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HELI G2 Series Operation & Service Manual

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Summary of Contents for HELI G2 Series

  • Page 1 Operation&Service Manual...
  • Page 2 G2 series 3 ton stand-on lithium battery tractor，famous for it’s multifunctional, is a new product designed by HELI. This tractor can tow 3 tons in narrow spaces while carrying 800kg on the deck.It also comes standard with 2 step ladder for easy access to goods.
  • Page 3 CONTENTS I．Tractors Driving and Operation ....................1 1.Tractors Delivery and Hanging ....................1 2. Tractor Conservation ......................2 3. Preparations for First Time Using ..................2 4. Operations ..........................2 II. Specifications of Tractors .......................3 1. Specifications of Whole Tractor ..................... 3 2.
  • Page 4 3. Backward ..........................32 4. Brake ............................. 33 5. Steering ..........................33 VI. Notice to Use ..........................34 VII. Fuse for Tractor ......................... 36 VIII. Lubrication ..........................37 IX. Routine Maintenance ........................38 1. Daily maintenance ........................ 38 2. Maintenance every 50h ......................38 3.
  • Page 5 I．Tractors Driving and Operation Tractor users and managers should always keep “safety first” in mind and stick to 《operation and service manual》when operating. Please abide by the following rules:  Notice to use tractors;  Traffic rules in street and public; ...
  • Page 6  Make sure there are rope and crane with proper lift capacity when lifting tractor. The specific service weight refers to tractor decals;  Please place four hooks in each slinging point. And wedge rubber cushion between the tractor and the sling to protect the tractor. 2.
  • Page 7 II. Specifications of Tractors 1. Specifications of Whole Tractor Technical parameters Item Unit Model QYD30S-B2G2Li Rated towing weight 3000 Rated carrying weight Max. towing force 3100 Rated towing force 1250 Length L(mm) 2340 Width W(mm) Height H1(mm) 1400 Overhang length L2(mm) Overhang length L3(mm)
  • Page 8 L4xWxH2(mm Platform size 1500x750x640 Pedal height H3(mm) Traction hook height H4/H5(mm) 275/320 Min. ground clearance H6(mm) Approach angle a（°） Departure angle b（°） Min. steering radius 1500 Wheel base L1(mm) 1050 Front Tread Rear Front 4.00-8 Tyre Rear 2x4.00-8 Tractor weight Front axle load Rear axle load Travelling speed（loaded/unloaded）...
  • Page 9 Type: AC Rated power:4KW, Rated voltage:48V, Rated current:87A Rated rotation: 2200rpm 2.2 Drive axle Type: driving wheel (rear wheel) Construction；fixed frame and axle case 2.3 Steering wheel Type: mechanical Steering 2.4 Braking Type: electric brake for driving brake,foot brake for parking brake 2.5 Tyre Type: solid tyre Front tyre: 4.00-8...
  • Page 10 III. Construction, Principle of Tractors 1. Driving System 1.1 General description The Driving system consists of a reduction assembly and differential assembly. With direct connection of the drive gear and the drive motor, the travel speed of the tractor can be changed with the speed of the motor, and the travel direction can be changed with the rotation direction of the motor.
  • Page 11 12. semi-shaft (left) 35. O-ring 46. Motor connector 1.2 Main reduction The main reduction of drive axle is hyperbola gear, and can only use the hyperbola gear oil API GL-5 80W/90. Main driven gear has been adopted by contact standard. It can be used for a long time without regulation. Regulate the main gear assembly only when replacing the damaged parts or parts loosing because of abrasion.
  • Page 12 at differential case flange hole. Then fix the driven gear on differential case tightly. (4) Tighten every bolt alternately and uniformly with torque 70-100Nm when fixing the driven gear bolt. (5) Do not energize to bearing when installing the differential bearing to prevent the damage of bearing.
  • Page 13 rim and tyre. The head of rim bolt should towards the outside of the frame. 油压机压配轮辋 Fig. 1-2 Tyre 2. Brake System 2.1 General description Electric braking is used for driving, while foot braking is used for parking. The drum arrester is fixed on drive axle’s two sides. On parking the cable acts on the drum arrester.
  • Page 14 The operating cylinder give the primary and secondary shoes respectively a force equal in value to push the brake drum until the top of the brake shoe force strongly against the anchor pin and the brake shoe moves towards the rotation direction of the brake drum.
  • Page 15 1. foot brake 2.cable Fig. 2-2 Parking brake assembly 2.4 Troubleshooting diagnostic Problem Probable Cause Remedy 1) Maladjustment of brake shoe clearance Adjust the adjuster 2) Brake overheating Poor Check for dragging 3) Poor contact between drum and friction braking Readjust 4)Foreign matter adhered on friction piece Repair or replace...
  • Page 16 bevel gears. Thus steering is achieved. 3.2 Steering operation system Fig. 3-1 Steering operation system 1. transmission column assembly 2. chain 3. bearing end cap 4. steering wheel 5. small sprocket 6. bearing 7. heel 8. bolt 9. shim 3.3 Steering mechanism assembly Steering mechanism assembly consists of a steering bracket, a slewing bracket, bearings, hubs and tires.
  • Page 17 Fig.3-2 Steering mechanism assembly 1.Steering axle 2. Bevel gear 3.Bolt M8x35 4.Washer 5.Washer 6.Hub nut 7.Hub bolt 8. Hub 9.Nut M24x2 10.Washer 11.Washer 12.Axle 13 .Washer 14.Round nut 15.Washer 16.Bush 17.U-cup 18.Bearing 32008 19.Bolt M10x45 20.Nut 21.O-cup 3.4 Adjustment and maintenance Turning wheel bearing pre-tighten load adjustment: (1) Fill up wheel hubs, wheel hub bearings and wheel hub covers with lubricating grease.
  • Page 18 and in the meantime, rotate the hub for 3-4 turns. (5) Tighten the castle nut and align one of its notches with a cotter pin hole drilled in the steering knuckle (6) Again slightly knock at the hub with a wooden hammer and in this time, rotate manually the hub for 3-4 turns to ensure its smooth rotation with a specified torque of 2.
  • Page 19 4. Electric System 4.1 Characteristics The electric system is composed of battery, drive motor, controller assembly, controller switch, multifunctional instrument and lamps etc. see Fig.4-1.The circuit diagram of electric system is shown in Fig.4-2. Fig.4-1 Electric system ( battery tractor) QYD30S-B2G2LI 1.Front lamp 2.Combination lamp...
  • Page 20 Fig. 4-2 Electric principle diagram (QYD30S-B2G2LI battery tractor)
  • Page 21 (3) Improper using of the product may lead to battery cell ballooning which may even cause plastic housing broken or crack. If occurs, stop using the truck at once and contact with HELI technical department or after sale service department.
  • Page 22 (12) It is prohibited to make the lithium battery protective circuit board or battery management system power system in series or parallel with other system. The operation may lead on injuries or property loss. If necessary, contact with HELI technical department or after sale service department.
  • Page 23 (2) Charge the battery full after using. It is prohibited to over charge. (3) When the truck has to be stored for a long time, keep the battery electricity to be 40%~60%. Do not be full. Charge the battery before using. (4) Check the lithium battery charging socket regularly and make sure the frame is firm, the socket cover plate is well sealed, and the terminal inside of the battery is not rusty and has no foreign matters such as dust, rain and so on.
  • Page 24 4.3.1 Display of the instrument 4.3 Instrument Fig.4-3 MDI meter 1、 Hour meter 2、 Turtle speed 3、 Fault code 4、 Fault symbol display 4.3.2 Function and application 5、Electricity display 6、Fault lamp (1) battery electricity display (2) accumulative time of vehicle electrification (3) battery capacity alarm (4) fault code (a) Turn on the electric lock switch, the liquid crystal meter’s main electric...
  • Page 25 squares in the graph, then the battery capacity has been below 30%, the battery should be timely to charge, in case the battery overdischarge. (c ) Battery capacity alarm When there are only one square in the graph, then the red light turns on, and the fault symbol flickers.
  • Page 26 Rated current 108A 4.4.2 Working Environment Rated speed 2050rpm This tractor adopts AC motor as the driving motor, and it can be used on following occasion. (1) Not higher than 1200m altitude; (2) Surrounding temperature between –25℃-40℃; (3) Relative humidity gets to 100%, until the dew forms; (4) Normal conditions of the shock and quiver.
  • Page 27 Fig.4-4 Controller Notice: The manufacturer will provide quality warranty for motor controller and the manufacturer will be informed in time for after sales service in case of fault. Please do not open it for maintenance without authorization of manufacturing. The users will be responsible for the personal and property losses caused by maintenance at their own will.
  • Page 28 2F0 INIT ERR OFFSET SPD.SENS. // all153 SIXSTEP ERROR // all154 SIN/COS D.ERR XX // all168 ENCODER D.ERR XX // all169 HOME SENS.ERR XX // all176 2F0 TIMEOUT FAULT DRV.POWER // all157 NOT RDY DRV.POW. // all158 IMS ERROR // all167 HVIL FAIL // all159 SHORT CIRCUIT KO...
  • Page 29 2F1 TIMEOUT PUMP VMN HIGH BMS 02 VMN LOW INIT VMN LOW // all207 VMN HIGH INIT VMN HIGH // all206 HW FAULT MC // all203 HW FAULT // all227 PUMP VMN NOT OK // all190 HW FAULT EB. // all229 POSITIVE LC OPEN // all213 FIELD ORIENT.
  • Page 30 BRAKE RUN OUT // all204 BMS 09 TILLER ERROR // all185 MOTOR TEMPERAT. MOTOR TEMP. STOP // all178 BATTERY LOW NO CAN MSG. // all248 SENS MOT TEMP KO // all218 SMARTDRIVER KO // all193 EPS RELAY OPEN // all205 BMS 10 WRONG RAM MEM.
  • Page 31 4.6 Accelerator This tractor adopts the COMESYS accelerator, the specifications of the accelerator as shown below: The interface definition of the pedal accelerator AMP 174264-2 Function Color Note The battery of the accelerator 12-80V DC The output of the pedal signal Vs Green 0.1±0.1V~5.0±0.3V Signal reception place of the...
  • Page 32 Notice: After chopper is installed, raise the wheel of vehicle (off the ground) for test. In this way, there will be no danger even connection is wrong. After electric lock switch is off, there is a certain voltage left in filter capacitor within a period of time.
  • Page 33 275/320mm and the value can be customized according specific conditions (it must be confirmed by engineer of HELI first.)
  • Page 34 IV. Delivery, Hanging and Transporting 1. Delivery Notes Every tractor passes the careful inspection first before leaving factory to keep the perfect state to hand over. The sales company has the responsibility to inspect the tractor again before consignment, and hand over strictly by the process. When taking over, please confirm that the tractor is on good condition, intact and at correct installation.
  • Page 35 Fig.2-1 Hanging sketch map Put rubber cushion between sling and tractor, to prevent the damage of tractor. Fig.2-2 Transporting When transporting, the wedges should be settled in front and behind tires, and pull parking brake to prevent vehicle moving. Adding assistant ropes to fit vehicle from four directions to avoid damage tractor when long transporting.
  • Page 36 V. Correct Use Heli tractor can only draw the weight that nameplate states. The operator and maintenance man should do according to the manual. Company cannot respond caused by no rational use. If want to operate the tractor on other purposes the manual does not mention, Please contact to local Heli engineer.
  • Page 37 Notes: if the parking brake force is not enough or it do not work, one trained by Heli can adjust the screw. If there is still a problem, please contact Heli sales department or Heli engineer.
  • Page 38 VI. Notice to Use 1. Adjust, maintain and lubricate the tractor before use according to the manual. 2. The new tractor has a running-in period before use. 3. The life of the tractor has a direct connection with the usage in its youth time. The running-in period (50h) is to increase the life of the tractor.
  • Page 39 i) Make sure there is no case of seepage in fuel system and lubrication system. j) Make sure the display of the meter is normal. (3) Work need to do after running-in a) Change the engine oil and the lubrication oil of each assembly. b) Change the double-curved line gear oil in front and rear axle case.
  • Page 40 (6) Fuse for reversing buzzer and brake lamp 1×10A Note: though the fuse of the tractor can be exchanged with HELI forklift, please make sure the capacity of the fuse first so that the tractor can work under the proper voltage.
  • Page 41 VIII. Lubrication The proper tractor lubrication can reduce the friction and wear of the parts. Apply the clean and correct lubrication oil when lubricating. Tractor lubrication chart Lubri- Lubrication time（h） Lubrication cation Lubrication oil type Every parts point Front and rear molybdenum disulfide Filling hub bearing...
  • Page 42 IX. Routine Maintenance In order to prolong the life of the tractor, please follow the below procedure in the usage: 1. Daily maintenance 1.1 Check the oil and the brake fluid and make sure there is no case of seepage. 1.2 Check the tires condition and make sure the tires are tight.
  • Page 43 5.2 Clean and check the battery and make sure there is no case of electricity leakage. 5.3 Clean the controller, motor and other electric system. 5.4 Clean the inside of the steering case and adjust the hand wheel. 5.5 Clean and check steering wheel assembly. 5.6 Run the dirty oil in the master cylinder and wheel cylinder away according to the way of brake system deflating.

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Qyd30s-b2g2li