Heli G3 Series 2-3.5t Internal Combustion Forklift Operation and Service Manual

Description

Heli G3 Series 2-3.5t Internal Combustion Forklift Operation and Service Manual

This is the complete Heli G3 Series 2-3.5t Internal Combustion Forklift Operation and Service Manual, covering the diesel, LPG and dual-fuel counterbalanced trucks in the 2,000 kg to 3,500 kg capacity class. It combines the driver’s operating instructions with the workshop-level service and maintenance guidance, so a single document serves both the operator on the floor and the technician in the service bay.

File Details

• Manual type: Operation and Service Manual (Operation and Maintenance Manual)
• Brand: Heli (Anhui Heli Co., Ltd.)
• Series: G3 Series, 2-3.5t internal combustion counterbalanced forklift truck
• Language: English
• Page count: 200 pages
• File format: PDF
• Manufacturer address: No.668, Fangxing Road, Hefei, Anhui Province, P.R.China
• Manufacture licence shown on nameplate example: TS2510341-2024

Models Covered

The manual is written for the following Heli G3 Series configurations:

• CPQYD20-35-KU1HG3 — Kubota WG2503 engine, Euro V / CARB IV / EPA (Tier 2)
• CPYD20-35-KU1HG3 — Kubota WG2503 engine, Euro V / CARB IV / EPA (Tier 2)
• CPCD20-35-Q17HG3 — Quanchai V32-50C42 engine, China IV
• CPCD20-35-CU6HG3 — Cummins F2.8CS449 engine, China IV
• CPCD20-35-M3HG3 — Mitsubishi SPC-S4S-455 engine, Euro III A / China III
• CPCD20-30-WS1HG3 — GK-C240NKFC01 engine, Euro III A / China III
• CPQYD20-35-RC1HG3 — GCT K25 engine
• CPYD20-35-RC1HG3 — GCT K25 engine
• CPQD20-35-RC1HG3 — GCT K25 engine
• CPCD20-30-W8HG3 — GK-4JG2NKFC01 engine, China II
• CPCD35-W4HG3 — GK-4JG2NKFC01 engine, China II

Chapters Covered

• Scope of application and description of the Manual
• Safety signals, terms and indicators
• Applicable truck models and list of applicable models
• Forklift truck overview — purpose, direction conventions, operation site and working environment
• Measurement units, operation qualification
• Precautions for use of a new forklift truck — running-in, first-month maintenance
• Warranty and maintenance — regular replacement of parts, use of original Heli parts and oil
• Basic information of forklift truck — information form, nameplate, VIN and position, operating schedule, licence plate mounting
• Safety Precautions — labels and signs on truck, main safety labels, other labels, load curve label
• Fire prevention — engine fire, fuel or oil fire, attached flammables, wire failure, oil pipe failure, cleaning after operation, in case of fire
• Basic precautions — compliance with rules, faulty truck handling, work clothes and safety equipment, fire extinguisher and first-aid kit, safety devices, practice, mounting and dismounting, cab cleanliness, flushing, scalding, modification, overhead guard and load backrest, work area safeguarding, engine exhaust, window washer, no welding
• Before starting operation — startup inspection, inspection and adjustment before starting the engine
• Forklift truck travelling — preparation, precautions, stopping and precautions for stopping
• Load handling
• Precautions for inspection and maintenance — mandatory starting inspection, warning signs, working area, before maintenance, staff, tools, working under the working device, mast stuck/fall, boiling coolant, high-pressure oil, rotating fans and belts, electrical system repair, compressed air, battery handling, sparks, battery removal and installation, tire handling, oil cylinder maintenance, waste disposal, after repair, regular inspection of safety critical parts
• Lifting and transportation of forklift truck
• Structure and stability of forklift truck — longitudinal stability, centre of gravity of load, composite centre of gravity, actual bearing capacity, wind load
• Towing
• Introduction to truck safety device — OPS systems, driver authority information collector, video monitoring, warning lamps, fire extinguishers, master power switches
• Operation Instructions and Requirements — general view, instruments and control devices, component descriptions, truck instrument, control devices, accessory removal and installation
• Operation — inspection before startup, getting on/off and adjustment, starting, shifting and travelling, starting and stopping on slopes, inching travelling, steering, snow and icy roads, deceleration/braking/parking, load handling, solid tire selection, cab/windshield, inspection after operation
• Transportation and storage of forklift truck — transportation, mast transportation, lifting, storage
• Maintenance Instructions and Requirements — relevant inspection and maintenance, startup inspection, post-operation inspection and reporting, simple maintenance
• Lubricating oil, grease and coolant; lubrication form and list of oil products
• Fuel and liquefied petroleum gas (LPG)
• Cleaning of air filter element; drainage and exhaust of fuel filter (CPCD model)
• Tire replacement; replacement of fuse; replacement of bulb; parking brake handle adjustment
• Steps to deal with faulty battery
• Operation in cold weather; engine overheating treatment
• Operation of forklift truck in special environment or in a forced manner
• Measures for fork lowering failure; cleaning forklift truck; loading and unloading of forklift truck
• Forklift truck maintenance data; regular replacement of safety critical parts; inspection and maintenance interval table
• Main Parameters and Design Drawings — general drawing, main technical parameters, tire parameters, engine parameters, mast parameters, main stressed structural members, brake schematic, hydraulic schematic, electrical schematic, load curve, optional configuration list
• Operation and Maintenance of Diesel Particulate Filter (DPF) — description, regenerate DPF (active, inhibit, parked), non-regenerate DPF

Working through the Heli G3 Series 2-3.5t internal combustion forklift operation and service manual end to end, a technician gets the full picture of the machine: how the truck is laid out and how it is meant to be used, what the nameplates and VIN tell you, how the safety and warning labels are arranged around the mast, overhead guard and battery, and which checks belong to the daily startup routine versus the longer interval service. The maintenance chapters then walk through the lubrication points, oil and coolant specifications, filter servicing, brake and parking brake adjustment, fuse and bulb replacement, battery jump-starting, cold-weather preparation, overheating response and DPF regeneration or cleaning, with the actual torque figures, pressures, clearances and interval tables presented in the maintenance data and design drawing chapters. The inclusion of the hydraulic and electrical schematics in the design drawing section is what turns this from a general operating booklet into a document a workshop can actually diagnose from.

Why This Manual Matters

The Heli G3 Series covers a wide engine spread — Kubota WG2503 and V2403, Quanchai V32-50C42, Cummins F2.8CS449, Mitsubishi SPC-S4S-455, GCT K25, GK-C240NKFC01 and GK-4JG2NKFC01 — across diesel, LPG and dual-fuel trucks. That range means the service details are not interchangeable between machines. Having the correct manual for the specific truck in front of you is the difference between a repair that holds and one that causes a repeat failure, a brake that fades on a ramp, or an aftertreatment system that goes into torque limit because it was regenerated at the wrong time or in the wrong place.

The safety chapter alone justifies keeping the document on hand: the label plans, load curve explanation, stability and centre-of-gravity discussion, and the prohibited-use examples are all things an operator and a supervisor need to be able to point to during training and refresher sessions. The fire-prevention and inspection sections give a structured daily walk-around that catches fuel, oil, coolant and battery electrolyte leaks before they become a fire or a breakdown.

What You Can Do With It

• Run the daily and pre-shift startup inspection exactly as Heli specifies, item by item
• Understand the nameplate, VIN location, load curve and lifting system information for the exact truck in front of you
• Carry out simple maintenance — filter cleaning, fuel filter drain and exhaust, fuse and bulb replacement, tire replacement, parking brake adjustment
• Interpret the dashboard warning lamps, seat switch warnings and controller DTC display
• Work through the inspection and maintenance interval table for monthly, quarterly, semi-annual and annual service
• Follow the DPF active, inhibit and parked regeneration procedures, and the non-regenerate DPF cleaning steps
• Read the hydraulic and electrical schematics when tracing a fault
• Lift, transport, store and unload the forklift truck safely
• Train new operators on the safety labels, OPS systems, prohibited uses and load handling rules
• Reference actual torque values, tire pressures, pedal clearances and system capacities during repair

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Instant PDF Delivery

The Heli G3 Series 2-3.5t internal combustion forklift operation and service manual is delivered as a PDF download immediately after purchase. There is no shipping, no waiting for a printed copy and no regional restriction — the file opens on a workshop PC, a laptop, a tablet or a phone, and individual pages or whole chapters can be printed for the bench when a paper copy is more practical. Keep it on the service laptop for fault tracing, print the maintenance interval table for the workshop wall, and hand the operator the safety and load handling sections during training. One purchase, and the same document is available to everyone who needs it, whenever they need it.