carrier 12. Planetary gear 13.
  • Page 20 2.1.2 Wheel hub reducer The wheel hub reducer includes a sun gear, a set of planetary gears and an internal gear ring. Two sets of hub reduction gears are respectively installed at both ends of the drive axle housing. The sun gear is integrated with the axle shaft. The planetary carrier is installed on the wheel housing.
  • Page 21 2.1.3 Troubleshooting See Table 3.2.1.2. Table 3.2.1.2 Fault Cause Troubleshooting Loose connecting bolts or damaged gaskets between the powertrain and the drive axle Tighten or replace and the hub end cover Oil leakage The vent hole is blocked Clean or replace Oil seal is worn or damaged Replace The gear is worn, damaged or broken...
  • Page 22 2.1.5 Reducer assembly 2.1.5.1 Main technical parameters Input torque (N.m) 410N.m Weight (Kg) 150kg The input end is connected by involute spline, and the Installation method output end is connected by involute spline Speed ratio of drive reducer 20.034 2.1.5.2 Structural features The reducer integrates the drive reducer.
  • Page 23 2.1.5.3 Working principle Fig. 3.2.1.4 Wheel hub reducer 2.1.5.4 Operation and maintenance The reducer is lubricated by splash lubrication. After the reducer is installed on the truck, 85W/90 GL-5 heavy-duty gear oil (for all seasons) shall be added. The amount of oil to be filled is determined according to the volume of the customer's axle housing until the oil overflows from the oil observation port.
  • Page 24 first. It is very important to keep the reducer breather plug clean and unblocked. The breather plug is located on the upper part of the drive axle housing. Due to its installation position and tightness, it is easy to cause blockage. Poor ventilation will increase the air pressure of the reducer, resulting in oil leakage and accelerated wear and corrosion of parts.
  • Page 25 30 minutes) with the oil temperature up to 130° C under severe working conditions is allowed. 2.2 Transmission system - HELI Fig. 3.7.2.4 Transmission system assy 1-axle shaft 2-reducer 3- wheel hub reducer 4- actuator 5-hub 6-half axis 2.2.1 Overview...
  • Page 26 working, the power is transmitted from the differential to the axle shaft, and then to the wheel hub reducer, and the wheel hub reducer is connected to the hub, and ultimately drive the rotation of the front wheel. Power transmission route: differential → axle shaft → wheel hub reducer→ hub → front wheel.
  • Page 27 Fig. 3.2.2.1 6-7t Drive Axle 8-Axle housing 2-axle shaft 3-brake 4-drum brake 5-oil seal 6- Conical roller bearing 7-hub Conical roller bearing 9- Adjusting nut 10- Lock nut 11- Planetary gear carrier 12- End cover 13- shaft 14- Steel ball 15- Planetary gear 16- Gear ring 17- Sun gear...
  • Page 28 Fig. 3.2.2.2 8.5-10t Drive Axle 1- Axle housing 2-axle shaft 3-brake 4-drum brake 5-oil seal 6-Conical roller bearing 7-hub 8- Conical roller bearing 9- Adjusting nut 10- Lock nut 11- Planetary gear carrier 12- Planetary gear 13- Steel ball 14- Shaft 15- Sun gear 16- End cover 17- Gear ring 2.2.2 Wheel hub reducer The hub reducer includes a sun gear, a set of planetary gears and an internal gear ring.
  • Page 29 gear shafts installed in the planetary carrier. The principle of power transmission by the internal gear is as follows: See Fig. 3.2.2.3. When the sun gear rotates (i.e. the axle shaft rotates), the rotation is transmitted to the planetary gear and the inner ring gear. However, since the inner ring gear is fixed on both ends of the drive axle housing, the planetary gear rotates around the sun gear and also rotates on its own.
  • Page 30 2.2.4 Repair data See Table 3.2.2.3. Component Item Standard value (mm) Tightening torque of bolts securing the axle housing and 150-175(N.m) the powertrain Diameter of fit between small bearings (Item 6 in Fig. 4.1 or Item 6 in Fig. 4.2) at both ends of axle housing 89.66-89.88 and axle housing Diameter of fit between oil seals at both ends of axle...
  • Page 31 The function of the reducer is to increase the input torque of the motor and reduce the speed, so as to achieve the use needs of different working conditions of the truck. Working principle: The involute internal spline is designed in the drive gear of the reducer, which is coordinated with the external spline of the motor output shaft to receive the power, which is transmitted to the gear at all levels of the reducer, and then transmitted to the axle shaft of the drive axle through the differential.
  • Page 32 is installed on the outside of the differential housing, and the power is transmitted from the gear ring to the differential housing and the cross shaft. The back of the planetary gear is designed as a spherical surface to ensure that the planetary gear is better centered and properly engaged with the two axle-shaft gears.
  • Page 33 Fig. 3.2.2.4 Differential 1-left housing 2-right housing 3-axle shaft gear 4- planetary gear 5- spherical pad 6- universal joint pin 7- flat pad 8- bearing support 9-bearing 10- adjusting nut 2.2.5.4 Use and maintenance The reducer adopts oil bath lubrication, should add 85W/90 GL-5 heavy duty gear oil (suitable for any season), the reducer and the drive axle are assembled, in the loading state, the fuel amount until the front of the drive axle oil port overflow, with 8-10t drive axle when about 20L(including the wheel reducer), with 6-7t drive axle when about 15L.
  • Page 34 After the first maintenance for 600 hours or three months, add new gear oil, whichever comes first; after that, replace the gear oil every 1200 hours or six months, whichever comes first. It is very important to keep the reducer breather plug clean and unblocked. The breather plug is located on the upper part of the drive axle housing.
  • Page 35 2.2.5.5 Common faults and troubleshooting methods Faults Cause analysis Troubleshooting ● The gear has burrs, bruises, fracture, or ● grind or replace the gear nonconforming tooth profile and tooth direction (new truck) ● Fuel shortage ●Check the fuel level and refuel as prescribed ●...

  • Page 36: Steering System

    oil temperature reaching up to 130℃ for a short time (not more than 30 minutes) is allowed. 3. Steering system See table 3.3.1 for the main parameters. Table 3.3.1 Items Parameters, structure Type of steering system Full hydraulic powered steering system Diameter of steering wheel Model Load sensing steering unit...
  • Page 37 rear wheel. The steering operation device is mainly composed of steering wheel, pipe column, transmission shaft, steering gear and mounting bracket (as shown in Figure 3.3.1). They are fixed on the dash board of instrument by mounting bracket, the steering wheel, pipe column and transmission shaft are connected together, the steering gear is fixed at the lower end of transmission shaft, and the rotation of steering wheel will drive the steering gear to rotate.
  • Page 38 Figure 3.3.2 Dynamic load sensing steering system 1. Steering wheel and steering shaft 2. Oil pump 3. Priority valve 4. Hydraulic steering unit 5. Steering cylinder 6. Steering axle Figure 3.3.3 Cycloid hydraulic steering unit 1. Thrust needle bearing 2. O ring 3.
  • Page 39 3.1.2 Working principle See figure 3.3.4 for working principle. Steering unit Other circuit Priority valve Figure 3.3.4 Working principle of oil circuit of steering The centering valve, valve sleeve and valve body consist rotating valve which is to control the direction of oil flow. The cycloidal gearing pair is consisted of rotator and stator which is to measure elements when steering and thus to make sure the oil quantity into the cylinder is in direct proportion when steering.
  • Page 40 right and the oil circuit CF is connected. The steering unit is in standby condition. When the hydraulic pump supplies oil, the oil distributed to CF circuit by the priority valve generates pressure drop flowing through throttle port C0 at the neutral position. The pressure at the two sides of C0 is transmitted to the two ends of priority valve’s core and thus a balance between hydraulic power and spring power is generated to keep the valve core to stay at a balanced position.
  • Page 41 sharply. When the pressure of steering oil circuit exceeds the set value of safety valve, the valve is open. The drop pressure is generated when the pressure oil flow through G2 and the drop pressure is transmitted to the two ends of priority valve core to push the core to left. And the valve port to the CE circuit is turned down and port to the EF increases.
  • Page 42 oil suction pipe shall plug into the oil so that it can feed oil during manual steering and avoid air mixing in the oil. For the safety and repair convenience, it is suggested to install a pressure gauge connector at the oil inlet of the steering gear for the pressure gauge installation. (2) Oil temperature range: -20℃～+80℃...
  • Page 43 filter elements and oil regularly according to requirements. Hydraulic oil condition can be checked by putting one drop of oil on absorbent paper. If there is a black spot in the center of oil stain, it will be changed. If something abnormal happen during operation, try to find the reasons.
  • Page 44 other in assembly f) The gasket of limit bolt (with pin) should be made of copper or aluminum. g) The tightening method of the seven bolts on the rear cover: tighten every third orderly and gradually, not one by one. The tightening torque is 30-40Nm. h) When installing the oil pipes, pay attention to the “inlet”, “return”, “left”...
  • Page 45 6. X ring 7. Buffer ring 8. Bearing 9. Slid ring 10. Valve core and valve sleeve 12. Pin 13. Valve body 14. O ring 15. Spacer 16. Coupling shaft 17. Steel ball 18. Pin 19. Rotator and stator 20. Stopper 21. Rear cover 22.
  • Page 46 3.3.1 Steering axle body Steering axle body is a steel plate welding structure. On its two ends there are upper and lower bosses (holes) . The left and right steering knuckle assembly are connected with the axle body through steering king pin. 3.3.2 Left and right steering knuckle assembly Left and right steering knuckle assembly is supported on the wheel hub through two thrust bearings and the wheel is mounted on the wheel hub.
  • Page 47 Figure 3.3.6 Steering axle 1.Steering axle body 2. Steerin gcylinder Figure 3.3.7 Steering axle 1.hub 2.M6 bolt 3. Steering axle main pin 4. dust cap 5. potentiometer 6.M8 bolt 7. Oil seal 8. sealing gasket 9. needle roller bearing 10. steering axle assy 11.

  • Page 48: Brake System

    Fig. 3.3.8 Steering cylinder 1. welded parts 2. Nitrile rubber 3. Polytef 4. Nitrile rubber 5.Plug 6. Cylinder bore 7. O ring 8. Guide sleeve 9. Bearing 10. O ring 11. Support ring 12. Guide sleeve 4. Brake system 4.1 Overview The service brake system consists of the service brake, pump station, bladder accumulator, full hydraulic dynamic brake valve, steel pipe, rubber hose and connector integrated in the left and right driving wheels.
  • Page 49 Fig. 3.4.1 Assembly Diagram of Service Brake System Fig. 3.4.2 Hydraulic Schematic Diagram of Service Brake System Forklift truck model CPD60, 70 CPD85, 100 Item Braking mode Dynamic braking Service Brake type Front-wheel, internal-expanding, shoe brake brake Inner diameter of brake drum Φ...
  • Page 50 Inner diameter of slave Φ 31.75 Φ 47.62 cylinder (mm) Shoe dimension (length x 324× 100× 10 489× 100× 12.7 width x thickness) (mm) Shoe surface area (cm 4× 324 4× 489 Installed on the intermediate shaft of the Type gearbox, mechanical internal-expanding type Inner diameter of brake drum Parking...
  • Page 51 prevent the forklift from exceeding a certain speed when going downhill and ensure that the forklift parks on the slope. The driving safety of a forklift depends greatly on the reliability of the brake device. The parking brake is generally a mechanically driven mechanism to ensure long-term braking or emergency use when the foot brake fails, which is also generally called hand brake.
  • Page 52 1. Bottom plate 2. Brake shoe 3 Fixing bolt 4. Nut 5. Spring washer 6. Washer 7. Return spring 8. Regulator 9. Regulator spring 10. Pin 11. Spring mounting support 12. Rod 13. Supporting plate 14. Pin 15. U-shaped retaining ring 16.
  • Page 53 Set the pressure of pressure switch to 9MPa Set the pressure of pressure switch to 13MPa Fig. 3.4.5 Service Brake System Pump Station Fig. 3.4.6 Schematic Diagram of Service Brake System Pump Station 4.3 Full hydraulic dynamic brake valve The hydraulic brake valve is a direct-acting three-channel pressure-reducing valve, as...
  • Page 54 shown in Fig. 3.4.7. The braking force is determined by the pedal force applied by the operator, and the pedal is installed on the frame through a bracket. The brake pedal height has been set before leaving the factory and does not need to be readjusted.
  • Page 55 Fig. 3.4.7 Hydraulic Brake Valve 4.4 Bladder accumulator The accumulator is an energy storage device in the hydraulic system. The bladder accumulator mainly uses the compressibility principle of gas (generally nitrogen) to store energy, and its specific principle is as follows: The inside of the bladder is filled with nitrogen, and the outside is surrounded by hydraulic oil;...
  • Page 56 beginning, and once half a year after half a year. If any leakage is found, gas shall be supplemented immediately. If the leakage is serious, the cause (bladder damage, poor sealing of inflation valve or poor sealing between inflation valve and inflation valve seat) shall be found out and repair carried out without delay.
  • Page 57 can the inflation speed be appropriately increased. (9) When the pressure reaches the predetermined pressure (5.5MPa), immediately turn off the control switch of the filling tool; (10) Close the valve switch on the nitrogen cylinder, and then rotate counterclockwise the needle valve at the upper end of the accumulator to close the valve;...

  • Page 58: Hydraulic System

    4.5 Fault diagnosis Symptoms Cause analysis Troubleshooting External leakage: Replace the joint, Frequent start of rubber hose or seal ring; Insufficient accumulator liquid filling of Low inflation pressure: Inflate; pressure pump station Diaphragm fracture: Replace the accumulator 1) Low set pressure of overflow Readjust valve Excessively long...
  • Page 59 positioning and fork bracket left and right shifting can be realized. Load sensing type flow priority control valve is integrated in the control valve to make the flow for steering be controlable. Through steering wheel, load sensing hydraulic steering unit controls the flow direction and makes the steering wheel steers according to relative requirement.
  • Page 60 Figure 3.5.1 Oil circuit for hydraulic system Figure 3.5.2 Principle diagram of hydraulic system When the gear pump 1 is working, oil is sucked from the oil tank through oil sucking filter and the oil flows to the pieces of control valve through port P2. When the gear pump 2 is working, oil is sucked from the oil tank through oil sucking filter and the oil flows to the priority valve through port P1 and then it is divided into two circuits, one circuit flows to load sensing steering unit through port CF preferentially;...
  • Page 61 forklift truck. When the lifitng and steering does not work and only the tilting (or attachment) works, the gear pump 1 works seperately. The hydraulic oil goes to tilting (or atachment) controls through port P1 and then flows to tilting (or attachment)cylinder, and thus mast tilting (or attachment) acts.
  • Page 62 valve, oil return control piece. The three parts are connected through three double end bolts and nuts. See figure 3.5.3 for its structure. In the oil inlet control piece, there is a main safety valve to adjust the oil pressure in the circuit;...
  • Page 63 installed on the same shaft which is installed on the dash board. The operataion levers are connected with sliding valves through link rod. See figure 3.5.4. Lifting tilting attachment attachment attachment Link rod Figure 3.5.4 Operation device for the control valve 5.5 Hydraulic oil return filter It is installed between oil return pipe of control valve and hydraulic oil tank for filtering the oil returning to oil tank.
  • Page 64 Oil inlet port outlet port Upper case Lower case Core Figure 3.5.5 main filter 5.6 Hydraulic oil tank The hydraulic oil tank is arranged on the right side of the truck body and welded with the frame, as shown in figure 3.5.6. The hydraulic oil tank is mainly composed of hydraulic oil tank body, oil tank cover plate, oil drain plug, oil suction filter, oil suction pipe, oil return pipe and refueling cover (including breathing filter).
  • Page 65 (2) After the installation is completed, the system shall be filled with oil from the hydraulic oil tank up to the level between two scale lines on the oil gauge. Make sure that the new oil must be filtered by 10μ filter before filling. (3) Operate the truck with inching motor when driving for the first time, first, observe if the rotation direction of motor is correct, if not, change the phase position of wires.
  • Page 66 (2) Fault analysis and trouble shooting Fault Cause Troubleshooting Lifting 1)Gears and body of oil pump worn out. Clearance too 1)Change worn-out parts or oil pump. weakness or big. 2)Change with new piston or sealing unable to lift 2)Piston seals of lifting cylinder worn out, clearance rings.

  • Page 67: Lifting System

    6. Lifting system 6.1 General Description of basic type lifting system The basic lifting system is a two-stage roller type vertical lifting and lowering structure, which is composed of inner and outer mast, two rear lifting cylinders and fork carriers. The lifting system is equipped with buffer, lowering the impact to the goods.
  • Page 68 The maintenance of the roller and the side rollers on the inner and outer masts belong to maintenance at high position abover the floor level. Please be careful. Outer mast Inner mast Main roller Side roller Side roller Main roller Figure 3.6.2 inner mast and outer mast 6.1.2 Fork carrier The fork carrier moves up and down smoothly along the channel of the inner mast...
  • Page 69 Backrest Side roller Side roller shaft Fork carrier Side roller Main roller Main roller Fork Figure 3.6.3 fork carrier 6.2 Adjustment method of roller See figure 3.6.4 for roller layout. There are 8 main rollers with 2 on top of outer mast and 2 at the lower end of inner mast and 6 on two sides of upright plate of fork bracket.
  • Page 70 Rear lifting Main roller cylinder Side roller Inner mast Outer mast Hook type fork carrier Figure 3.6.4 Roller layout Note: (a) The clearance of the side roller is 0-0.5mm. (b) Apply grease onto the contacting face of the main roller surface and mast. 6.3 Repair 6.3.1 Adjusting of liting cylinder Readjust the stroke of the lift cylinder when the lift cylinder, the inner mast or the outer...
  • Page 71 6.3.2 Adjust fork bracket’s height (1) The truck should be stopped on horizontal ground. And ensure the masts erect. (2) Lower the forks on the ground, adjust the set nut of tie-in on the upper of chains and there is a distance A (1/4----1/3 of the main roller’s diameter) between main rollers and the fork bracket.
  • Page 72 Figure 3.6.6 6.3.4 Replacing rollers of masts (1) Take apart the fork bracket from the inner mast, then replace the main roller follows the way as 6.3.4. (2) Park the truck on the horizontal ground and lift up the front-wheel 250～300mm from the ground.

  • Page 73: Electrical System

    7. Electrical system 7.1 Overview The electrical system of this forklift is a high-performance full AC electronic control system, which can realize the mute, efficient, smooth and safe control of the truck. The electrical system consists of the lithium battery, 12V battery, VCU, motor and motor controller, protection and power converter, operation control devices, signal and lighting lamps, connecting wire harness, etc.
  • Page 74 Fig. 3.7.1 CPD60/70-A11LIG2-H & CPD85/100-A11LIG2-M Electrical Schematic Diagram (LV Part)
  • Page 75 Fig. 3.7.2 CPD60/70-A6LIG2-H & CPD85/100-A6LIG2-M Electrical Schematic Diagram (LV Part)
  • Page 76 高压部分 快充+ QC-P- QC-P+ 充电继电器 250A 泵供电2+ 泵供电1+ BK-P+ BK-P- 泵系统最大功率约60KW， 泵控继电器 300A 继电器选300-350A左右 高压DC输入+ 400A QY-P+ QY-P- 牵引控继电器 300A 牵引供电+ 驱动系统最大功 率约52KW继电器 选250-300A左右 400A BMS主机 高压继电器驱动 400A 总负继电器400A ZF-P+ ZF-P- 分流器 快充- 快充+ 分流器 Quick charging+ Diverter 充电继电器 250A 速度编码器（旋变）...
  • Page 77 1) The traction control system consists of the direction switch, pedal accelerator, electromagnetic brake, traction motor controller and AC traction motor; 2) The lifting control system consists of the valve-controlled switch, lifting speed regulating sensor, pump motor controller and AC pump motor; 3) The 12V battery is used to supply power for the low-voltage system before the lithium battery works;...
  • Page 78 external impact, falling from high altitude, etc. This operation may cause personal injury or property loss; 5) The main series circuit of the battery pack is equipped with a manual service switch to ensure that the main circuit can be disconnected when the power supply system is short-circuited, and the main circuit of the power system can be manually disconnected when the truck is maintained.
  • Page 79 operation. The inspection items are as follows: 1) Whether there is abrasion, damage and looseness of HV and LV harness and connector of battery system; 2) Whether there is mud, crack, deformation, odor and bulging in the battery box and HV box;...
  • Page 80 2605 Rated power (kW) Rated voltage (V) 345.6V 345.6V IP grade IP67 Cooling mode Liquid cooling Table 3.7.7 Motor Specification of HELI system Specification item Traction motor Pump motor Rated speed (rpm) 2850 2200 Rated power (kW) Rated voltage (V)
  • Page 81 7.4.2 Precautions for use Please check whether the mechanical installation and electrical connection are safe, reliable and properly grounded before the motor is powered on. If any abnormal sound or vibration is found in motor during operation, please stop operation immediately, cut off the power supply, check the motor and load equipment, and remove the troubles before it is put into use again.
  • Page 82 stator and rotor) Return to the factory (adjust the Wrong driver and incompliance phase relationship between the Idling / excessively between phase of main motor and that main motor and the resolver so large on-load current of resolver that the no-load current is at the minimum value) Unreasonable installation Reassembly...
  • Page 83 2146000-WDX011-B00 Reducer assembly KTZ34X48SAPB01 Motor controller BDM230XS041WDX01 Drive motor Fig. 3.7.5 Drive Assembly of HELI system Table 3.7.10 Parts Catalog of Drive System Assembly of HELI system Item No. Part No. Edition Name of parts Qty. A0081579 TZ250XS60-2850-336Q2 A1091434...
  • Page 84 7.4.5 Pump system assembly The pump motor assembly is of an integrated structure, and the dual-pump motor and dual-pump electronic controller are integrated and installed on the same base. The pump electronic controller is fixed on the pump motor through a bracket to form a small assembly, and the two motor assemblies are fixed on the bottom plate mounting frame through four fixing points at the lower end of the pump motor with shock pads to form a pump system assembly.
  • Page 85 Low-voltage wire harness 2 2149047-WDX011-A00 LV connector Hexagon flange nut 2149034-WDX011-A00 Harness bracket Lifting lug bolts 2149048-WDX011-A00 Pipe clamp 2149033-WDX011-A00 Water pipe 4 2149010-WDX011-A00 Water pipe adapter 2149028-WDX011-A00 Electric controller bracket 2 Fig. 3.7.8 Pump system assembly of HELI system...
  • Page 86 Fig. 3.7.9 Exploded View of Pump Assembly of HELI system Table 3.7.12 Parts Catalog of Pump Assembly of HELI system Item No. Part No. Edition Name of parts Qty. A2991820 Support hex socket screw M12× 1.25× 70-12.9 (fine QD201A344 pitch thread) Gasket ∅...
  • Page 87 Sweep frequency vibration and random vibration, GB/T 18488.1 The resistance between the conductive part accessible by the IP grade controller and the fixing bolt is lower than 0.1Ω Table 3.7.14 Environmental Requirements of Motor Controller of HELI system Storage temperature -40℃~+85℃ pump electronics： -40℃~+85℃ drive electronics： -40℃~+65℃...
  • Page 88 8) Handle with care and hold the bottom plate of the product during handling to prevent the controller from crushing or damaging! 9) Do not drop drilling residues, thread ends or screws into the controller during installation, otherwise it may cause controller failure! 10) Do not touch the controller directly given the risk of mechanical damage and scalding! 11) Try not to touch the component body during maintenance, inspection or replacement of parts given the risk of electrostatic damage to the component!
  • Page 89 Powertrain open-circuited 3044 Drive secondary alarm 2045 Drive tertiary alarm 3045 Hydraulic secondary alarm 2046 Hydraulic tertiary alarm 3046 Power steering start timeout 2050 Power-assisted startup failure 3050 Low brake oil pressure 2051 Overload/overtemperature of brake pump 2052 BMS relay response timeout 3062 Power battery charging connection or interlocking fault 3063...
  • Page 90 Table 3.7.16 Fault code of HELI system Equipment code Fault name Fault code Level High input voltage 10（high pressure low input voltage DC） High temperature of DC Overcurrent of DC （20/30/40）1 Second level fault of the controller overcurrent （20/30/40）2 Third class fault of the controller overcurrent （20/30/40）3...
  • Page 91 Pump 1 failure Pump 2 failure Heat dissipation fan is faulty The independent pumping station is faulty Accumulator pressure is low Traction sequence is faulty Hydraulic sequence is faulty Accelerator calibration is faulty Lift adjustment sensor calibration is faulty DC node is lost The meter node is lost Traction OPS sequential protection Hydraulic OPS sequential protection...

  • Page 92: Cooling System

    8. Cooling system 8.1 Overview The cooling system consists of the radiator assembly (three-way), electric cooling water pump, pump motor suction pipe, drive motor suction pipe, and outlet pipe (rubber) and inlet pipe (rubber) for WEIDE system and autonomous control system respectively. 8.2 Assembly principle The assembly diagram of the cooling system is shown in Fig.
  • Page 93 The cooling water pump 1 sucks out the water from the cooling water tank through the outlet of the pump motor suction pipe. The water flows into the pump motor through the pump motor outlet pipe and then enters the cooling water tank through the pump motor inlet pipe to complete the cooling water circulation of the pump motor.
  • Page 94 The schematic diagram of the cooling water circuit is shown in Fig. 3.8.4 below. Water in the cooler enters pump controller 1 through the pipeline first, pump controller 2 next, then pump motor 1 through the internal pipeline and finally the cooler through pump motor 2, which forms a circulating cooling water circuit of the pump motor.
  • Page 95  For the treatment of wastewater (discharged during coolant replacement and radiator repair) from refueling coolant, please contact a professional treatment institution or HELI forklift agent/dealer. The coolant is toxic, so it must not be discharged into ditches or on the ground.
  • Page 96 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 S404-3:2024 E-mail/heli@helichina.com All rights reserved...

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