Heli G Series 1-3.5t Battery Forklift Operation and Service Manual – CPD10 to CPD35 Electric Forklift Repair Guide

Description

Heli G Series 1-3.5t Battery Forklift Operation and Service Manual

This operation and service manual covers the Heli G Series battery counterbalanced forklift trucks in the 1 to 3.5 tonne capacity range, including the CPD10, CPD15, CPD18, CPD20, CPD25, CPD30 and CPD35 models in both GC and GD variants. The document combines operating instructions with detailed service and repair information for the transmission, brake, steering, electric, hydraulic and lifting systems. Whether you are running a CPD18-GC in a warehouse or servicing a CPD35-GD in a port application, this manual provides the specifications, adjustment values and maintenance procedures needed to keep the truck working correctly.

File Details

• Manual type: Operation and Service Manual
• Brand: Heli
• Series: G Series
• Models covered: CPD10, CPD15, CPD18, CPD20, CPD25, CPD30, CPD35 (GC and GD variants)
• Capacity range: 1 to 3.5 tonnes
• Language: English
• Page count: 152 pages
• File format: PDF

Chapters Covered

• Safety Rules for Operation and Daily Maintenance of Forklift Truck
  • Delivery of Forklift Truck
  • Storage of Forklift Truck
  • Precautions Before Operation
  • Operation of Forklift Truck
  • Daily Maintenance of Forklift Trucks
• Main Specifications of Forklift Truck
  • CPD10, CPD15, CPD18 specifications
  • CPD20, CPD25 specifications
  • CPD30, CPD35 specifications
  • Size and weight of main disassemblable parts
• Construction, Principle, Adjustment and Maintenance of Forklift Truck
  • Transmission System
  • Brake System
  • Steering System
  • Electric System
  • Hydraulic System
  • Lifting System

The Heli G Series 1-3.5t Battery Forklift Operation and Service Manual is organised into three main parts. The first part deals with safety, covering delivery, storage, pre-operation checks and daily maintenance requirements. The second part lists the main specifications for every model in the range, including rated capacity, load centre, lifting height, mast tilt angle, fork dimensions, wheelbase, tread, overall dimensions, travel speeds, lifting speeds, gradeability, tyre sizes, motor ratings, battery specifications and service weights. The third and largest part is a detailed workshop section that works through each major assembly in turn, explaining how it is built, how it works and how to adjust, maintain, disassemble and reassemble it. This structure makes the manual useful both as a reference for daily operation and as a guide for planned maintenance and repair work.

Transmission and Brake Systems

The transmission system chapter describes the differential assembly and the gearbox and axle assembly. It explains how the differential is mounted, how the gearbox and axle are constructed, and how the wheel hub is assembled. Detailed diagrams show the differential for both the 1 to 2.5 tonne and the 3 to 3.5 tonne trucks, along with torque values for the various fasteners. The brake system chapter covers the front two-wheel braking setup in full. It walks through the brake pedal, master cylinder and wheel brake, including the parking brake and the clearance self-adjusting mechanism. There are step-by-step disassembly and reassembly procedures for the wheel brake, inspection criteria for the operating cylinder and friction pieces, and a troubleshooting table for problems such as poor braking, noisy brakes, uneven braking and spongy brake pedal feel. Brake pedal adjustment and brake switch adjustment are also covered.

Steering, Electric and Hydraulic Systems

The steering system chapter explains the fully hydraulic power steering used on these trucks. It covers the steering control mechanism, the steering gear, the steering axle, the steering knuckle and the steering cylinder, with adjustment and maintenance procedures including rear wheel bearing pre-load adjustment. The electric system chapter is the largest section of the manual. It includes full circuit diagrams for every model variant, covering the CPD10 to CPD18 in GC2, GD1, GD2 and GD3 configurations, the CPD20 to CPD25 in GC1, GC2, GD1, GD2 and GD3 configurations, and the CPD30 to CPD35 in GC1, GD1, GD2 and GD3 configurations. It describes the CURTIS and ZAPI control systems, the instruments, the controllers, the motors and the battery. There are fault code tables for the CURTIS 1236/1238 series, the CURTIS 1253 series, the ZAPI AC2/ACE2 controller, the ZAPI HP-CAN controller and the INMOTION controller, along with battery maintenance and troubleshooting information. The hydraulic system chapter covers the oil pump, control valve, lift cylinder, cut-off valve, flow regulator valve, tilt cylinder and oil tank. It includes the hydraulic system principle diagram and the hydraulic oil circuit diagram, plus maintenance, fault analysis and remedies. The lifting system chapter describes the basic two-stage, two-stage free lift and three-stage free lift configurations, covering the inner, middle and outer masts, the fork bracket, roller layouts and the adjustment procedures for lift cylinders, fork bracket height and roller replacement.

What This Manual Enables You to Do

With this Heli G Series battery forklift service manual, you can carry out routine maintenance to the manufacturer’s schedules, diagnose electrical faults using the controller fault code tables, adjust the brakes and parking brake correctly, service the hydraulic system including relief valve pressure setting, replace worn rollers and lift chains, and rebuild the differential and gearbox assemblies. The specification tables let you confirm capacities, pressures, torques and clearances before starting work, so you are not relying on guesswork. The safety section is equally important, covering the correct procedures for operating the truck, travelling on slopes, handling loads and parking safely, which helps reduce the risk of accidents in the workplace.

Who This Manual Is For

This manual is written for forklift operators, maintenance technicians, fleet managers and workshop staff who work with Heli G Series battery counterbalanced trucks. It is also useful for anyone responsible for commissioning, inspecting or repairing these machines, as it provides the baseline specifications and service procedures in one document. The operation and service manual is intended to help operators use the trucks correctly and help service personnel maintain them in optimised working condition for a long period.

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The Heli G Series 1-3.5t Battery Forklift Operation and Service Manual gives you the full picture of these electric counterbalanced trucks, from daily checks and safe operating practice through to major assembly overhaul. Correct procedures and accurate specifications matter because they protect the truck, the load and the operator. A brake adjusted to the wrong clearance or a hydraulic relief valve set to the wrong pressure can lead to poor performance or unsafe operation, while the electrical fault code tables can save hours of diagnostic time. This manual is delivered as an instant PDF download, so there is no shipping and no waiting. You can open it on any device, print the pages you need for the workshop and keep the complete document for future reference. Whether you are servicing a single CPD18 or managing a fleet of CPD10 to CPD35 trucks, this manual is a practical reference you can rely on.