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HELI G2 Series Operation & Service Manual

Three-wheel type electric tractor
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G2 SERIES 2-5 TON
THREE-WHEEL TYPE
ELECTRIC TRACTOR
2-5t

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Summary of Contents for HELI G2 Series

  • Page 1 G2 SERIES 2-5 TON THREE-WHEEL TYPE ELECTRIC TRACTOR 2-5t...

  • Page 2: Forward

    HELI R&D system that “Oriented by market demand” and core values that “people-oriented and repay the society with high quality products” are fully expressed by G2 series 2-5 ton AC type electric tractor. The tractor is mainly used in car industry, postal service, medicine, tobacco, and other transport and logistics industry.

  • Page 3: Table Of Contents

    CONTENTS FORWARD ............................1 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 4.4 Motor ......................... 31 4.5 Control system ......................32 4.6 Maintenance ......................33 4.7 Trouble code display ....................34 4.8 Inching device………………………………………………………………………62 4.9 Accelerator………………………………………………………………………….62 4.10 Control switch and lighting device………………………………………………..64 5. Tractor Body ........................64 6. Towing Base Assembly ....................... 65 IV.

  • Page 5: I．tractors Driving And Operation

    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: Tractor Conservation

     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: Specifications Of Tractors

    II. Specifications of Tractors 1. Specifications of Whole Tractor Technical parameters(2-3t) G2 series 2-3 ton AC type Item unit electric tractor Model QYD20S-J2G2 QYD30S-J2G2 Rated towing weight 2000 3000 Max. towing force 3100 3100 Rated towing force 1000 Length...
  • Page 8 H4/H5 Traction hook height 250/310 (mm) Min. ground clearance H3(mm) Min. steering radius 1530 1200 Wheel base L2(mm) Front Tread Rear Front 3.50-8 Tyre Rear 2x4.00-8 Tractor weight Front axle load Rear axle load Travelling speed km/h 12/9 （ unloaded/loaded） Gradeability（unloaded/loaded）...
  • Page 9 Technical parameters(2-3t) G2 series 2-3 ton AC type electric Item unit tractor Model QYD20S-J3G2Li QYD30S-J3G2Li Rated towing weight 2000 3000 Max. towing force 3000 3100 Rated towing force Length L(mm) 1740 Width W(mm) Height H(mm) 1270 Overhang length(front) L1(mm) Overhang length(rear)
  • Page 10 Mechanical Driving motor power V/Ah Battery voltage/capacity 24/200 Battery weight Steering method Mechanical Operator's ear noise <65 Technical parameters(4-5t) G2 series 4-5 ton AC type Item Unit electric tractor Model QYD40S-J2G2 QYD50S-J2G2 Rated towing weight 4000 5000 Max. towing force...
  • Page 11 Driving motor power V/Ah 48/240 Battery voltage/capacity weight Battery Steering method Mechanical Operator's ear noise <65 Technical parameters (4-5t) G2 series 4-5 ton AC type electric Item Unit tractor Model QYD40S-J3G2Li QYD50S-J3G2Li Rated towing weight 4000 5000 Max. towing force 6000...
  • Page 12 Pedal height H2(mm) Traction hook height H4/H5 290/350 (mm) Min. ground clearance H3(mm) Min. steering radius 1600 1310 Wheel base L2(mm) Front Tread Rear Tyre Front 4.00-8 Rear 2x4.00-8 Tractor weight Front axle load Rear axle load Travelling speed km/h 12/8 （unloaded/loaded）...

  • Page 13: Specifications Of Parts

    2. Specifications of Parts 2.1 Driving motor Type: AC 2.1.1 G2 series 2-3 ton AC type electric tractor Rated power:3KW, Rated voltage:24V, Rated current:131A Rated rotation: 2500rpm 2.1.2 G2 series 4-5 ton AC type electric tractor Rated power:4KW, Rated voltage:48V, Rated current:87A Rated rotation: 2200rpm 2.2 Drive axle...

  • Page 14: Frame

    2.6 Frame Type: welding 2.7 Towing mechanism Type: standard towing base 2.8 Electric equipment 2.8.1 QYD20/30S-J2G2 Battery: D-240Ah（2 ton） 、D-320Ah（3 ton） Voltage: 24V 2.8.2 QYD40/50S-J2G2 Battery: D-240Ah（4-5 ton） Voltage: 48V Controller: ZAPI 3. Oil for Tractor Lubrication oil：HQ-10 Gear oil：85W/90 Brake fluid：4604 brake fluid Lubrication grease：3 Li-base lubrication grease, drop point: 170...

  • Page 15: Construction, Principle Of Tractors

    1. Driving System 1.1 General description The Driving system of G2 series 2-5 ton AC type electric tractor consists of a reduction assembly, 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 16: Main Reduction

    12. semi-shaft (left) 35. O-ring 46. M otor c onnector 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.

  • Page 17: Installation Of Tyre

    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 18: Brake System

    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 The brake system consists of brake pedal, master cylinder, wheel brakes. The drum arrester is fixed on drive axle’s two sides. On traveling the hydraulic arrester acts on the drum arrester.

  • Page 19: Master Brake Cylinder

    2.3 Master brake cylinder The master cylinder contains valve support, nonreturn valve, return spring, primary cup, piston and secondary cup, which are all kept in place with a stop washer and a stop wire. The exterior of the cylinder is protected from dust by means of a rubber dust cover.

  • Page 20: Brake

    Fig.2-2 Master brake cylinder 1. Push r o d 2. Dust cover 3.Stop ring 4.Piston 5. O-ring 6.Oil-inlet port 7. Dust stopper 8. Cylinder body 9. Valve seal ring 10.Seal prick 11.Dust stopper 2.4 Brake The brake is the double shoe brake fixed on the two sides of the motor. The brake consists of two brake shoes, operating cylinder and adjuster.

  • Page 21: Parking Brake Assembly

    against the anchor pin and the brake shoe moves towards the rotation direction of the brake drum. The friction between the friction piece and brake drum increase when forcing against the pin. Due to the secondary shoe bearing of a larger pressure given by the primary shoe than that offered by operation of the operating cylinder, the brake occurs.

  • Page 22: Troubleshooting Diagnostic

    Fig. 2-4 Parking brake assembly Adjustment：The value of the brake force can be adjusted by adjusting the L’s distance. The pull force is appropriate within range of 20-30kg. 2.6 Troubleshooting diagnostic Problem Probable Cause Remedy 1) Fluid leaks from brake system Repair 2) Maladjustment of brake shoe clearance Adjust the adjuster...

  • Page 23: Steering Operation System

    steering column can be tilt forward and backward to proper position. The steering wheel assembly is connected to frame through steering hub and connected to steering column through gears. Thus steering is achieved. 3.2 Steering operation system Fig. 3-1 Steering operation system 1.

  • Page 24: Adjustment And Maintenance

    bracket. The steering bracket is connected to the slewing bracket via the bearings. The steering bracket is fixed to the frame. The steering mechanism assembly can rotate so steering can be achieved via the bearings. Fig.3-2 Steering mechanism assembly 1.Slewing bracket 2.Gear 3.Bolt 4.Washer...
  • Page 25 (2) Press the hub bearing into the hub and fit the hub on the steering axle. (3) Fit a bush and tighten a castle nut to a torque of 206-235N.m(21-24kgm) and loosen it, and then tighten it again to a torque of 9.8N.m(1kgm). (4) To ensure firm installation of the hub, slightly knock at it with a wooden hammer and in the meantime, rotate the hub for 3-4 turns.

  • Page 26: Electric System

    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.4-1-1, Fig.4-1-2. The circuit diagram of electric system is shown in Fig.4-2-1, Fig.4-2-2. Fig.4-1-1 Electric system (QYD20/30S-J2G2 battery tractor) 1.
  • Page 27 13. Battery 14. Cable 15. Traction motor 16. Motor wiring harness 17. Horn 18. Horn filter 19. Wiring harness 20. Meter 21. Panel cover 22. Fuse box 23. F lasher 24. Relay 25. R elay c able 26. Backward buz zer 27.
  • Page 28 Fig. 4-2-1 Electric principle diagram (QYD20/30S-J2G2 battery tractor)

  • Page 30: Battery

    Fig. 4-2-2 Electric principle diagram (QYD40/50S-J2G2 battery tractor) Note: The manufacture or the qualified persons can install road lamps, working lamps or signal lamps in the vehicle. 4.2.1 Construction of Battery 4.2 Battery Batteries are made of positive plate, negative plate, clapboard, cell cover and 4.2 2 Specifications electrolyte.
  • Page 31 batteries. (c) You must use direct current to charge。The + pole and the – pole of the Charging equipment should be connected with the + pole and the – pole of the batteries in separate for fear the batteries damaged. (d) During charging, the electrolyte temperature cannot exceed 45℃.
  • Page 32 ventilated, the temperature stays between 5－40°C, and should be kept off any heat source at least at a distance of two meters. (b) The batteries should not be placed and upside down, No mechanical shock or heavy weight. Prevent to contact with all liquid and harmful substance. All metal impurity cannot drop into battery.

  • Page 33: Instrument

    plate 4) Prematurely or at start 5) .The density over the 4) The density don’t produce air bubble during Prescribed value. over charging. 6) The level too low that the prescribed value 5) The temperature rise too the top of plate exposed 5) The level and the quickly during charging.
  • Page 34 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 circuit plate begins to work.

  • Page 35: Motor

    (c ) Battery capacity alarm When there are only one square in the graph, then the red light turns on, and the fault symbol flickers. The instrument shows "02A66" failure, the vehicle can still drive, but vehicle performance decreased.Please refer to the following figure: Instrument display power (grid) Percentage of electrically controlled electricity (%) 98%~100%...

  • Page 36: Control System

    2500rpm Rated speed model QYD40S-J2G2 QYD50S-J2G2 item AC-4（AC type） Driving motor type Rated power Rated voltage 31VAC Rated current 2200rpm Rated speed 4.4.2 Working Environment This tractor adopts AC motor as the driving motor, and it can be used on following occasion.

  • Page 37: Maintenance

    1、Fuse 2、Main contactor 3、Motor controller 4、Fuse 5、Flasher 6、Relay box 7、Relay s et 8、Wire harness 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.

  • Page 38: Trouble Code Display

    Make sure the well insulation condition of the cables and circuits are tightly connected. Check it every three months. (4) Check the mechanical moving of the pedal and knob; check if the spring is out of shape; check if the spring of the potentiometer can reach to the max. length or set length.
  • Page 39 Connect the Console to the 02A01 WARNING SLAVE Warning on supervisor uC. supervisor uC and check which alarm is present. Controller is acquiring data The alarm ends when the 02A02 ACQUIRING A.S. from the absolute feedback acquisition is done. sensor. The acquiring procedure 02A02 ACQUIRE ABORT...
  • Page 40 The controller detected a difference between the estimated absolute orientation of the rotor and the position of the index signal (ABI encoder). It is caused by a wrong Repeat the auto-teaching 02A03 HOME SENS.ERR XX acquisition of the angle procedure. offset between the orientation of the rotor and the index signal.
  • Page 41 - Check if there is a short circuit or a low-impedance conduction path between the negative of the coil and -B. - Collect information about: - The EVP driver (output o the voltage applied across A24) is shorted. the EVP coil, - The microcontroller o the current in the coil, 02A09...
  • Page 42 02A11 ENCODER PHASES Encoder error Check Encoder - Check the encoder condition. - Check the wiring. - Through the TESTER The traction rotor is stuck or function, check if the sign of the encoder signal is not 02A11 STALL ROTOR FREQUENCY and ENCODER are correctly received by the the same and if they are...
  • Page 43 This alarm can appear only - Check if there are wrong in a Traction + Pump connections in the external configuration or in a wiring. multi-motor one. - Using the TESTER function, There is an input mismatch verify that the seat inputs are in between the traction accordance with the actual state 02A15...
  • Page 44 Troubleshooting (fault at startup or in standby) - Fault can be caused by a key input signal characterized by pulses below the undervoltage threshold, possibly due to external loads like DC/DC converters starting-up, relays or contactors during switching periods,solenoids energizing or This fault is displayed when de-energizing.
  • Page 45 - Check the connections between the controller outputs and the loads. - Collect information about characteristics of the coils connected to the drivers and ask for assistance to a Zapi This alarm occurs when an technician in order to verify that 02A21 COIL SHOR.
  • Page 46 The voltage on PEB output (pin A2) is at high value even if it should not. For the versions where the smart driver is not installed (36/48V and 80V), it is possible to decide where the positive supply for pin A2 comes from by choosing a dedicated hardware configuration.
  • Page 47 A) If the problem occurs at start up (the LC does not close at all), check: - Motor internal connections; - Motor power cables connections; - If the motor connection are OK, the problem is inside the controller. B) If the problem occurs after closing the LC (the LC closes and then opens back again), check:...
  • Page 48 Cause 1 Start-up test. Before switching the LC on, the Troubleshooting software checks the power 1. If the problem occurs at bridge: it turns on start up (the LC does not close at alternatively the high-side all), check: power MOSFETs and - motor internal connections expects the phase voltages (ohmic continuity);...
  • Page 49 Cause 1 Before switching the LC on, 1. If the problem occurs at the software checks the start-up (the LC does not close), power bridge: it turns on check: alternatively the low-side - motor internal connections power MOSFETs and (ohmic continuity); expects the phase voltages - motor power cables decrease down to -B.
  • Page 50 At start-up, some hardware circuit intended to enable and disable the power bridge or the LC driver This type of fault is related to 02A32 HW FAULT (output A12) is found to be internal components. Replace faulty. The hexadecimal the logic board. value “XX”...
  • Page 51 - Verify LC coil is properly connected. - Verify CONF. POSITIVE LC parameter is set in accordance with the actual coil positive supply (see paragraph 8.2.5). Software, depending on the parameter value, makes a The positive voltage of LC is 02A35 POSITIVE LC OPEN proper diagnosis;...
  • Page 52 contactor is open. The error between the Ask for assistance to a Zapi power setpoint and the technician about the correct 02A39 POWER MISMATCH estimated power is out of adjustment of the motor range. parameters. - Check if there is a short or a low impedance path between - The EB driver is the negative coil terminal and...
  • Page 53 - Check that the SET BATTERY parameter inside the ADJUSTMENTS list matches with the battery nominal voltage. - If the battery nominal voltage is not available for the SET BATTERY parameter inside the ADJUSTMENTS list, record At start-up, the controller the value stored as HARDWARE checks the battery voltage BATTERY RANGE parameter in...
  • Page 54 If DC Pump option is set to ON, the software expects the voltage on -P output to be at a “steady state” value, before switching the LC on. If the voltage is different, it could be due to the fact that - If the motor connected to -P the motor connected to -P is is still moving, just wait for it to...
  • Page 55 The minimum voltage of the It is suggested to repeat the 02A50 PUMP VACC NOT OK lift potentiometer is not acquiring procedure of MIN correctly set. LIFT and MAX LIFT - Activate the tiller/seat input. - Check the tiller/seat input state through the TESTER Tiller/seat input has been function.
  • Page 56 - Check if an external load in parallel to the capacitor bank, which sinkscurrent from the capacitors-charging circuit, thus When the key is switched preventing the caps from on, the inverter tries to charging well. Check if a lamp or charge the power capacitors a dc/dc converter or an through the series of a PTC...
  • Page 57 - Check the mechanical The CPOT BRAKE input read calibration and the functionality by the microcontroller is out of the brake potentiometer. 02A63 BRAKE RUN OUT of the range defined by - Acquire the minimum and parameters SET PBRK. MIN maximum potentiometer values.

  • Page 58: Battery Low

    - Check the temperature read by the thermal sensor inside the motor through the MOTOR TEMPERATURE reading in the The temperature sensor has TESTER function. overtaken the threshold - Check the sensor ohmic 02A65 MOTOR TEMP. STOP defined by STOP value and the sensor wiring.
  • Page 59 - Verify that the EB coil is connected correctly between pin A2 and pin A4. - Verify that the parameter POSITIVE E.B.is set in accordance with the actual There is a hardware configuration (see paragraph problem in the smart driver 8.2.5).
  • Page 60 - Check the connections between the controller outputs and the loads. - Collect information about characteristics of the coil connected to the driver and ask for assistance to a Zapi This alarm occurs when an technician in order to verify that 02A76 COIL SHOR.
  • Page 61 - Check the wirings. At key-on and immediately - Check the mechanical after that, the travel calibration and the functionality demands have been turned of the accelerator off. This alarm occurs if the potentiometer. 02A78 VACC NOT OK ACCELERATOR reading (in - Acquire the maximum and TESTER function) is minimum potentiometer value...
  • Page 62 - Check that the sensor used is compatible with the software release. - Check the sensor This alarm occurs if the mechanical installation and if it absolute position sensor is works properly. used also for speed - Also the electromagnetic 02A81 SPEED FB.
  • Page 63 - Acquire the maximum and - The CPOT input read by minimum potentiometer values the microcontroller is not through the PROGRAM VACC within the MIN VACC÷ MAX function. If the alarm is still VACC range, programmed present, check the mechanical 02A85 VACC OUT RANGE through the PROGRAMM...
  • Page 64 NetWork function The traction controller start to continuous check the 0x1AA 01 . When traction controller have received the 0x1AA 01 , the controller will continuous read status flag byte from 0x1AA 01 . If traction controller can not Turn off remote device or Turn 02A87 0x1AA TIMEOUT receive the 0x1AA 01 in...
  • Page 65 - If the battery voltage is ok, replace the logic board. - Check that motor phases are correctly connected. The DC-link voltage drops to - Check that there is no zero when a high-side or 02A89 POWERMOS SHORTED dispersion to ground for every low-side MOSFET is turned motor phases.

  • Page 66: Analog Input

    This alarm occurs when the A/D conversion of the analog inputs returns frozen values, on all the converted signals, for more than 400 If the problem occurs ms. The goal of 02A96 ANALOG INPUT permanently it is necessary to this diagnosis is to detect a replace the logic board.
  • Page 67 This tractor adopts the COMESYS accelerator, the specifications of the accelerator as shown below: Specifications Model FZ3-152-341 Input voltage V c c 12V DC(8-15VDC) Working current 20mA (25MAX) Pedal stroke 17.5°±2° Output voltage 0.1±0.1V~9.1±0.3V Max. carrying current of the pedal switch Working carrying current of 1A@30VDC the pedal switch...

  • Page 68: Control Switch And Lighting Device

    4.10 Control switch and lighting device Electrical description of control switch and lighting device: A) A double-handle combination switch is installed on the steering column. The right switch is integrated with headlights, turn lights and width lights. The left switch controls the forward and backward movement of the tractor.

  • Page 69: Towing Base Assembly

    Fig. 5-1 Tractor Body 1. Frame 2. Tractor base 3. Hood 6. Towing Base Assembly Before towing goods, please notice the rated traction and weight, refer to the nameplate. Overload working is forbidden. The max. towing ability refers to the max. energy of the tractor need when towing the load.(The load is the total of the goods and the service weight.) While starting or stopping, press or depress the accelerator pedal slowly, avoid the freight or tractor leaning.
  • Page 70 Fig. 6-1 Towing base assembly 1、Towing Base 2、Towing pin The clearance of the towing base is 250/310mm and the value can be customized according specific conditions (it must be confirmed by engineer of HELI first.)

  • Page 71: Delivery, Hanging And Transporting

    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 72 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 73: Correct Use

    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 74: Brake

    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 75: Lamps And Horn

    6. Lamps and Horn 6.1 Lamps The key switch is the two-gear switch.  Pull the first location, both the head lamp and the signal of the head lamp in the meter will be on.  Pull the second location, the head lamp, the width lamp and the signal of both lamps will be on.

  • Page 76: Notice To Use

    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 77 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 78: Fuse For Tractor

    (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 79: Lubrication

    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 80: Routine Maintenance

    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 81 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.
  • Page 82 QS001-26:2020...

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