HELI G Series Installation and operating instructions

FOREWORD
G series 1-3.5t lithium battery counterbalanced forklift truck is designed on the base
of G series 1-3.5t battery counterbalanced forklift truck combined with lithium battery
manage system. The truck has characters of environment friendliness, maintenance free,
long service life, high efficient, energy saving, safety and it is suitable for low
temperature. These trucks are all suited for handling and stacking packed goods in
stations, ports, goods yards and warehouses and used widely in food processing, light and
textile, mining industries and other factories, with some of attachments fitted, the trucks
can be applied more and more.
These trucks feature a wide-visible hoisting system, full powered steering unit,
continuously variable speed adjuster, overhead guard with opened port and high quality
motor, battery, MOSFET controller and LED display with large screen so they have a lot
of advantages such as good performance, easy operation, wide visibility of operator,
flexible steering, reliable braking, powerful and smooth power, low noise, no
contamination to environment and beautiful contour.
This manual states the trucks’specifications, operation, maintenance, service, main
assemblies’constructions and working principles so as to help operators to use the trucks
correctly and attain the highest functions. It is necessary to read over the manual before
they operate the trucks or service personnel serve these trucks.
The rules and notices in the manual should be abided seriously by all of relative
personnel to enable these trucks in optimized working state for long period and bring the
highest efficiency.
This manual content might not correspond with the actual condition because of the
improving of our products. Our products are subject to improvements and changes
without notice.

CONTENTS
Ι. Safety Rules for Operation and Daily Maintenance of Forklift Truck ............................ 1
Ⅱ. Main Specifications of Forklift Truck........................................................................... 6
Ⅲ. Construction, Principle, Adjustment and Maintenance of Forklift Trucks................. 14
1. Transmission System ............................................................................................ 14
2. Brake System ........................................................................................................ 19
3. Steering System..................................................................................................... 34
4. Electric System ..................................................................................................... 41
5 Hydraulic System................................................................................................. 100
6. Lifting System..................................................................................................... 121

1
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.Delivery of Forklift Truck
It must be pay attention to the following items when you deliver forklift trucks with
container or trucks.
(1) Apply the parking brake.
(2) Fix the mast and the balance weight with steel wire. Wedge up all wheels.
(3) Sling points should be always at the positions specified in sling index plate when
hoisting up the forklift truck.
(4) Charge the battery to make the electricity quantity to stay between 40% and 60% and
press the emergency button.
2.Storage of Forklift Truck
(1) Apply antirust to the surface of the parts not painted. Apply lubrication oil to the lift
chain.
(2) Lower the mast to the lowest position.
(3) Apply the parking brake.
(4) Wedged up the wheels.
(5) Charge the battery to make the electricity quantity to be more than 60% and press the
emergency button.
3.Precautions Before Operation
(1) Don’t check fuel leakage and lever or instruments at the place where there is open
flame. Never fill the fuel tank with the truck running.
(2) Check the tire inflation pressure.

2
(3)Check the devices of lighting, sound and alarm: check the lights, buzzer and horn
(button on the handle included).
(4) The forward-reverse lever should be in neutral.
(5) Check all the levers and pedals.
(6) Complete the provisions before starting.
(7) Release the parking lever.
(8) Make trying operation of the mast for lifting, lowing and Fwd/Bwd tilting and the
truck for steering and braking.
4.Operation of Forklift Truck
(1) Only trained and authorized operator shall be permitted to operate the truck.
(2) Wear all the safety guards, such as shoes, helmet, clothing and gloves while operating
the truck.
Check all the control and warning devices before starting the truck. If any damages or
defects are found, operate it after repairing.
(4) At the rated loading center, either overload or overload operation is strictly prohibited.
The center of cargo should be in line with the frame center, not out of the line. The fork
should insert completely under the cargo and make the cargo placed on it evenly. Do not
raise an object with one fork end.
(5) The starting, turning, driving, braking and stopping operation of the truck should be
done smoothly. When steering on the humid or low friction road, the truck should be
decelerated.
(6) Travel with loads as low as possible and tilted backward.
(7) Be careful when traveling on a slope. When climbing grades with a slope of more
than 10%, the truck should forward travel, and when descending so grades, backward
travel. Never turning on a slope. Avoid loading and unloading operation when

3
descending.
(8) Pay attention to pedestrian, obstacle and bumpy road when driving. Pay attention to
the clearance over forklift truck.
(9) Never allow any persons to stand on the forks or the truck to carry persons.
(10) Never permit anyone to stand or walk under upraised forks.
(11) Don’t operate truck and attachment of it at any position out of the drive seat.
(12) On the high lift forklift truck, when the lift high more than 3m, it is noted that the
goods on it should not fall down or the protection measures must be taken if necessary.
(13) Tilt the mast of the high lift forklift truck as backward as possible while the truck
working. Use minimum forward tilt angle and Min. reverse tilt when loading and
unloading.
(14) Be careful and slowly driving over a dockboard or bridge-plate.
(15) Shut down the truck and don’t stay on the truck when checking fuel level.
(16) The unloaded forklift truck with attachments should be operated as a loaded truck.
(17) Don’t handle unfixed stacked goods. Be careful to bulky goods to be handled.
(18) If leaving the truck, lower the forks on the ground and let the shift lever to neutral,
shut down the engine or cut down electric supply. If parking on a slope is unavoidable,
apply the parking brake and block the wheels.
(19) Don’t adjust the control valve and relief valve at will to prevent the damage of
hydraulic system and its components because of excessive pressure passing them.
(20) Inflate a tyre according to its stated air pressure. Never over inflate a tyre.
(21) Be familiar with and pay attention to the functions of the decals on the forklift
trucks.
5. Daily Maintenance of Forklift Trucks
(1) Inspection before startup

4
a) Hydraulic oil volume: oil level should stay in the middle of oil meter scale;
b) Check piping, joints, pumps and valves for leaks or damages;
c) Check service brake:
The free travel of brake pedal should be within the range of 40mm;
The clearance between the front floor and the pedal should be bigger than 20mm;
d) Check parking brake. The unladen truck can park on the 15% grade ramp, when
the parking lever is pulled to the bottom;
e) Check instruments, lighting, switches and wiring to see if they work normally or
not.
(2) Oil used for forklift trucks
Name
Recommended
brand
Brand and temperature of using
Level per unit (L)
1-1.8t
2-2.5t
3-3.5t
Hydraulic oil
Long pan
Sticky
grade
L-HM32
wearable
hydraulic
oil
L-HV32
low temp.
wearable
hydraulic
oil
25
34
40
Temp.
of using
(℃)
≥-5
≥-20 (cold
region)
Brake fluid
Chong qing
yi ping
4604 compound brake fluid GB
12981 HZY4
0.2
Lubricating
grease
Long pan
2# L-XDCBB2 low temperature
lubrication grease (-40℃～
+120℃)
Gear oil of
heavy-laden
truck(GL-5)
Long pan
Sticky
grade
85W/90
80W/90
3.2
3.2
8
Temp.
of using
(℃)
-15～+49
-25～+49
●Apply lubricating grease NYOGEL 782G to the conductive plate which the
connecting point of the steering wheel horn switch acts on.
(3) The table of lubrication system

5

6
Ⅱ. Main Specifications of Forklift Truck
Enternal view of forklift trucks

7
Main Specifications（1）
Model
Unit
CPD10
CPD15
CPD18
GC1Li
/GD1Li
GC1Li
/GD1Li
GC1Li /GD1Li
Rated capacity
kg
1000
1500
1750
Load center
mm
500
Lifting height
mm
3000
Free lifting height
mm
145
Mast tilt angle (fwd/bwd)
(α/β)
°
6/8
Fork size (T×W×L4)
mm
32×100×770
35×100×920
Wheelbase L1
mm
1380
Tread (front/rear) (W3/W2)
mm
910/920
Overall length (without
forks) L’
mm
2070
Overall width W1
mm
1086
Overall height
(mast/overhead guard)
(H1/H4)
mm
1985/2130
Seat height
mm
1080
Under-clearance (H5/H6)
mm
90/80(in the middle of the
truck body)
80/75(in the middle
of the truck body)
Min. turning radius r
mm
1750
fork adjustment range
(outside) Max/min W5
mm
960/200
Travelling speed
(loaded/unloaded)
km/h
15/16
Lifting speed
(loaded/unloaded)
mm/s
DC: 290/450
270/450
280/530
AC: 410/600
400/600
380/600
Descending speed
(loaded/unloaded)
mm/s
400/500
Gradeability
(loaded/unloaded)
%
20/25
19/24
17/22
Tyre (front/rear)
6.00-9-10PR/16×6-8-10PR
6.00-9/16×6-8-10PR
Traction motor power
kW
8.2 (AC)
7.5(DC)
8.6(DC)
Pump motor power
kW
10.6 (AC)
Battery
V/Ah
48/400(standard)
48/500(optional)
Service weight (with/without
battery)
kg
2700/2350
2955/2605
3105/2755
Battery weight
kg
350

8
Main Specifications（2）
Model
Unit
CPD20
CPD25
GC1Li/GD1Li/GD3Li
GC1Li/GD1Li/GD3Li
Rated capacity
kg
2000
2500
Load center
mm
500
Lifting height
mm
3000
Free lifting height
mm
145
Mast tilt angle (fwd/bwd)
(α/β)
°
6/8
Fork size (T×W×L4)
mm
40×122×920
40×122×1070
Wheelbase L1
mm
1550
Tread (front/rear) (W3/W2)
mm
960/950
Overall length (without forks)
L’
mm
2285
2335
Overall width (front/rear) W1
mm
1185
Overall height (mast/overhead
guard) (H1/H4)
mm
1995/2150
Seat height Q
mm
1100
Under-clearance
(H5/H6)
mm
110(at mast)/115(in the middle of the truck
body)
Min. turning radius r
mm
2000
2060
fork adjustment range (outside)
Max/min W5
mm
1030/244
Travelling speed
(loaded/unloaded)
km/h
14.5/15
Lifting speed (loaded/unloaded)
mm/s
DC: 280/490
260/490
AC: 350/510
330/510
Descending speed
(loaded/unloaded)
mm/s
410/490
Gradeability (loaded/unloaded)
%
22/24
20/22
Tyre (front/rear)
23×9-10-16PR/18×7-8-14PR
Traction motor
kW
11.5 (AC)
Pump motor
kW
10.5 (DC)
15 (AC)
Battery
V/Ah
48/500
48/600(optional)
Service weight(with/without
battery)
kg
3615/3215
4035/3635
Battery weight
kg
400
500(optional)

9
Main Specifications（3）
Model
Unit
CPD30
CPD35
GC1Li/GD1Li/GD3Li
GC1Li/GD1Li/GD3Li
Rated capacity
kg
3000
3500
Load center
mm
500
Lifting height
mm
3000
Free lifting height
mm
145
150
Mast tilt angle (fwd/bwd) (α/β)
deg.
6/10
Fork size (T×W×L4)
mm
45×125×1070
50×125×1070
Wheelbase L1
mm
1685
Tread (front/rear ) W3/W2
mm
1000/950
Overall length (without forks) L’
mm
2545
2550
Overall width (front/rear) W1
mm
1238
Overall height (mast/overhead guard)
(H5/H6)
mm
2075/2215
2180/2215
Seat height
mm
1165
Under-clearance (H1/H2)
mm
135（at mast ）/145（in the middle）
Min. turning radius r
mm
2240
2260
fork adjustment range (outside) Max/min
W5
mm
1060/250
Travelling speed (loaded/unloaded)
km/h
15/15.5
14.5/15
Lifting speed (loaded/unloaded)
mm/s
DC:280/460
270/440
AC:340/460
325/450
Descending speed (loaded/unloaded)
mm/s
-/500
Gradeability (loaded/unloaded)
%
17/20
15/20
Tyre ,front
28x9-15-12PR
28x9-15
Tyre, rear
18x7-8-14PR
18x7-8
Traction motor
kW
16.6 (AC)
Pump motor
kW
13 (DC)
13.5 (AC)
Battery
V/Ah
80/400（standard）
80/500, 80/600（optional）
Service weight(with/without battery)
kg
4760/4200
5330/4770

10
Main Specifications（4）
Model
Unit
CPD30
CPD35
GB3Li
GB3Li
Rated capacity
kg
3000
3500
Load center
mm
500
Lifting height
mm
3000
Free lifting height
mm
145
150
Mast tilt angle (fwd/bwd) (α/β)
deg.
6/10
Fork size (T×W×L4)
mm
45×125×1070
50×125×1070
Wheelbase L1
mm
1715
Tread (front) W3
mm
1000
Tread (rear) W2
mm
990
Overall length (without forks) L’
mm
2525
2550
Overall width W1
mm
1245
Overall height (mast/overhead guard)
(H1/H4)
mm
2075/2215
2180/2215
Seat height
mm
1165
Under-clearance (H5/H6)
mm
135（at mast）/145（in the middle）
Min. turning radius r
mm
2240
2260
Fork adjustment range (outside) Max/min
W5
mm
1060/250
Travelling speed (loaded/unloaded)
km/h
17/18
16.5/17.5
Lifting speed (loaded/unloaded)
mm/s
340/460
325/450
Descending speed (loaded/unloaded)
mm/s
-/500
Gradeability (loaded)
%
18
15
Tyre ,front
28×9-15-14PR
28x9-15
Tyre, rear
200/50-10
Traction motor
kW
16.6 (AC)
Pump motor
kW
13.5 (AC)
Battery
V/Ah
80/400（standard）
80/404、80/500、80/542、80/600（optional）
Service weight(with/without battery)
kg
4490/4030
5100/4640

11
Main Specifications（5）
Model
Unit
CPD30
CPD35
GB7Li
GB7Li
Rated capacity
kg
3000
3500
Load center
mm
500
Lifting height
mm
3000
Free lifting height
mm
145
150
Mast tilt angle (fwd/bwd) (α/β)
deg.
6/10
Fork size (T×W×L4)
mm
45×125×1070
50×125×1070
Wheelbase L1
mm
1715
Tread (front) W3
mm
1000
Tread (rear) W2
mm
990
Overall length (without forks) L’
mm
2525
2550
Overall width W1
mm
1245
Overall height (mast/overhead guard)
(H1/H4)
mm
2075/2215
2180/2215
Seat height
mm
1165
Under-clearance (H5/H6)
mm
135（at mast）/145（in the middle）
Min. turning radius r
mm
2240
2260
Fork adjustment range (outside)
Max/min W5
mm
1060/250
Travelling speed (loaded/unloaded)
km/h
17/18
16.5/17.5
Lifting speed (loaded/unloaded)
mm/s
340/460
325/450
Descending speed (loaded/unloaded)
mm/s
-/500
Gradeability (loaded)
%
18
15
Tyre ,front
28×9-15-14PR
28x9-15
Tyre, rear
200/50-10
Traction motor
kW
16.6 (AC)
Pump motor
kW
13.5 (AC)
Battery
V/Ah
80/400（standard）
80/404、80/500、80/542、80/600（optional）
Service weight(with/without battery)
kg
4490/4030
5100/4640

12
Main Specifications（6）
Model
Unit
CPD30
CPD35
GB2Li
GB2Li
Rated capacity
kg
3000
3500
Load center
mm
500
Lifting height
mm
3000
Free lifting height
mm
145
150
Mast tilt angle (fwd/bwd) (α/β)
deg.
6/10
Fork size (T×W×L4)
mm
45×125×1070
50×125×1070
Wheelbase L1
mm
1715
Tread (front) W3
mm
1000
Tread (rear) W2
990
990
Overall length (without forks) L’
mm
2525
2550
Overall width W1
mm
1245
Overall height (mast/overhead guard)
(H1/H4)
mm
2075/2215
2180/2215
Seat height
mm
1165
Under-clearance (H5/H6)
mm
135（at mast）/145（in the middle）
Min. turning radius r
mm
2240
2260
Fork adjustment range (outside)
Max/min W5
mm
1060/250
Travelling speed (loaded/unloaded)
km/h
17/18
16.5/17.5
Lifting speed (loaded/unloaded)
mm/s
340/460
325/450
Descending speed (loaded/unloaded)
mm/s
-/500
Gradeability (loaded)
%
18
15
Tyre ,front
28×9-15-14PR
28x9-15
Tyre, rear
200/50-10
Traction motor
kW
16.6 (AC)
Pump motor
kW
13.5 (AC)
Battery
V/Ah
80/400（standard）
80/404、80/500、80/542、80/600（optional）
Service weight(with/without battery)
kg
4490/4030
5100/4640

13
Main dismountable parts size and weight
Counterweight
Overhead guard
Mast （lifting height
3000mm）
Max. outline
dimension
Weig
ht
Max. outline
dimension
Weig
ht
Max. outline
dimension
Weig
ht
Model
mm
Kg
mm
Kg
mm
Kg
CPD10-GC1Li /GD1Li
300×825×10
70
500
1050×1414×1
551
72
1010×480×1 9
25
450
CPD15-GC1Li /GD1Li
300×825×10
70
720
1050×1414×1
551
72
1010×480×1 9
25
450
CPD18-GC1Li /GD1Li
300×825×10
70
770
1050×1414×1
551
72
1010×480×1 9
25
450
CPD20-GC1Li /GD1Li
370×890×11
50
790
1100×1457×1 5
15
86
1102×506×1 9
30
745
CPD25-GC1Li /GD1Li
420×920×11
50
1160
1100×1457×1 5
15
86
1102×506×1 9
30
745
CPD30-GC1Li
/GD1Li/GB3Li/GB7Li/G
B2Li
405×8 95×1 2
25
1330
1140×1578×15
73
77
1164×459×19
57
785
CPD35-GC1Li
/GD1Li/GB3Li/GB7Li/G
B2Li
465×8 95×1 2
25
1490
1140×1578×15
73
77
1164×464×19
57
815

14
Ⅲ. Construction, Principle,Adjustment and Maintenance of Forklift
Trucks
1. Transmission System
1.1 General description
The transmission system consists of differential assembly and gearbox & axle
assembly. With direct connection of the drive gear and the drive motor, the travel speed of
the truck can be changed with the speed of the motor, and the travel direction can be
changed with the rotation direction of the motor.
1.2 Differential assembly
The differential is respectively installed on the main housing of the reducer casing
and spindle head assembly of the axle housing through bearings on both ends. The
differential housing of 1-2.5t truck is of integral type. The differential of 3-3.5t truck is of
right and left split type. The differentials include two half-shaft gears and two planet
gears. (See Fig. 1-1)
Fig. 1-1 Differential assembly

15
1. Differential house 2. Planetary gear 3. Half axle gear 4. One-line axle
5. Half axle gear adjusting gasket 6. Duplex stopping locking plate 7. Bearing
8. Bolt 9. Pin 10. Gear ring
Figure 1-2 differential assembly (3-3.5t)
1.3 Gearbox & axle assembly
The gearbox & axle assembly mainly consists of the housing, differential, half shaft,
wheel hubs, brake and the wheels. It is installed in the front of the frame.
The housing of 1-2.5t truck is a fission cast. The housing of 3-3.5t truck is of wholly
casted structure. The tyre with the rim is fixed to the hub with bolts and nuts. The power
is transmitted to the half-shafts through the differential and drives the front wheels
through the hubs. Each hub is fixed on the housing with two tapered roll bearings, so that
the half-shafts bear only the torque transmitted to the hubs. In the inside of the hub are oil
seals to prevent water and dust from entering or oil leakage. (See Fig. 1-2)
The tyre, rim and the pressure of the front wheel are followed. (See Table 1-1)
Table 1-1

16
Truck model
1t,1.5t,
1.8t
2t,2.5t
3t
3.5t
Tyre size
6.0-9-10PR
6.0-9
23×9-10-16PR
28×9-15-14PR
28×9-15
Rim size
4.00E
6.50F-10
7.00-15
Tyre pressure
860kPa
Solid tyre
1030kPa
830kPa
Solid tyre
Fig. 1-3 Gearbox & axle assembly
(1) Differential assembly (2) Main housing of the reducer casing (3) Spindle head
assembly of the axle housing Ⅰ(4) Connecting plate (5) Brake assembly (R) (6)
Brake drum hub assembly (7) Half-shaft Ⅰ(8) Oil seal AE2483E0 (9) Bolt
(10) Washer 20 (11) O-ring seal 90×5.3 (12) Nut M30×1.5 (13) Washer 30
(14) Bearing 32208 (15) Dual gear Ⅱ(16) Bearing 6010/C3 (17) Washer 12
(18) Bolt M12×40 (19) Oil seal AE2791A0 (20) Pinion (21) Bearing 6208
(22) Dual gearⅠ(23) Bearing 6206 (24) BoltM20×1.5×55 (25) Bearing 32915
(26) Half-shaft Ⅱ(27) Spindle head assembly of the axle housing Ⅱ(28) Washer
75 (29) Nut M75×2 (30) Cone nut (31) Bolt M18×1.5 (32) Brake assembly (L)
Note: the bolts (9)(18)(24) should be applied with GY-340 adhesive; the o-ring
shown in (11) used on 1-1.8t truck is 75×5.3 and other trucks are 75×5.3.

17
Fig. 1-4 Gearbox & axle assembly(1-1.8t,2t,2.5t)
Figure 1-5 reducer and differential (3-3.5t)