PDF Operation & Service Manual Heli G2 Series 1.5-2T Forklift - 670 KB
This is the complete Operation and Service Manual for the Heli G2 Series 1.5-2T Three-Wheel Battery Counterbalanced Forklift Trucks.
The manual provides operators with instructions for safe and efficient daily use.
It also includes service information for routine maintenance and minor repairs, helping to keep your electric forklift in optimal working condition.
This is an essential guide for maximizing the performance and lifespan of your Heli forklift.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 3 ---
Ⅲ. Construction, Principle, Adjustment and Maintenance of Forklift Trucks
1. Transmission system
1.1 General description
The transmission system of the three wheeled forklift truck includes transmission
system we call traditionally and brake system. Front wheel dual driving motor structure
makes the right and left wheel of three wheeled truck has drive axle, redactor, brake and
driving motor independently to improve working efficiency. Transmission unit is
assembled inside of drive axle housing while brake is assembled on motor shaft. The
structure is compact.
Truck travelling speed is increased with the increase of motor speed; travelling
direction is changed with motor rotation direction; The sensor installed on rear wheel
sends information to drive motor controller on right and left front wheel, after receiving
different information, right and left front wheel give out different speed and thus steering
of the truck is realized. The steering of the three wheeled truck is realized through electric
differential. The system has no bevel gear which thus not only improves working
efficiency but also reduce bevel gear noise.
1.1.1 Front wheel assembly
Front wheel is made up of solid tyre and rim. Refer to the following for front wheel
and rim model:
Model
CPD15SQ CPD16SQ CPD18SQ CPD20SQ
Tyre parameters
Super 18×7-8 18×7-8 200/50-10 200/50-10
Model elasticity
Rim 4.33R 4.33R 6.50F 6.50F
1.2 Disassembling of transmission system
Disassemble the front wheel assembly and travelling motor first before disassemble
transmission box. Then parts inside of the transmission box can be repaired or
10
--- Page 4 ---
Figure 3-2 steering axle
1. Rack 2. Bearing axle 3. Steering support 4. Steering cylinder
5. Slewing bearing 6. Steering hub 7. Steering axle 8. Seal ring
9. Tapper roller bearing 10. Tapper roller bearing
3.5 Adjustment and Maintenance
3.5.1 Rear wheel bearig pre-load adjustment
(1) As shown in Fig. 3-3, fill up the chamber formed by wheel hubs, wheel hub bearings
and wheel hub covers with lubricating grease. Coat the lips of the oil seals with
lubricating grease.
(2) Press the hub bearing into the hub and fit the hub on the knuckle shaft.
(3) Fit a flat washer and tighten a castle nut to a torque of 206-235Nm (21-24kgm) and
loosen it, and then tighten it again to a torque of 9.8Nm (1kgm).
21
--- Page 5 ---
；
Figure 4-8 CPD16SQ-GB1 control device assembly
32
--- Page 6 ---
timely, undercharge, excessive discharge or unused for a long time without additional
charging will vulcanize polar plate of battery and result in performance degradation and
use difficulty when serious.
(9) In the course of use, equalizing charge should be made to the battery once a month so
that all monomers of battery can reach well-balanced and good state when in use.
4.5.4 Care and storage
(1) The battery should be stored in a warehouse which is dry, well ventilated and away
from direct shinning. The temperature inside should stay between 5-40℃。
(2) Keep the battery from the heat source at least at a distance of 2m.
(3) The battery should not lie upside down or on the side. It should not bear any
mechanical shock or any heavy load.
(4) Keep off any liquid and harmful foreign matter. Be care with the falling of the any
metal impurity.
(5) Do not store the battery with electrolyte in. If it is necessary, charge the battery fully.
Adjust the lever and density of the electrolyte well. Charge the battery once a month
during its storage.
Notice:
(1) During battery charging, the charge should be temporally suspended in the
place where the temperature of electrolyte exceeds 40ºC.
(2) In battery charging, the service life of battery will be affected if the
temperature of electrolyte is more than 50ºC.
(3) Do not charge the battery at low temperature (e.g. cold outdoor), this would
affect the service life of battery.
Notice:
(1) The rated voltage of traction battery is not the safe voltage and there is
43
--- Page 7 ---
MAXIMUM CURRENT=100% 86℃
Now, the max. current of controller decreases with the
increase of the max. current temperature. When the
temperature is 105℃, the current of controller decreases
to zero.
The fault appears if chopper is in the cold state:
(1) Temperature calibration parameter of logic card is
incorrect, check parameters.
(2) The internal temperature sensor of controller has
trouble and change the controller.
If temperature digital switch of motor is turned on or
analog signal exceeds the cutoff value, the trouble is
produced. When the motor temperature reaches 120℃, the
controller gives alarm, the vehicle can move at this time.
MOTOR High motor
65 But the max. current and performance are cut down.
TEMPERAT. temperature
When the motor temperature reaches 125℃, motor stops
working. Now try to lower the temperature of the motor.
If the fault still exists when motor is cooled, check the
circuit and change the controller if he circuit is OK.
If parameter of “BATTERY CHECK” for battery test is
not set as 0 and when charging capacity of battery is lower
than 15% and there is no grid on instrument, fault alarm is
BATTERY Low capacity
66 given and the lifting function is locked, now charge it
LOW of battery
timely. In case the battery has electricity, check if the
value of parameter “ADJUST BATTERY” of controller is
consistent with battery voltage.
When electric lock is close, the microprocessor will detect
if driver of main contactor is short-circuited and alarm
DRIVER Short circuit
74 will be given if yes. Check if there is short circuit on the
SHORTED of driver
positive pair A 16 of main contactor coil or negative pole.
Change the controller if everything is OK.
Fault of The coil of main contactor can not be normally driven and
CONTACTOR
75 contactor change the controller if the coil of main contactor has no
DRIVER
driver fault.
Detection time : Standby state
The alarm indicates the voltage of accelerator is 1V larger
than the min. value set in the signal scope （PROGRAM
VACC）of accelerator.
Accelerator Possible causes：
78 VACC NOT OK (1) The upper and lower voltage limit values of
error
accelerator have not been collected and do it again when
entering into PROGRAM VACC.
(2) Accelerator error: Accelerator pedal possibly fails to
return or internal error of accelerator.
(3) The failure of controller
Possible causes for incorrect starting sequence:
(1) Direction switch is closed before starting.
Incorrect
INCORRECT (2)Incorrect operation sequence.
79 starting
START (3)Incorrect wire joining.
sequence
(4)If the trouble still can not be eliminated, change the
controller.
54
--- Page 8 ---
minimum value. If not, an alarm is signalled and the machine is shut down.
Possible causes:
● The current sensor is faulty. Replace the power unit.
e) < WATCH-DOG >
The test is made in both running and standby. It is a self-diagnosis test within the
logic. If an alarm should occur, replace the logic.
f) < COIL SHORTED >
Cause:
This alarm occurs when there is a short circuit of LC coil connected to driver output
of the HP CAN. After the overload condition has been removed, the alarm exits
automatically by releasing and then enabling an hydraulic demand.
Troubleshooting:
● The typical root cause for this error code to be displayed is in the harness or in
the load coil. So the very first check to carry out concerns connections between controller
outputs and loads.
● In case no failures/problems have been found
g) < DRIVER SHORTED >
Cause:
The driver of the main contactor coil is shorted.
Troubleshooting:
● Check if there is a short or a low impedance pull-down between NMC and
–BATT.
● The driver circuit is damaged in the controller, which has to be replaced.
h) < VMN LOW >
Cause:
65
--- Page 9 ---
(5) Setting pressure of the control valve (See Fig. 5-15)
The pressure of the safety valve shall not be adjusted by non-professional personnel.
The adjustment shall follow following procedures:
a) Screw off the plug of the measuring hole on the inlet of the control valve. Install
an oil pressure gauge capable of measuring 25MPa.
b) Operate tilting lever and measure the pressure at the end of the cylinder stroke.
c) If the oil pressure is different with the specified value, loosen the locking nut of
the relief valve and turn the adjusting screw left and right until the pressure reaching the
specified value. Turn left when the pressure is high and turn right when the pressure is
low.
d) Tighten the nut after adjusting.
Fig. 5-15
5.1.3 Lift cylinder
The lift cylinder is of single-acting piston type. It consists of cylinder body, piston,
piston rod, cylinder cap, cut-off valve and oil seals. The cylinder head is equipped with
bushing and oil seal and the bushing supports the piston rod and the oil seal keeps dust
off. (See Fig. 5-16)
76
--- Page 10 ---
k) Tighten up the connecting bolts
with a specified torque of 9 to 10kg.m
after all.
Fig. 5-38
l) Take down the pump from the
clamping. Apply lubricating grease on the
outside circle and lip of the oil seal, install
it on the front cover with mould.
Fig. 5-39
m) Install the snap ring with callipers, fixed
the oil seal.
Fig. 5-40
(4) Test run
The test run is a running-in period for the oil pump and a inspection whethter the
running of the pump is normal. Test the oil pump on the test station. And also the test can
be done on the forklift truck according to the following procedures:
(If the oil pump needs maintenance because of serious wear or its being stuck caused
by the hydraulic oil, change the hydraulic oil or filter before carrying out the test run on
the forklift truck.)
a) Install the pump onto the truck and the pressure gauge onto the pressure test end
of the control valve.
b) Loose the adjusting screw of the relief valve and make the pump running at a
speed of 500～1000rpm for 10 minutes. Make sure the oil pressure be lower than
10kg/cm2.
87