Skip to content
A Reliable, Sustainable, and High-Performance Solution for Modern Operations
Since late 2023, Fork Truck Direct has been proud to offer the HELI G2 Series Lithium Counterbalance Forklift Truck to our customers across the South East of England. We introduced this model to address a growing demand in the materials handling market for sustainable, low-emission, and cost-efficient forklift solutions — a shift driven by economic, environmental, and regulatory pressures. Businesses are increasingly looking to reduce their carbon footprint, cut reliance on non-renewable fuels, and invest in equipment that supports long-term operational sustainability.
However, as demand surged, the market became saturated with low-cost lithium forklift trucks — many of which are imported from China. This flood of cheap alternatives has led to a noticeable decline in product quality, brand reputation, and customer confidence in lithium forklift technology. Yet amidst this noise, the HELI G2 Lithium Forklift Truck stands out. Without relying on flashy marketing gimmicks or unsustainably low prices, it delivers what really matters: reliability, durability, and performance that you can trust.
In this article, we’ll explore how the HELI G2 Lithium Forklift has earned its reputation as a reliable and efficient choice for businesses of all sizes — from operations managers seeking to make a lasting impact, to managing directors focused on ROI, and procurement teams managing tight budgets. We’ll highlight the key features and benefits that have made this truck a trusted solution for companies like Cargo Secure Ltd, Sea Transport, Global Coastal Building Services, The Logistics Terminal Tilbury, Aspalls Suffolk Cyder, DH Industries, Cargo Partner Ltd, Denholm Good Logistics, Jaylow Supplies Ltd, Arnold Laver (NTG), and many more.
We’ll tackle crucial topics such as total cost of ownership, ESG implications, modularity in design and use.
Lower Total Cost of Ownership: A Smart Investment
For the HELI G2 Lithium Counterbalance Forklift Truck, the Total Cost of Ownership (TCO) debate comprises of 3 core tenants which highlight the financial edge the product can bring to all businesses looking replace or implement forklift trucks for their operations. These tenants are, procurement, maintenance, and fuel.
Procurement
If you’re tasked with procuring a forklift truck for your business, you already know how challenging this decision can be. The market feels like a minefield — on one end are the premium, established, and costly brands such as Linde, Toyota, and Jungheinrich, and on the other are the budget-friendly but less reliable, lesser-known names like Greenpower and EP.
Choosing the right forklift is more than comparing prices — you need a brand that supports your operations reliably, won’t drain your budget, and comes with a proven track record. And while sales reps bombard you with quotes, emails, and calls around the clock, it’s crucial to cut through the noise and focus on what actually matters.
That’s where the HELI G2 Lithium Forklift Truck stands out as the perfect middle ground. HELI combines the efficiency, global support network, advanced technology, and robust engineering you’d expect from a premium brand — but without the inflated price tag.
With over 65 years of manufacturing expertise, HELI ranks as the 7th largest forklift manufacturer globally. The G2 Lithium series proves their reputation in the UK market, offering a dependable, cost-effective alternative that you can trust to keep your operation moving.
The HELI G2 Lithium Forklift typically costs 10–20% less than premium competitors like Linde or Toyota, while being only 5–10% more than budget brands. This makes it an ideal choice for businesses that operate their forklifts between 500 and 2,000 hours per year, and who need a dependable, fully supported machine without overspending.
For companies that can’t justify premium-brand pricing but also can’t afford to gamble on unproven, budget models, the HELI G2 offers the best of both worlds: affordable reliability, supported across the UK, Europe, and beyond.
Maintenance
It’s well understood in the forklift industry that electric forklifts are generally cheaper to maintain than their diesel or LPG counterparts. Without an internal combustion engine — and all its associated parts like fuel filters, engine oil, spark plugs, and exhaust components — maintenance costs are already significantly reduced.
However, at Fork Truck Direct, we’ve been genuinely impressed by just how little maintenance the HELI G2 Lithium Forklift Truck requires, thanks to its clever, dependable design.
Unlike some newer forklifts that rely heavily on complex and failure-prone electronics, the HELI G2 combines proven mechanical components with advanced lithium technology for a best-of-both-worlds approach. By forgoing unnecessary complexity — such as sensitive electronic braking systems — and instead opting for rugged, reliable systems like hydraulic levers, ratchet hand brakes, and drum brakes, the HELI G2 achieves exceptional dependability.
These mechanical elements work seamlessly alongside its advanced electronic components, including the CATL lithium battery, ZAPI control logic board, a powerful 16.6 kW drive motor, and 25.5 kW lift motor, to deliver superior performance without the maintenance headaches.
While most electric forklifts already offer maintenance costs about 20% lower than diesel or LPG models, they often still incorporate problematic and costly components such as lead-acid batteries and auto-fill water systems, which are prone to failure. The HELI G2 eliminates these weak points altogether, delivering maintenance savings of up to 40% compared to diesel or LPG trucks.
But numbers only tell part of the story. From the field data we’ve collected across our customers’ fleets, the HELI G2 outperforms expectations, maintaining uptime and reliability even where other brands fall short. This resilience is the result of thoughtful, preventative design features such as:
- Securing clamps on hydraulic hoses to prevent leaks
- Intelligent battery management systems that extend battery life
- A sturdier, well-constructed chassis and axles built to withstand heavy use
- Larger drive tyres for better durability and traction
- Air-suspension seats to reduce operator fatigue and wear
Below, we’ve put together a cost comparison analysis of four forklifts — all the same age, operating in similar environments and hours — to demonstrate just how much more cost-effective the HELI G2 Lithium Forklift really is over time.
| Forklift Type | Yearly Cost |
| 2023 Diesel 3.0T Counterbalance | £1,631.27 |
| 2023 Gas 3.0T Counterbalance | £2,455.60 |
| 2023 Lead-Acid Electric 3.0T Counterbalance | £1,299.22 |
| 2023 HELI G2 Lithium Electric 3.0T Counterbalance | £840.80 |
Fuel
One of the most impactful ways the HELI G2 Lithium Forklift Truck delivers value is by dramatically lowering running costs through fuel savings — while eliminating harmful emissions entirely.
Traditionally, businesses operating in challenging environments — such as outdoor yards, cold stores, or heavy-duty applications — have relied on diesel or LPG forklifts. Electric forklifts, while cleaner and cheaper to run, have often struggled to match the durability and performance needed for harsher conditions.
The HELI G2 Lithium Forklift breaks that barrier. By using HELI’s robust diesel chassis, but replacing the engine and its components with a fully enclosed, water-resistant, steel-cased lithium battery, it delivers the best of both worlds: the resilience and capability of a diesel machine, combined with the efficiency and environmental benefits of lithium power.
This design allows the HELI G2 to operate confidently in environments and applications where many electric trucks cannot, making it a true replacement for gas or diesel forklifts — without compromise.
By switching from diesel or LPG to lithium, customers can enjoy:
- Up to 80% lower energy costs, as electricity is much cheaper per kWh than fuel
- No need to store, handle, or manage volatile fuels on site
- Elimination of tailpipe emissions, supporting ESG and sustainability goals
- Consistent power delivery, even under heavy loads or in cold conditions
- Opportunity charging during breaks, ensuring high uptime without needing spare batteries
Our data, alongside industry-standard fuel cost comparisons, shows just how much switching to lithium forklifts like the HELI G2 can save — whether you operate a single machine or an entire fleet. These savings compound over time providing a highly cost-effective long-term solution.
Below, you’ll find a clear breakdown of fuel cost savings based on real-world usage data. And if you’d like to calculate the potential savings for your own operation, you can easily use our Fuel Cost Comparison Calculator to see the numbers for yourself.
| Diesel Forklift | Gas Forklift | HELI G2 Lithium | |
| Cost for Fuel | £1.20 Per Litre | £34.00 Per 18kg Bottle | £0.38 Per KwH |
| Hours Per Shift | 5 | 5 | 5 |
| Shifts Per Week | 5 | 5 | 5 |
| Cost Per Hour | £4.00 | £6.00 | £2.00 |
| Cost Per Shift | £20.00 | £30.00 | £10.00 |
| Cost Per Week | £100.00 | £150.00 | £50.00 |
| Cost Per Month | £434.00 | £650.00 | £216.00 |
ESG Impact: Supporting Sustainability, Wellbeing, and Accountability
Today, businesses of all sizes are under growing pressure to align their operations with ESG (Environmental, Social, and Governance) principles. Whether driven by corporate responsibility, customer expectations, or regulatory requirements, materials handling operations are a prime area to demonstrate meaningful progress.
The HELI G2 Lithium Forklift Truck makes it easier than ever for companies to meet their ESG goals — by reducing environmental impact, improving operator wellbeing, and providing better transparency and control over operational costs.
Environmental: Reducing Carbon Footprint and Energy Waste
At the core of the HELI G2’s ESG credentials is its zero-emission electric powertrain, which helps businesses dramatically lower their carbon footprint compared to diesel or LPG forklifts. By eliminating tailpipe emissions, the HELI G2 enables operators to comply with stricter environmental regulations, improve air quality in warehouses and yards, and support corporate sustainability reporting.
Its advanced lithium-ion battery technology also ensures efficient energy use, minimal energy waste, and a longer battery lifecycle than traditional lead-acid batteries — all of which contribute to reduced resource consumption and less landfill waste over the forklift’s lifetime.
Social: Prioritising Operator Comfort, Health, and Safety
Beyond environmental benefits, the HELI G2 Lithium Forklift also promotes a healthier, safer, and more comfortable working environment for operators — a key component of the Social aspect of ESG.
The elimination of harmful exhaust fumes means operators are no longer exposed to toxic emissions, improving indoor air quality and protecting their long-term health.
Additionally, HELI has engineered the G2 with ergonomic, operator-friendly features, including:
- Air-suspension seats to reduce fatigue and back strain during long shifts
- Low vibration and quieter operation, improving comfort and reducing noise-related stress
- Spacious and intuitive controls that reduce the risk of operator error and increase productivity
By prioritising operator wellbeing, businesses can foster higher morale, lower absenteeism, and demonstrate a tangible commitment to their workforce.
Governance: Enhancing Oversight and Operational Transparency
Finally, the HELI G2 Lithium Forklift enables better operational oversight and accountability — crucial for the Governance aspect of ESG.
Electric forklifts, particularly lithium-powered models, make it far easier to monitor and manage fleet performance and costs. With integrated Battery Management Systems (BMS) and smart controllers, businesses gain visibility into energy usage, charge cycles, maintenance schedules, and overall efficiency.
This data-driven approach allows decision-makers to track and optimise operations, demonstrate cost savings, and produce detailed reports to satisfy internal and external stakeholders — including auditors, investors, and regulators.
Choosing the HELI G2 isn’t just about improving your materials handling operations — it’s a visible and measurable step toward building a more sustainable, responsible, and resilient business.
Modularity: Adaptable Design for All Applications
Modern businesses across the UK are increasingly seeking investments that are modular, flexible, and future-proof, ensuring that operational decisions made today don’t limit growth tomorrow. This need for scalability and adaptability applies just as much to materials handling equipment as it does to any other part of the business.
For decision-makers and operations managers, the ideal solution is a forklift truck that can be deployed anywhere in the business, at any time — without costly modifications or site-specific restrictions.
The HELI G2 Lithium Forklift Truck excels in this regard. Designed with flexibility and modularity at its core, it minimises site-specific limitations and supports your business as it evolves. Thanks to a combination of adaptable hardware and intelligent software, it fits seamlessly into a wide range of operations and environments.
Below, we explore how the HELI G2’s modular features — from its charging infrastructure to its programmable logic board and versatile mast configurations — make it a uniquely scalable solution in the market.
Dual Charger Setup & Opportunity Charging
The HELI G2 Lithium Forklift Truck offers a unique advantage with its dual charging capability, enabling two different charging methods on the same machine — a feature that significantly enhances flexibility, usability, and modularity across diverse operational environments.
This innovative design means the HELI G2 can adapt to the electrical infrastructure of almost any site in the UK, while also supporting advanced opportunity charging to keep your operations running longer and more efficiently.
Left Side: Slow Charging with Single-Phase Power
On the left-hand side of the HELI G2 is a slow charging port designed for a built-in single-phase 35A charger, located within the battery bay. This connects directly to a standard 16A blue Commando socket, one of the most common and cost-effective socket types in UK industrial facilities.
This setup is perfect for overnight charging, bringing the battery from 20% to 100% while the truck is idle, ensuring it’s fully ready at the start of each shift.
Why does this matter?
- Most UK industrial buildings are equipped with single-phase power, while 3-phase power is less common and more expensive to install.
- If your facility doesn’t already have a 16A Commando socket, it can typically be installed for just £60–£200, depending on the location and electrician.
This capability enables businesses to integrate the HELI G2 into operations with minimal additional investment, making it a highly cost-effective choice for widespread deployment.
Right Side: Fast Charging with 3-Phase Power
On the right-hand side of the truck, you’ll find the fast charging port, which connects to a standalone 3-phase 200A charger via a 32A socket.
While 3-phase power may be less common and more expensive to install (typically £200–£600 for a 32A socket), this setup delivers outstanding performance, recharging the battery from 20% to 100% in as little as 2 hours.
This ultra-fast charging capability maximises uptime, enabling the HELI G2 to handle even the most demanding, multi-shift environments with ease.
Opportunity Charging: Redefining Electric Forklift Usage
The combination of dual charging ports and advanced lithium-ion technology introduces a revolutionary approach to materials handling: opportunity charging.
With traditional lead-acid batteries, forklifts were limited to a single shift before needing a full, uninterrupted overnight charge — leaving them unusable for 8–12 hours during the charging cycle. Any interruption risked damaging the battery and shortening its life.
The HELI G2, powered by CATL lithium cells, eliminates these limitations. Its lithium battery can be plugged in and charged as many times as needed throughout the day — much like a smartphone — without suffering degradation. CATL, the battery manufacturer, estimates the cells can withstand more than 12,000 charge cycles before noticeable wear.
With the 200A fast charger, operators can opportunistically charge during breaks, shift changes, or downtime, dramatically extending daily runtime. With proper planning, a single HELI G2 can even support double-shift operations, something that was previously unthinkable for electric forklifts.
Why Dual Charging and Opportunity Charging Matter
Together, the dual charger setup and opportunity charging capability make the HELI G2 one of the most modular and versatile forklifts available today.
- Compatible with nearly all UK sites, thanks to the standard single-phase slow charger.
- Capable of ultra-fast charging on sites with 3-phase power for maximum uptime.
- Flexible charging throughout the day to match operational needs, without runtime limitations or infrastructure bottlenecks.
The HELI G2 ensures your operations are no longer constrained by outdated charging methods or electrical infrastructure — giving you complete control over how and when your fleet runs.
Programmable ZAPI & Standardised Mast Configurations
The HELI G2 Lithium Forklift Truck is designed with adaptability in mind — offering both advanced programmable controls and versatile mast configurations to meet the diverse needs of modern operations.
At the heart of the truck is a fully programmable ZAPI controller, which acts as the intelligent brain of the machine, translating operator inputs into precise actions in real time. This system allows virtually every aspect of the forklift’s behaviour — from throttle response to lift speed — to be tailored to suit your site conditions and your operators’ preferences.
Complementing this is the HELI G2’s range of standardised, cost-effective mast configurations, which strike the perfect balance between reach and compactness. The most common setup, the ZSM4700 mast, delivers exceptional versatility, allowing the truck to handle container work, warehouse stacking, and vehicle loading without compromise.
The ZAPI Controller
The HELI G2 comes equipped with a best-in-class ZAPI controller, offering over 400 programmable settings organised across three preset modes: slow, economy, and performance. These settings govern how the forklift operates in real time — and our technicians can easily configure them to match your operation’s requirements.
For example:
- If your site has strict speed limits, the truck can be programmed to comply in just a few clicks.
- If your operators are used to the feel of a diesel forklift, we can adjust variables so the HELI G2 behaves as close to a diesel machine as possible — ensuring a smooth transition.
- If, at a later stage, you find the truck needs more acceleration or better handling on gradients, those parameters can be quickly adjusted.
This level of customisation not only enhances operator comfort and confidence but also ensures the forklift operates safely and efficiently within the unique constraints of your site. The ZAPI controller reinforces the modularity of the HELI G2 by enabling it to evolve as your business and workforce evolve.
Standardised Mast Configurations
In addition to its intelligent control system, the HELI G2 offers practical and versatile mast configurations that maximise its usability across different tasks and environments.
The most commonly specified option — featured on 80–90% of HELI G2s delivered by Fork Truck Direct — is the ZSM4700 mast.
Why is this mast so popular?
- It provides a maximum lift height of 4,700mm, making it ideal for stacking goods at height, loading curtain-side vehicles, and general warehouse operations.
- When fully lowered, the mast sits at just 2,230mm, which is low enough to fit through standard shipping container doors — allowing for efficient container devanning.
This clever combination means a single HELI G2 can seamlessly switch between multiple roles in your operation, eliminating the need for dedicated trucks for each task and improving overall fleet efficiency.
However, the ZSM4700 is not the only mast configuration available. We can design the forklift directly to your needs regardless of required lifting heights or restrictions on closed heights due to doors and such.
Ready to Transform Your Operations with the HELI G2 Lithium Forklift?
The HELI G2 Lithium Forklift Truck combines everything modern businesses need in a materials handling solution: low total cost of ownership, advanced lithium battery technology, modular design, customisable controls, and industry-leading reliability. Whether you’re aiming to reduce emissions, cut operating costs, improve operator wellbeing, or future-proof your fleet, the HELI G2 delivers proven performance you can trust.
At Fork Truck Direct, we’ve helped countless businesses across the UK upgrade to the HELI G2 — unlocking greater efficiency, flexibility, and sustainability in their operations. We’re here to help you do the same.
If you’re ready to learn more about how the HELI G2 can fit your operation, or if you’d like a free consultation, tailored quote, or on-site demonstration, our team is here to help.
Contact us today to discover how the HELI G2 Lithium Forklift can transform your business.