wpt 45 series lift llc manual no. bl-wpt-0118 - 02-27-2018 wpt 45 series self-propelled, pallet lift...

Big Lift LLC MANUAL NO. BL-WPT-0118 - 02-27-2018www.bigjoeforklifts.com

WPT 45 SERIESSELF-PROPELLED,

PALLET LIFT TRUCK

Operation

Maintenance

Repair Parts List

WARNING

Do not operate this truck unless you have been autho-rized and trained to do so, and have read all warningsand instructions in Operator’s Manual and on thistruck.

Do not operate this truck until you have checked itscondition. Give special attention to tires, horn, battery,controller, lift system, brakes, steering mechanism,guards and safety devices.

Operate truck only from designated operating position.Do not carry passengers. Keep feet clear of truck andwear foot protection.

Observe applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is obstructed.

Start, stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfaces thatcould cause truck to slide or overturn. Use specialcare when traveling without load as the risk of overturnmay be greater.

Always look in direction of travel. Keep a clear view,and when load interferes with visibility, travel with loadtrailing.

Use special care when operating on ramps travelslowly, and do not angle or turn. Travel with loaddownhill.

Do not handle loads which are higher than the loadbackrest or load backrest extension unless load issecured so that no part of it could fall backward.Before lifting, be sure load is centered, forks are com-pletely under load, and load is as far back as possibleagainst load backrest.

When leaving truck, neutralize travel control, fullylower lifting mechanism and set brake. When leavingtruck unattended, also shut off power.

TABLE OF CONTENTS

Section Page Section Page

1LIST OF ILLUSTRATIONS .............................................1-II

1LIST OF TABLES............................................................1-II

1DESCRIPTION..................................................................1-1

1-1. INTRODUCTION..............................................1-11-2. GENERAL DESCRIPTION...............................1-11-3. SAFETY FEATURES. ......................................1-2

2OPERATION.....................................................................2-1

2-1. GENERAL. .......................................................2-12-2. OPERATING PRECAUTIONS. ........................2-12-3. BEFORE OPERATION.....................................2-12-4. GENERAL CONTROL OPERATION................2-42-5. DRIVING AND STOPPING PROCEDURES. ...2-42-6. BELLY-BUTTON SWITCH. ..............................2-42-7. STEERING ARM GAS SPRING.......................2-52-8. LIFT AND LOWER CONTROLS. .....................2-52-9. LOADING AND UNLOADING. .........................2-52-10. PARKING. ........................................................2-5

3PLANNED MAINTENANCE..............................................3-1

3-1. GENERAL. .......................................................3-13-2. MONTHLY AND QUARTERLY CHECKS. .......3-13-3. BATTERY CARE.............................................3-13-3.1. GENERAL ........................................................3-13-3.2. SAFETY RULES ..............................................3-23-3.3. BATTERY CARE AND CHARGING.................3-23-3.4. BATTERY CLEANING......................................3-23-3.5. MAINTENANCE FREE BATTERIES................3-33-4. CHARGING BATTERIES .................................3-33-5. LUBRICATION. ................................................3-4

4TROUBLESHOOTING......................................................4-1

4-1. GENERAL ........................................................4-14-2. CONTROLLER TROUBLESHOOTING............4-44-2.1. ZAPI HANDSET ...............................................4-44-2.2. FAULT DETECTION. .......................................4-44-2.3. TESTING TRUCK OPERATION. .....................4-44-2.4. SETTINGS AND ADJUSTMENTS ...................4-5

5STEER ARM, CONTROL HEAD & COMPARTMENT ......5-1

5-1. CONTROL HEAD.............................................5-15-1.1. CONTROL HEAD REMOVAL ..........................5-15-1.2. CONTROL HEAD INSTALLATION ..................5-25-1.3. CAP ASSEMBLY REMOVAL. ..........................5-35-1.4. CAP ASSEMBLY INSTALLATION. ..................5-35-1.5. BELLY-BUTTON SWITCH REPLACEMENT. ..5-35-1.6. HORN SWITCH REPLACEMENT....................5-45-1.7. LIFT & LOWER SWITCH REPLACEMENT .....5-55-1.8. SPEED POTENTIOMETER REPLACEMENT .5-65-2. STEERING ARM ..............................................5-65-2.1. RETURN SPRING REPLACEMENT................5-65-2.2. STEERING ARM REMOVAL............................5-6

5-2.3. STEERING ARM INSTALLATION................... 5-65-3. COMPARTMENT COVERS............................. 5-65-3.1. REMOVAL. ...................................................... 5-65-3.2. INSTALLATION. .............................................. 5-6

6BRAKE SERVICING......................................................... 6-1

6-1. BRAKES. ......................................................... 6-16-1.1. AIR GAP ADJUSTMENT. ................................ 6-16-1.2. STOPPING DISTANCE ADJUSTMENT. ......... 6-26-1.3. BRAKE ASSEMBLY REPLACEMENT ............ 6-2

7TRANSMISSION, DRIVE WHEEL, LOAD WHEEL.......... 7-1

7-1. DRIVE WHEEL. ............................................... 7-17-2. TRANSMISSION. ............................................ 7-17-3. LOAD WHEEL. ................................................ 7-27-3.1. REMOVAL ....................................................... 7-27-3.2. REPAIR .......................................................... 7-27-3.3. LOAD WHEEL INSTALLATION....................... 7-2

8ELEVATION SYSTEM SERVICING................................. 8-1

8-1. GENERAL........................................................ 8-18-2. LIFT LINKAGE................................................. 8-18-2.1. REMOVAL ....................................................... 8-18-2.2. INSTALLATION ............................................... 8-18-3. POWER SECTION AND FORK SECTION...... 8-18-3.1. SEPARATING POWER SECTION AND FORK SECTION ................................................ 8-18-3.2. FORK FRAME REPAIR. .................................. 8-18-3.3. CARRIER FRAME REPAIR............................. 8-18-3.4. MATING POWER SECTION

AND FORK SECTION ..................................... 8-1

9HYDRAULIC SYSTEM SERVICING ................................ 9-1

9-1. LINES AND FITTINGS .................................... 9-19-2. HYDRAULIC PUMP, MOTOR,

AND RESERVOIR ASSY ................................ 9-19-2.1. REMOVAL ....................................................... 9-19-2.2. DISASSEMBLY AND REASSEMBLY ............. 9-39-2.3. INSTALLATION ............................................... 9-39-2.4. LIFT CYLINDER .............................................. 9-3

10ELECTRICAL COMPONENTS....................................... 10-1

10-1. ELECTRICAL CONTROL PANEL ................. 10-110-1.1.MAINTENANCE............................................. 10-110-1.2.CLEANING .................................................... 10-110-1.3.PANEL REMOVAL. ....................................... 10-110-1.4.PANEL DISASSEMBLY................................. 10-110-1.5.PANEL INSTALLATION. ............................... 10-110-2. HORN REPLACEMENT ................................ 10-310-3. PUMP MOTOR. ............................................. 10-410-4. DRIVE MOTOR. ............................................ 10-410-4.1.MOTOR REMOVAL....................................... 10-410-4.2.MOTOR REPAIR ........................................... 10-410-4.3.MOTOR INSTALLATION............................... 10-4

BL-WPT-0118 - 02-27-2018 i

TABLE OF CONTENTS - Continued

10-5. LIFT LIMIT SWITCH ...................................... 10-610-5.1.REPLACEMENT............................................ 10-610-5.2.ADJUSTMENT............................................... 10-610-6. DEADMAN SWITCH...................................... 10-610-6.1.REPLACEMENT............................................ 10-6

11

OPTIONAL EQUIPMENT ...............................................11-111-1. LOAD BACKREST. ........................................11-111-2. CASTERS ......................................................11-1

12ILLUSTRATED PARTS BREAKDOWN ..........................12-1

LIST OF ILLUSTRATIONS

Figure Page Figure Page

1-1 NAME PLATE ..................................................... 1-11-2 WPT 45 LIFT TRUCK ......................................... 1-12-1 SAMPLE OF OPERATOR CHECK LIST ............ 2-32-2 FORWARD/REVERSE CONTROL..................... 2-42-3 PUSHBUTTON SWITCHES ............................... 2-42-4 BRAKE ACTUATION .......................................... 2-42-5 BELLY-BUTTON SWITCH.................................. 2-53-1 LUBRICATION DIAGRAM .................................. 3-54-1 CONNECTING THE HANDSET.......................... 4-44-2 ZAPI HANDSET .................................................. 4-54-3 ZAPI HANDSET .................................................. 4-94-4 THROTTLE REGULATION............................... 4-104-5 ZAPI HANDSET ................................................ 4-114-6 ZAPI CONTROLLER CONNECTIONS ............. 4-135-1 STEERING ARM................................................. 5-15-2 CONTROL HEAD................................................ 5-25-3 EMERGENCY REVERSE SWITCH ASSY ......... 5-35-4 CAP ASSEMBLY ................................................ 5-45-5 LEFT LIFT/LOWER SWITCH ASSY ................... 5-56-1 BRAKE ASSEMBLY............................................ 6-17-1 TRANSMISSION, MOTOR, BRAKE ASSY......... 7-17-2 WHEEL ASSEMBLY ........................................... 7-28-1 FRAME (SHEET 1) ............................................. 8-28-2 FRAME (SHEET 1) ............................................. 8-29-1 HYDRAULIC SYSTEM........................................ 9-29-2 PUMP AND MOTOR ASSEMBLY ...................... 9-39-3 LIFT CYLINDER.................................................. 9-410-1 ELECTRICAL SYSTEM .................................... 10-210-2 ELECTRICAL PANEL ....................................... 10-310-3 TRANSMISSION, MOTOR, BRAKE

ASSEMBLY....................................................... 10-4

10-4 DRIVE MOTOR ................................................. 10-512-1 STEERING ARM ............................................... 12-212-2 CONTROL HEAD .............................................. 12-412-3 CAP ASSEMBLY............................................... 12-612-4 EMERGENCY REVERSE SWITCH

ASSEMBLY ....................................................... 12-812-5 TRANSMISSION, MOTOR, BRAKE

ASSEMBLY ..................................................... 12-1012-6 TRANSMISSION,

USED FROM SERIAL # E2210275................. 12-1212-7 COMPARTMENT ............................................ 12-1412-8 CASTER WHEEL (OPTIONAL)

USED UP TO SERIAL # E2210274 ................ 12-1612-9 CASTER WHEEL (OPTIONAL)

USED FROM SERIAL # E2210275................. 12-1812-10 FRAME ............................................................ 12-2012-11 LINKAGE......................................................... 12-2412-12 LOAD WHEEL ................................................. 12-2812-13 HYDRAULIC SYSTEM .................................... 12-3012-14 PUMP & MOTOR ASSY.................................. 12-3212-15 LIFT CYLINDER .............................................. 12-3412-16 ELECTRICAL SYSTEM................................... 12-3612-17 ELECTRICAL PANEL...................................... 12-3812-18 DRIVE MOTOR ............................................... 12-4012-19 WIRING HARNESS......................................... 12-4212-20 WIRING CABLES ............................................ 12-4412-21 BATTERY ASSY.

USED FROM SERIAL E1922226.................... 12-4612-22 COLD CONDITIONING ................................... 12-48

LIST OF TABLES

Table Page Table Page

2-1 OPERATOR CHECKS......................................... 2-23-1 MONTHLY AND QUARTERLY INSPECTION

AND SERVICE CHART....................................... 3-13-2 RECOMMENDED LUBRICANTS ........................ 3-43-3 LUBRICATION CHART ....................................... 3-5

4-1 TROUBLESHOOTING CHART............................4-14-2 SET OPTIONS.....................................................4-54-3 ADJUSTMENTS...................................................4-94-4 PARAMETER ADJUSTMENTS .........................4-114-5 ZAPI CONTROLLER CONNECTOR PINS ........4-13

ii BL-WPT-0118 - 02-27-2018

SECTION 1DESCRIPTION

1-1. INTRODUCTION.

This publication describes the 24 volt transistor WPT 45 lift truck distributed by Big Lift LLC. Includedare operating instructions, planned maintenanceinstructions, lubrication procedures, corrective mainte-nance procedures and a complete parts list with partlocation illustrations.

Users shall comply with all requirements indicated inapplicable OSHA standards and current edition ofA.N.S.I. B56.1 Part II. By following these requirementsand the recommendations contained in this manual,you will receive many years of dependable servicefrom your WPT 45 lift truck.

1-2. GENERAL DESCRIPTION.

The self-propelled WPT 45 truck, Figure 1-2, lifts andtransports payloads up to 4500 pounds on rigid forks.

The forward and reverse motion is controlled by eitherof two controller levers mounted on the control head.Stopping and turning is controlled by the steering arm.Lift and Lower is controlled by pushbuttons on the con-trol head. The battery powered lift truck is quiet andwithout exhaust fumes.

The reversible AC motor propels the lift truck in for-ward or reverse direction throughout the availablespeed range. The WPT 45 lift truck can be driven with

forks raised or lowered. The lift truck must be pro-tected from the elements.

The model number will be found on the name plate(Figure 1-1) along with the serial number, lifting capac-ity, and load center. Figure 1-2 shows the locations ofthe truck’s main components and controls.

Figure 1-1 Name Plate

Figure 1-2 . WPT 45 Lift Truck

R6209

R6622

BL-WPT-0118 - 02-27-2018 1-1

1-3. SAFETY FEATURES.

The WPT 45 is designed and engineered to providemaximum safety for operator and payload. Some ofthe safety features incorporated into the design are:

• Dead-man brake to apply the brake and cut off drivepower when the steering arm is released.

• Belly-button switch to reverse truck should the oper-ator accidentally pin himself against a wall orobstruction when backing up in slow speed.

• All control functions automatically return to “OFF”when released.

• Externally accessible quick-disconnect battery plugwithin operator's reach.

• Separately fused control circuits and power circuits.

• Readily accessible horn button.

• Handle to provide a firm hand hold for operator.

• Flow control valve regulates maximum loweringspeed within prescribed limits.

• Relief valve maintains hydraulic pressure within pre-scribed limits.

• High visibility color scheme of truck provides visualalert of truck’s presence.

• Battery Indicator

• Casters

1-2 BL-WPT-0118 - 02-27-2018

SECTION 2OPERATION

2-1. GENERAL.

This section gives detailed operating instructions forthe WPT 45 lift truck. The instructions are divided intothe various phases of operations, such as operatinglift, driving, and stopping. Routine precautions areincluded for safe operation.

2-2. OPERATING PRECAUTIONS.

WARNING: Improper operation of the lift truck mayresult in operator injury, or load and/or lifttruck damage. Observe the followingprecautions when operating the WPT 45lift truck.

The following safety precautions must be adhered toat all times.

• Do not operate this truck unless you have beentrained and authorized to do so and have read allwarnings and instructions in this manual and on thetruck.

• All warnings and instructions must be read andunderstood before using the equipment.

• Equipment must be inspected by a qualified personon a regular basis.

• Do not operate this truck until you have checked itscondition. Give special attention to Tires, Horn, Bat-teries, Controller, Lift System, Brakes, SteeringMechanism, Guards and Safety Devices

• Operate truck only from designated operation posi-tion. Wear foot protection. Do not carry passengers.

• Observe applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is obstructed.

• Start, stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfacesthat could cause truck to slide or overturn. Use spe-cial care when traveling without load as the risk ofoverturn may be greater.

• Always look in direction of travel. Keep a clear view,and when load interferes with visibility, travel withload or lifting mechanism trailing.

• Do not overload truck. Check nameplate for loadweight and load center information.

• Before lifting, be sure load is centered, forks arecompletely under load, and load is as far back aspossible against load backrest.

• Do not handle loads which are higher than the loadbackrest unless load is secured so that no part of itcould fall backward.

• When leaving truck, neutralize travel control. Fullylower lifting mechanism and set brake. When leavingtruck unattended, turn off key switch and disconnectswitch, remove key and disconnect battery.

2-3. BEFORE OPERATION

Table 2-1 covers important inspection points on theWPT 45 lift truck which should be checked prior tooperation. Depending on use, some trucks mayrequire additional checks.

Figure 2-1 shows a sample format for an OperatorChecklist, which can be modified as necessary to fityour operation.

WARNING: Periodic maintenance of this truck by aQUALIFIED TECHNICIAN is required.

CAUTION: A QUALIFIED SERVICE TECHNICIANshould check the truck monthly forproper lubrication, proper fluid levels,brake maintenance, motor maintenanceand other areas specified in the SEC-TION 3.

WARNING: If the truck is found to be unsafe and inneed of repair, or contributes to anunsafe condition, report it immediately tothe designated authority. Do not operateit until it has been restored to a safeoperating condition. Do not make anyunauthorized repairs or adjustments. Allservice must be performed by a qualifiedmaintenance technician.

BL-WPT-0118 - 02-27-2018 2-1

Table 2-1 Operator Checks

ITEM PROCEDURE

Transmission and hydraulic systems.

Check for signs of fluid leakage.

Forks Check for cracks and damage.

Safety signs Check that warning labels, nameplate, etc., are in good condition and legible.

Horn Check that horn sounds when operated.

Steering Check for binding or looseness in steering arm when steering.

Travel controls Check that speed controls on control head operate in all speed ranges in forward and reverse and that belly button switch functions.

Wheels Check drive wheel for cracks or damage. Move truck to check load for freedom of rotation.

Hydraulic controls

Check operation of lift and lower to their maximum positions.

Brakes Check that brakes actuate when steering arm is raised to upright position, and when lowered to horizontal position.

Deadman/Parking brake

Check that steering arm raises to upright position when released and brake applies.

Battery disconnect

Check that battery can be disconnected and recon-nected. Check for connector damage.

Battery charge Check the battery indicator.

ITEM PROCEDURE

2-2 BL-WPT-0118 - 02-27-2018

Figure 2-1 Sample of Operator Check List

R6479

BL-WPT-0118 - 02-27-2018 2-3

2-4. GENERAL CONTROL OPERATION.

The speed control (See Figure 2-2) located on eachside of the control head provides fingertip control fordriving the truck. Rotate the control in the direction youwant to travel. The farther you rotate the control fromthe neutral position, the faster the truck will travel.

Figure 2-2 Forward/Reverse Control

The pushbutton switches (See Figure 2-3), located onthe front of the control head activate the lift-lower con-trols and the horn.

Figure 2-3 Pushbutton Switches

The brake is fully applied by lowering or raising thesteering arm. (See Figure 2-4) All traction controlpower is shut off when the brake is engaged. Whenthe steering arm is in the upright position, the brakeacts as a parking brake. Deadman braking occurswhen the handle is released and spring action raisessteering arm to the upright position.

Figure 2-4 Brake Actuation

2-5. DRIVING AND STOPPING PROCEDURES.

1. Connect the batteries and turn on the key switch.Grasp the grips of the steering head so that thespeed control can be comfortably operated byeither thumb.

2. Lower the steering arm to a comfortable positionabove horizontal to disengage the brake and toenergize the electrical circuits. If the truck is notmoved, the electrical circuits will time out and willdeenergize. See Figure 2-4.

3. To move forward (with load in front), slowly pressthe speed control forward. See Figure 2-2. Pressthe forward speed control farther to increasespeed.

4. To slow down or stop, release the speed controland lower or raise the steering arm to the horizon-tal or vertical position. See Figure 2-4. In thosepositions, the brake engages, slowing or stoppingthe truck.

5. Procedures for movement in reverse are thesame as in the forward direction except slowlypress the speed control backward. See Figure 2-2.

2-6. BELLY-BUTTON SWITCH.

The belly-button switch (Figure 2-5) minimizes thepossibility of the driver being pinned by the steeringarm while driving the lift truck in slow speed. If theswitch presses against the operator while the lift truckis being driven toward the operator, the switchchanges the direction of the lift truck.

R6617

R6618

R6620

2-4 BL-WPT-0118 - 02-27-2018

Figure 2-5 Belly-Button Switch

2-7. STEERING ARM GAS SPRING.

The steering arm gas spring automatically raises thesteering arm to the upright position when the steeringarm is released. If the steering arm does not returnfully, the steering arm gas spring requires replace-ment. Return truck to maintenance for repair.

2-8. LIFT AND LOWER CONTROLS.

Lift/Lower Control buttons are located on the steeringcontrol head. (Figure 2-3)

To lift forks, push in either LIFT button and hold untilforks reach desired height. To lower forks, push ineither LOWER button and hold until forks descend todesired height.

2-9. LOADING AND UNLOADING.

1. Move truck to location where load is to be pickedup.

2. Move the truck into position so forks are withinpallet or skid, and the load is centered over theforks and as far back as possible.

3. Raise forks to lift load.

4. Drive to area where load is to be placed.

5. Move truck to align load with its new position.

6. Lower the load until it rests squarely in place andthe forks are free.

7. Slowly move the truck out from under the load.

2-10.PARKING.

When finished with moving loads, return the truck to itsmaintenance or storage area. Turn off the key switchand disconnect the batteries. Charge batteries as nec-essary. Refer to battery care instructions, SECTION 3.

R6619

BL-WPT-0118 - 02-27-2018 2-5

NOTES

2-6 BL-WPT-0118 - 02-27-2018

SECTION 3PLANNED MAINTENANCE

3-1. GENERAL.

Planned maintenance consists of periodic visual andoperational checks, parts inspection, lubrication, andscheduled maintenance designed to prevent or dis-cover malfunctions and defective parts. The operatorperforms the checks in SECTION 2, and refers anyrequired servicing to a qualified maintenance techni-cian who performs the scheduled maintenance andany required servicing.

3-2. MONTHLY AND QUARTERLY CHECKS.

Table 3-1 is a monthly and quarterly inspection andservice chart based on normal usage of equipmenteight hours per day, five days per week. If the lift truckis used in excess of forty hours per week, the fre-quency of inspection and service should be increasedaccordingly. These procedures must be performed bya qualified service technician or your Big Lift LLC Ser-vice Representative.

3-3. BATTERY CARE.

3-3.1. General

The WPT 45 may be equipped with maintenance freeor industrial wet cell batteries.

The care and maintenance of the battery is veryimportant to obtain efficient truck operation and maxi-mum battery life.

CAUTION: Gases produced by a battery can beexplosive. Do not smoke, use an openflame, create an arc or sparks in thevicinity of the battery. Ventilate anenclosed area well when charging.

CAUTION: Batteries contain sulfuric acid which maycause severe burns. Avoid contact witheyes, skin or clothing. In case of contact,flush immediately and thoroughly withclean water. Obtain medical attentionwhen eyes are affected. A baking sodasolution (one pound to one gallon ofwater) applied to spilled acid until bub-bling stops, neutralizes the acid for safehanding and disposal.

Leakage voltage from battery terminals to battery casecan cause misleading trouble symptoms with the truckelectrical system. Since components of the truck elec-trical system are insulated from truck frame, leakagevoltage will not normally affect truck operation unless ashort circuit or breakdown of circuit wire insulation totruck frame occurs.

A voltage check from battery connector terminal tobattery case should indicate near zero volts. Typically,however, the sum of the voltages at both terminals willequal battery volts. This leakage voltage will dischargethe battery. As battery cleanliness deteriorates, theusable charge of the battery decreases due to this selfdischarge.

Table 3-1 Monthly and Quarterly Inspection and Service Chart

VISUAL CHECKS

INTERVAL INSPECTION OR SERVICE

Monthly Check mechanical brake for proper operation.

Monthly Check load wheels for wear. A poly load wheel must be replaced if worn to within 1/16 inch of hub. Check for separation from hub.

Monthly Check drive wheel for wear. A poly drive wheel must be replaced if worn to within 3/4 inch of hub. Check for separation from hub.

Monthly Inspect wiring for loose connections and damaged insulation.

Monthly Inspect contactors for proper operation.

Monthly Check deadman brake switch for proper operation.

Quarterly Check lift cylinder for leakage.

Quarterly Check for excessive jerking of steering arm when stopping or starting.

BL-WPT-0118 - 02-27-2018 3-1

Although a leakage voltage reading of zero volts maynot be possible, a cleaner battery will have moreusable charge for truck operation and not affect opera-tion of electronic devices on the unit.

3-3.2. Safety Rules

• Wear protective clothing, such as rubber apron,gloves, boots and goggles when performing anymaintenance on batteries. Do not allow electrolyte tocome in contact with eyes, skin, clothing or floor. Ifelectrolyte comes in contact with eyes, flush immedi-ately and thoroughly with clean water. Obtain medi-cal attention immediately. Should electrolyte bespilled on skin, rinse promptly with clean water andwash with soap. A baking soda solution (one poundto one gallon of water) will neutralize acid spilled onclothing, floor or any other surface. Apply solutionuntil bubbing stops and rinse with clean water.

• If truck is equipped with wet cell batteries, keep ventplugs firmly in place at all times except when addingwater or taking hydrometer readings. Do not allowdirt, cleaning solution or other foreign material toenter cells. Impurities in electrolyte has a neutraliz-ing effect reducing available charge.

• Do not bring any type of flame, spark, etc., near thebattery. Gas formed while the battery is charging, ishighly explosive. This gas remains in cell long aftercharging has stopped.

• Do not lay metallic or conductive objects on battery.Arcing will result.

• Do not touch non-insulated parts of DC output con-nector or battery terminals to avoid possible electri-cal shock.

• De-energize all AC and DC power connectionsbefore servicing battery.

• Do not charge a frozen battery.

• Do not use charger if it has been dropped or other-wise damaged.

3-3.3. Battery Care and Charging

CAUTION: Never smoke or bring open flame nearthe battery. Gas formed during chargingis highly explosive and can cause seri-ous injury.

1. Charge the battery only in areas designated forthat use.

2. Make certain the charger being used matches thevoltage and amperage of the truck battery.

3. Before disconnecting or connecting batteries to acharger, make sure the charger is “OFF”. If anattempt is made to do this while the charger is“ON”, serious injury to you, the battery and thecharger could result.

4. Before connecting the battery cable to the trucksreceptacle, make sure the key switch is off. Thebattery cable must be fully connected before thetruck is used. If the plug is not making good con-tact, heat will weld the two parts of the batteryconnector together, making it difficult to removeand necessary to replace.

5. Battery terminals should be checked and cleanedof corrosion regularly. Good battery terminal con-tact is essential not only for operation, but also forproper charging of the battery.

6. The charging requirements will vary depending onthe use of the truck. The battery should be givenas equalizing charge on a weekly basis. Thischarge should normally be an additional threehours at the finish rate.

7. Make certain battery used meets weight and sizerequirements of truck. NEVER operate truck withan undersized battery.

3-3.4. Battery Cleaning

Always keep vent plugs tightly in place when cleaningbattery. When properly watered and charged, the bat-tery will remain clean and dry. All that is necessary isto brush or blow off any dust or dirt that may accumu-late on them. However, if electrolyte is spilled or over-flows from a cell, it should be neutralized with asolution of baking soda and water, brushing the sodasolution beneath the connectors and removing grimefrom the covers. Then rinse the battery with cool waterfrom a low pressure supply to remove the soda andloosen dirt. If batteries stay wet consistently, they maybe either overcharged or over filled. This conditionshould be investigated and corrected.

3-2 BL-WPT-0118 - 02-27-2018

3-3.5. MAINTENANCE FREE BATTERIES

Some trucks may be equipped with maintenance freebatteries. These batteries are completely sealed, willnot require any watering and have a full 80% dis-charge available.

Sealed Maintenance Free batteries contain a pressurerelease valve and under normal operating conditionsdo not require any special ventilation.

CAUTION: Do not try to open this battery or removethe pressure release valve.

Only under severe overcharging, such as connectedto an improperly sized charger, will any significantamount of gas be released from the battery. Also,being a valve regulated battery, it never requireswatering.

3-4. CHARGING BATTERIES

Charging requirements will vary depending on depth ofdischarge and temperature. Follow safety rules whenplacing a battery on charge.

Proceed as follows:

1. Park truck at charging station with carriage low-ered and turn the key switch off.

2. Check the condition of the AC cord, the batteryconnector and battery cables. If there are any cutsin the cable, any exposed wires, loose plugs orconnectors, DO NOT attempt to charge the bat-teries. Contact appropriate personnel for repairsto be made.

3. Disconnect the batteries from the truck and con-nect the batteries to the charger. Make sure con-nectors are mated properly.

4. Connect the charger to the appropriate powersupply.

5. Follow the instructions for the charger being used.

BL-WPT-0118 - 02-27-2018 3-3

3-5. LUBRICATION.

Refer to Table 3-2 for the recommended types ofgrease and oil. Table 3-3 in conjunction with Figure 3-1identifies the items requiring lubrication.

Table 3-2 Recommended Lubricants(See Table 3-3 for Application)

No. 1 Transmission oil—EP SAE 80W-90Transmission oil—EP SAE 10W-30 (Note)

No. 2 Grease—Lithium base, general purpose.

No. 3 Hydraulic oil-Heavy duty with a viscosity of 150 SUS foam suppressing agent and rust and oxidation inhibitors

Hydraulic oil-Heavy duty with a viscosity of 100 SUS foam suppressing agent and rust and oxidation inhibitors (Note)

No. 4 SAE 30 or 40 Engine lubricating oil

NOTE: USED ON COLD CONDITIONED TRUCKS

3-4 BL-WPT-0118 - 02-27-2018

Figure 3-1 Lubrication Diagram

Table 3-3 Lubrication Chart

FIG 3-2 INDEX

NO.

LOCATION METHOD OF APPLICATION

TYPE (Table 3-3)

APPLICATION OF

LUBRICANT

1 TransmissionCapacity 2 pints

Can No. 1 Fill to level plug opening

2 Pivot Tube Fitting Gun No. 2 Pressure lubricate

3 Hydraulic ReservoirCapacity-1 quarts

Can No. 3 With lift carriage fully lowered, fill reservoir with hydraulic oil to 1 inch below opening

4 Lift Linkage Fittings Gun No. 2 Pressure lubricate.

5 Lift Linkage Fittings* Gun No. 2 Pressure lubricate.

* Raise lift carriage to gain access to grease fittings.

R6621

BL-WPT-0118 - 02-27-2018 3-5

NOTES

3-6 BL-WPT-0118 - 02-27-2018

SECTION 4TROUBLESHOOTING

4-1. GENERAL

Use Table 4-1 as a guide to determine possiblecauses of trouble. The table is divided into five maincategories: Truck and Hydraulic System Will Not Oper-

ate: Truck Does Not Operate Forward or Reverse:Trouble With Braking: Trouble With Lifting Or Lower-ing, and Miscellaneous malfunctions.

Table 4-1 Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

TRUCK AND HYDRAULIC SYSTEM WILL NOT OPERATE

Truck will not travel nor will lift sys-tem operate.

a. Fuse blown. Check fuse and replace if necessary.

b. Battery dead or disconnected. Check battery quick-disconnect plug and check battery voltage.

c. Keyswitch defective. Bypass keyswitch to determine if it is malfunctioning.

d. Defective wiring. Check for open circuit. Repair as required.

TRUCK DOES NOT OPERATE FORWARD OR REVERSE

Truck does not travel forward or reverse. All other functions oper-ate normally.

a. Check all wiring. A loose con-nection may be the cause of malfunction.

Tighten all loose connections before further troubleshooting.

b. Defective deadman switch. Check and replace switch if defective.

c. Defective main contactor. Check for proper operation and replace if necessary.

d. Defective potentiometer. Check and replace potentiometer if defective.

Truck travels forward but not in reverse.

Defective potentiometer in control head.

Check and replace potentiometer if defective.

Truck travels reverse but not in forward.



Truck travels forward and in reverse at lower speeds; will not travel at high speed.



TROUBLE WITH BRAKING

Truck does not slow with brake, or brake does not engage.

a. Defective deadman switch. Check deadman switch for continuity. If none found when the control arm is in the brake position, replace switch.

b. Defective electric brake. Adjust or replace brake.

BL-WPT-0118 - 02-27-2018 4-1

Table 4-1 Troubleshooting Chart - Continued


TROUBLE WITH BRAKING - Continued

Brake will not release. a. Air gap more than 0.01 in (0.25mm).

Adjust

b. Brake temperature above 281F (140 C).

Allow to cool and check air gap.

c. Open brake circuitry or wiring. Make voltage checks.

Brake drags. a. Air gap more than 0.01 in (0.25mm).

Adjust

b. Defective electric brake. Replace.

Brake grabs. a. Air gap more than 0.01 in (0.25mm).

Adjust

b. Defective electric brake. Replace.

Abnormal noise and chatter when brake is applied.

Defective electric brake. Replace.

TROUBLE WITH LIFTING OR LOWERING

Oil sprays or flows from the top of the lift cylinder.

Defective packing in lift cylinder Repair lift cylinder.

Squealing sounds when lifting forks.

a. Oil level too low. Identify oil leak.

b. Lift linkage binding. Apply grease.

Forks do not lift to top. Oil level too low. Add oil to reservoir.

Weak, slow or uneven action of hydraulic system.

a. Defective pump or relief valve. Check pressure. Adjust as necessary.

b. Worn lift cylinder. Replace cylinder.

c. Load larger than capacity. Refer to I.D.plate for capacity.

d. Defective lift motor solenoid. Replace solenoid on electrical panel.

e. Battery charge low. Charge battery.

Forks do not lift, pump motor does not run.

a. Battery is dead or discon-nected.

Check and recharge if required.

b. Defective wiring. Check and repair as required.

c. Defect in electrical system for operating pump motor.

Check lift switch in control head, as well as the solenoid.

Forks do not lift, motor runs. Defect in hydraulic system. Check the oil level in the reservoir and the oil lines to the lift cylin-der, and repair as required. If normal, check the hydraulic pump, and relief valve. Repair, or adjust.

4-2 BL-WPT-0118 - 02-27-2018

Table 4-1 Troubleshooting Chart - Continued


TROUBLE WITH LIFTING OR LOWERING - Continued

Forks lift, but will not go down. Defect in hydraulic system Check lowering control switch in control head and lowering sole-noid on valve assembly . Replace as required.

Load will not hold a. Oil bypassing internally in con-trol valve

Replace valve assembly.

b. Worn lift cylinder or packing. Repack cylinder.

Platform does not lift to top. Pump motor runs.

a. Oil level too low. Add oil to reservoir.

b. Load larger than capacity. Refer to nameplate on side of mast for maximum load capacity.

c. Batteries need charging. Change batteries.

Forks creep downward under load when in a raised position.

Leak in hydraulic system, lift cylin-der or lowering valve.

Check for leaking fitting in hydrau-lic line and repair as required. Repack lift cylinder or replace valve assembly.

MISCELLANEOUSSteering arm does not return to

the upright position.a. Week return spring. Replace spring.

b. Binding. Check and free the binding item. Verify that the cable has not been damaged. Repair or replace as needed.

Truck moves forward when arm is pulled down.

a. Belly-button switch defective. Check for short, and repair or replace as necessary.

b. Short in control head. Check wiring and repair as required.

Steering arm jerks excessively starting or stopping the truck.

Drive wheel worn. Replace drive wheel if worn to within 3/4 inch of hub.

Drive motor is jerky. Motor internally damaged or worn. Replace motor.

BL-WPT-0118 - 02-27-2018 4-3

4-2. CONTROLLER TROUBLESHOOTING

4-2.1. Zapi Handset

A Zapi Handset is available that is designed specifi-cally for use with the Zapi controller. It serves multiplefunctions of reading diagnostic data, testing truckoperation, setting options, adjustments and parameterchanges of the controller. The Zapi Handset is avail-able through your Big Lift LLC dealer. If you requiredealer location information, contact Big Lift LLC.

Remove the rubber plug from the CNC connector ofthe controller and plug in the Zapi Handset connectoras shown in Figure 4-1.

Figure 4-1 Connecting the Handset

4-2.2. Fault Detection.

4-2.2.1. General

The controller provides diagnostics information toassist technicians in troubleshooting problems. Whena fault is detected, an alarm is recorded in the logbook.It has a FIFO (First Input First Output) structure thatmeans the oldest alarm is lost when the database isfull and a new alarm occurs. The logbook is composedof alarms with the following information:

• The alarm code

• The number of times that each alarm occurs consec-utively

• The Hour Meter reading (value) when the latestevent of every alarm occurred

• The invert temperature when the latest event ofevery alarm occurred.

This function permits a deeper diagnosis of problemsas the recent history can be revisited.

4-2.2.2. Logbook Access

To view the alarm logbook proceed as follows:

1. Connect the Zapi Handset, refer to paragraph 4-2.1.

2. Press the ROLL down button (1, Figure 4-2) andthe ENTER button (3) at the same time to enterthe MAIN MENU.

3. Press the ROLL down button (2) or the ROLL upbutton (1) to find the ALARMS display.

4. Press the ENTER button (3) to view the alarms.

5. Press the OUT button (6) to exit the alarms.

NOTE: Refer to bigjoesupport.com for the Zapi sup-plement containing detailed information ofalarm codes. There are two versions shown.The PDS uses the Standard version whichlists the error by: Alarm Name, Repetitions,Temperature and Hour Meter reading.

4-2.3. Testing Truck Operation.

The Zapi Handset can be used to test certain truckoperations as follows:



3. Press the ROLL down button (2) or the ROLL upbutton (1) to find the TESTER display.

4. Press the ENTER button (3) to view the tests.

5. To verify various switch functions, locate theswitch on the display and then operate that func-tion to verify operation

6. Press the OUT button (6) to exit the tests.

R6623

4-4 BL-WPT-0118 - 02-27-2018

4-2.4. Settings and Adjustments

4-2.4.1. Set Options

To set options proceed as follows and refer to Table 4-2:


2. Press the ROLL up button (1, Figure 4-2) and theSET up button (5) at the same time to enter theCONFIG MENU.

3. Press the ROLL down button (1) or the ROLL upbutton (2) to find the SET OPTIONS display.

4. Press the ENTER button (3) to view the options.

5. Press the ROLL down (2) or the ROLL up button(1) to find the option to be changed.

6. Press the SET up button (5) or the SET down but-ton (6) until the desired value setting is reached.The option is now set at the desired value.

7. Press the OUT button (4) to exit the options.

Figure 4-2 Zapi Handset

Table 4-2 Set Options

R6624

Parameter Factory Setting Description

TILLER switch HANDLE This option handles the input CNB#3 (Table 4-5). This input opens when the operator leaves the truck (released). It is connected to a Keyswitch controlled voltage when the operator is present.

SET INPUT #1 OPTION #1 (Standard Version only). This option handles the digital input CNA#15. It can be can be set as:

• OPTION #1: CNA is managed as a cutback speed input (SR#1).• OPTION #2: CNA is managed as a digital handbrake input.• OPTION #3: CNA is managed as an inching backward.The input CNA#15 (Table 4-5) can only be used as Aux Lowering

request when the MDIPRC is PRESENT.This input must be connected to a Keyswitch controlled voltage.The SR#1 becomes active when CNA#15 (Table 4-5) is open.The inching backward becomes active when the CNA#15 (Table 4-

5) is closed to a Keyswitch controlled voltage.

BL-WPT-0118 - 02-27-2018 4-5

Table 4-2 Set Options - Continued


SET INPUT #2 PRESENT It can be can be set as:• PRESENT: CNA#14 (Table 4-5) is managed as a cutback speed

input (SR#2).• OPTION #1: CNA#14 (Table 4-5) is managed as an inching back-

ward.The input CNA#14 (Table 4-5) can only be used as Aux Lifting

request when the MDIPRC is PRESENT.This input must be connected to a Keyswitch controlled voltage.The SR#2 becomes active when CNA#14 (Table 4-5) is open.The inching backward becomes active when the CNA#14 (Table 4-

5) is closed to a Keyswitch controlled voltage.

SET INPUT #4 OPTION #1 This option handles the digital input CNB#7 (Table 4-5). It can be can be set as:

• BELLY CNB#7 (Table 4-5) is managed as a Belly Switch input.• BRAKE CNB#7 (Table 4-5) is managed as service brake input.

This information can be used also to recognize when the operator is driving with a pressed pedal braking.

• EX.HYDRO: CNB#7 (Table 4-5) is managed as Exclusive Hydro.This input must be connected to a Keyswitch controlled voltage.The Belly switch active level is specified on the QUICK INV LOGIC

below.The service brake of the exclusive hydro becomes active when

CNB#7 is opened.

HOUR COUNTER RUNNING This option specifies the hour counter mode. It can be set as:• RUNNING: The counter registers travel time only.• key on: The counter registers when the keyswitch is closed.

BATTERY CHECK Level = 1 This option specifies the handling of the low battery charge detec-tion. It can be set as:

• Level 0: Nothing happens, the battery charge level is ignored.• Level 1: A BATTERY LOW alarm is raised when the battery level

is calculated being less than 10% of the full charge. A BATTERY LOW alarm inhibits the Lifting function.

• Level 2: A BATTERY LOW alarm is raised when the battery level is calculated being less than 10% of the full charge. A BATTERY LOW alarm reduces the maximum truck speed down to 24% of the full truck speed then, if the MDI-PRC is absent, inhibits the Lift-ing function.

• Level 3 Equivalent to Level 1; a BATTERY LOW alarm is raised when the battery level is calculated being less than 10% of the full charge. A BATTERY LOW alarm inhibits the Lifting function.

HYDRO KEY ON OFF ON/OFF: If this options is programmed ON the traction Inverter manages a hydraulic steering function when the keyswitch is switched ON (only if the AUX OUTPUT #1 option is programmed as HYDRO CONTACT or as WXCLUSIVE HYDRO).

STOP ON RAMP OFF Not used.

4-6 BL-WPT-0118 - 02-27-2018



AUX OUTPUT #1 BRAKE This option handles output CNA#3 (Table 4-5). It can be used as:• BRAKE: CNA#3 (Table 4-5) drives an electromechanical Brake.• HYDROCOMNT: CNA#3 (Table 4-5) drives the contractor for a

hydraulic steering function when the direction input or brake pedal input are active or a movement of the truck is detected.

• EX.HYDRO: CNA#3 (Table 4-5) drives the contractor for a hydrau-lic steering function when the exclusive hydro input is active.

• FREE: CNA#3 (Table 4-5) is not used.The current this output can sink is up to 3Adc.

PEDAL BRAKING NONE The analog input CNA#18 (Table 4-5) has one of two functions:• Pedal Braking input.• Command input for lifting/lowering proportional valves in MDI-

PRC version.To turn from the first to the second function is just enough to set

PEDAL BRAKING to HNONE.This option handles the analog input CNA#18 (Table 4-5) when

used as pedal braking input:• ANALOG: With this setting it is possible to modulate the strength

of the braking when the accelerator is released. The strength of the braking is proportional to the brake pedal potentiometer con-nected to this input. When the pedal potentiometer voltage is equal/less than the SET POT BRK MIN, the minimum release braking strength is applied (following the RELEASE BRAKING setting).When the pedal potentiometer voltage is equal/higher than the SET POT BRK MAX, the maximum release braking strength is applied (following the PEDAL BRAKING setting). In the intermedi-ate position, the electrical braking strength is a linear function between the minimum (RELEASED BRAKING) and maximum (PEDAL BRAKING) intensity. When there is also a switch con-nected to the pedal braking (i.e. SET INPUT #4 to level BRAKE), it must be closed, otherwise the release braking is stuck to the mini-mum strength disregarding the pedal potentiometer position.

• DIGITAL: No pedal potentiometer is expected. Only when both the SET INPUT #4 is Level BRAKE and the brake switch connected to CNB#4 (Table 4-5) is closed, the release electrical braking follows the PEDAL BRAKING setting (maximum strength); in all of the other conditions the release electrical braking follows the RELEASE BRAKING setting (minimum strength).

• NONE: The analog input CNA#18 (Table 4-5) is not used for the release braking modulation.

QUICK INVERSION BELLY This option specifies the quick inversion mode when the SET INPUT #4 is set BELLY. It can be set as:

• NONE: The quick inversion function is not managed (no effect when CNB#7 (Table 4-5) switches over).

• TIMED: The quick inversion function is timed.• BELLY: The quick inversion function is managed but not timed.


BL-WPT-0118 - 02-27-2018 4-7


AUX VOLTAGE #1 100% This option specifies the percentage of the keyswitch controlled voltage to be applied to the loads on CNA#1 (Table 4-5) (main contactor coil) and CNA#3 (Table 4-5) (electromechanical brake). The voltage modulation is set with a PWM at 1 kHz frequency. After an initial delay of about 1 sec in which the entire keyswitch controlled voltage is applied to the loads, the PWM reduces the voltage at the loads down to the specified percentage.

PERFORMANCE OPTION #1 This option can be set • OPTION#1• OPTION#2

QUICK INV. LOGIC OPTION #1 This option specifies the active level for the Belly switch input (CNB#7)

• OPTION#1: The quick inversion is executed when CNB#7 (Table 4-5) is closed to a Keyswitch controlled voltage.

• OPTION#2: The quick inversion is executed when CNB#7 (Table 4-5) is opened from a Keyswitch controlled voltage.

MDI-PRC ABSENT This option specifies:• PRESENT: The MDI-PRC is connected to the ACO via the CAN

Bus: the handling of the Hydraulics is specified on the TRUCK TYPE setting.

• ABSENT: The MDI-PRC is not connected to the ACO: the TRUCK TYPE disappears from the SET OPTIONS function list.

MOT SET-UP LOCK OFF Not used.

4-8 BL-WPT-0118 - 02-27-2018

4-2.4.2. Adjustments

To change an adjustment proceed as follows and referto Table 4-3:


2. Press the ROLL up button (1, Figure 4-3) and theSET up button (5) at the same time to enter theCONFIG MENU.

3. Press the ROLL down button (1) or the ROLL upbutton (2) to find the ADJUSTMENTS display.

4. Press the ENTER button (3) to view the adjust-ments.

5. Press the ROLL down button (2) or the ROLL upbutton (1) to find the adjustment to be changed.

6. Press the SET up button (5) or the SET down but-ton (6) until the desired value setting is reached.The adjustment is now set at the desired value.

7. Press the OUT button (4) to exit the adjustments.


Table 4-3 Adjustments

R6624


SET POT BRK MIN 0.5 V This setting records the minimum value of braking pedal potentiom-eter when the braking pedal switch is closed; the procedure is similar to the PROGRAM VACC function. This procedure must be carried out only if the PEDAL BRAKING option is programmed as ANALOG. No adjustment is necessary when PEDAL BRAKING options is programmed as NONE.

SET POT BRK MAX 4.5 V This setting records the maximum value of braking pedal potenti-ometer when the braking pedal is fully pressed; the procedure is similar to the PROGRAM VACC function. This procedure must be carried out only if the PEDAL BRAKING option is programmed as ANALOG. No adjustment is necessary when PEDAL BRAKING options is programmed as NONE.

SET BATTERY TYPE 24V Selects the nominal battery voltage.

ADJUST BATTERY XX V Do not modify - Factory adjusted (Fine adjustment of the battery voltage measured by the controller.)

THROTTLE 0 ZONE 9% Establishes a deadband in the accelerator input curve.

BL-WPT-0118 - 02-27-2018 4-9

Figure 4-4 Throttle Regulation

Table 4-3 Adjustments - Continued


THROTTLE X POINT 45% This parameter together with the THROTTLE Y POINT, changes the characteristic of the accelerator input curve: when the acceler-ator is depressed to X point percent, the corresponding truck speed is Y point percent of the Maximum truck speed. The rela-tionship between the accelerator position and the truck speed is linear between the THROTTLE 0 ZONE and the X point and also between the X point and the maximum accelerator position but with two different slopes (Figure 4-4).

THROTTLE Y POINT 68% This parameter together with the THROTTLE X POINT, changes the characteristic of the accelerator input curve: when the acceler-ator is depressed to X point percent, the corresponding truck speed is Y point percent of the Maximum truck speed. The rela-tionship between the accelerator position and the truck speed is linear between the THROTTLE 0 ZONE and the X point and also between the X point and the maximum accelerator position but with two different slopes (Figure 4-4).

ADJUSTMENT #01 LEVEL = 5 Adjust the upper level of the battery charge table (Level 0 to 9).

ADJUSTMENT #02 LEVEL = 5 Adjust the lower level of the battery charge table (Level 0 to 9).

LOAD HM FROM MDI

OFF When set On, the Hourmeter of the Controller is transferred and recorded on the Hourmeter of the Standard MDI (connected on the Serial Link).

CHECK UP DONE OFF Turn it On when asked Maintenance service has been executed to cancel the CHECK UP NEEDED warning.

CHECK UP TYPE NONE It specifies the handling of the CHECK UP NEEDED warning:• NONE: No CHECK UP NEEDED warning.• OPTION#1: CHECK UP NEEDED warning on the handset and

MDIPRC after 300 hours.• OPTION#2: Equal to OPTION#1 but Speed reduction after 340

hours.• OPTION#3: Equal to OPTION#2 but the truck definitively stops

after 380 hours.

R6642

4-10 BL-WPT-0118 - 02-27-2018

4-2.4.3. Parameter Change

To change a parameter proceed as follows and refer toTable 4-4:



3. Press the ROLL down button (1) or the ROLL upbutton (2) to find the PARAMETER CHANGE dis-play.

4. Press the ENTER button (3) to view the parame-ters.

5. Press the ROLL down button (2) or the ROLL upbutton (1) to find the parameter to be changed.

6. Press the SET up button (5) or the SET down but-ton (6) until the desired value setting is reached.The parameter is now set at the desired value.

7. Press the OUT button (4) to exit the parameters.


Table 4-4 Parameter Adjustments

R6624


ACCELER. DELAY LEVEL = 8 Level 0 to 9. It determines the acceleration ramp. At Level 9 the truck takes a long time to accelerate.

RELEASE BRAKING LEVEL = 5 Level 0 to 9. It controls the deceleration ramp when the travel request is released. At Level 9 the truck brakes abruptly.

INVERS. BRAKING LEVEL = 4 Level 0 to 9. It controls the deceleration ramp when the direction switch is inverted during travel. At Level 9 the truck brakes abruptly.

PEDAL BRAKING LEVEL = 9 Level 0 to 9. It controls the deceleration ramp when the travel request is released and the brake pedal switch is pressed to its maximum. At Level 9 the truck brakes abruptly.

SPEED LIMIT BRK LEVEL = 1 Level 0 to 9. It controls the deceleration ramp when the accelerator has turned down but not completely released. At Level 9 the truck decelerates abruptly.

BRAKE CUTBACK LEVEL = 5 Level 0 to 9. It controls the deceleration ramp when the a speed reduction input becomes active and the motor slows down. At Level 9 the truck decelerates abruptly.

MAX SPEED FORW 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed in forward direction.

MAX SPEED BACK 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed in backward direction.

BL-WPT-0118 - 02-27-2018 4-11

Table 4-4 Parameter Adjustments - Continued


CUTBACK SPEED 100% Typically from 10% to 100%. It determines the percentage of the max speed applied when the cutback switch 1 (SR#1 on CNA#15 (Table 4-5) is active. When set to 100% the speed reduction is ineffective.

CUTBACK SPEED 2 37% Typically from 10% to 100%. It determines the percentage of the max speed applied when the cutback switch 2 (SR#2 on CNA#14 (Table 4-5) is active. When set to 100% the speed reduction is ineffective.

HS CUTBACK 100% Typically from 10% to 100%. It determine the percentage of the max speed applied when the Hard & Soft function (H&S switch on CNB#4 (Table 4-5) is active. When set to 100% the speed reduc-tion is ineffective.

FREQUENCY CREEP

5.00 Hz Hz value. This is the minimum speed applied when the forward or reverse switch is closed, but the accelerator at its minimum. In the ACO sense Coils this setting is higher equal than 5 Hz.

RPM CREEP 100% A Percentage value. Set to 100% and not Used.

MAXIMUM CURRENT

96% It specifies the percentage of the absolute current (150A) at which the current will be limited. Normally MAXIMUM CURRENT is 100%. DO NOT CHANGE.

INCHING SPEED 0 Hz Hz value. It determines the speed when the “Inching function” is active.

INCHING TIME LEVEL = 0 Level 0 to 9. It determines the duration time when the “Inching func-tion” is active.

AUXILIARY TIME 1 Time units value (seconds). For the encoder version, it determines the time duration (in seconds) in which the frequency was arrived to zero.

ANTIROLLBACK 80% A Percentage of the Maximum Current. This setting increases the phase current when low frequency during starting operation. It is used to push up, in feedforward way, the torque when it is not possible to control the flux, in feedback way, because of the lowfrequency.

4-12 BL-WPT-0118 - 02-27-2018

Figure 4-6 Zapi Controller Connections

Table 4-5 Zapi Controller Connector Pins

CNA Connector

PIN ABBREVATION DESCRIPTION

CNA#1 NMC Negative of main contactor coil.

CNA#2 PMC Positive of main contactor coil.

CNA#3 NEB Output for driving the electromechanical brake coil; drives the load to -Batt. Maximum current: 3 A.

CNA#4 NPC Negative of pump contactor soil.

CNA#5 PPC/PEV Positive of pump contactor coil and lowering electrovalve coil.

CNA#6 NEV Negative of the lowering electrovalve coil.

CNA#7 CAN LOW Low level CAN-BUS voltage I/O.

CNA#8 -BAT -Bat.

CNA#9 ENC+ Encoder Positive Supply (+5 or +12 Vdc)

CNA#10 ENC- Encoder Negative Supply (GND to minus battery)

CNA#11 HM(+B) Output for driving an hourmeter; when the hourmeter is active this output provides a +Batt signal; 3 maximum current.

R6628

BL-WPT-0118 - 02-27-2018 4-13

Table 4-5 Zapi Controller Connector Pins - Continued

CNA Connector - Continued

PIN ABBREVATION DESCRIPTION

CNA#12 -BATT -Batt.

CNA#13 MOT TH Motor thermal sensor input. The internal pull-up is a fixed 2mA (Max 5V) source current.

CNA#14 SR2 Speed reduction 2 input. Active low (switch opened).

CNA#15 SR1 Speed reduction 1 input. Active low (switch opened).

CNA#16 +12V This output provides a +12V signal for the MDI PRC, it present; mA maximum current.

CNA#17 CAN HIGH High level CAN-BUS voltage I/O.

CNA#18 CPOTB Brake potentiometer wiper.

CNA#19 ENC A Encoder Channel A.

CNA#20 ENC B Encoder Channel B.

CNB Connector

CONNECTOR PIN

ABBREVATION DESCRIPTION

CNB#1 KEY SW Connected to the power supply through a microswitch (KEY) with a 6.3-10 A fuse in series (this could be mounted on the AC-0 cover).

CNB#2 CM Common for FW/BW/SR1/SR2/TILLER/H&S/BELLY/LIFTING/LOWERING microswitches. This connection supplies a keyswitch voltage level.

CNB#3 TILLER SW Tiller request input. Must be connected to the tiller microswitch, active high.

CNB#4 H&S SW Hard & Soft request input. Must be connected to the Hard & Soft microswitch, active high.

CNB#5 BACKWARD SW Backward direction request input. Must be connected to the back-ward direction microswitch, active high.

CNB#6 FORWARD SW Forward direction request input. Must be connected to the forward direction microswitch, active high.

CNB#7 BELLY SW Quick inversion function input; must be connected to the Belly microswitch; it is active high.

CNB#8 LOWERING SW Lowering request input, active high.

CNB#9 LIFTING SW Lifting request input, active high.

CNB#10 CPOT Lifting request input, active high.

CNB#11 NPOT Negative of accelerator unit, tested for wire disconnection diagnosis.

CNB#12 PPOT Potentiometer positive: 10V output; keep load >1k

4-14 BL-WPT-0118 - 02-27-2018

Table 4-5 Zapi Controller Connector Pins - Continued

CNC Connector

CONNECTOR PIN

ABBREVATION DESCRIPTION

CNC#1 PCLRXD Positive serial reception.

CNC#2 NCLRXD Negative serial reception.

CNC#3 PCLTXD Positive serial transmission.

CNC#4 NCLTXD Negative serial transmission.

CNC#5 GND Negative console power supply.

CNC#6 +12V Positive console power supply.

CNC#7 FLASH Must be connected to C8 for the Flash memory programming (if used).

CNC#8 FLASH Must be connected to C7 for the Flash memory programming (If used).

BL-WPT-0118 - 02-27-2018 4-15

NOTES

4-16 BL-WPT-0118 - 02-27-2018

SECTION 5STEERING ARM, CONTROL HEAD AND COMPARTMENT

5-1. CONTROL HEAD

5-1.1. Control Head Removal

1. Turn off the key switch and disconnect the batter-ies.

1. Remove the cap assembly as described in para-graph 5-1.3.

2. Disconnect harness from the control head.

Figure 5-1 Steering Arm

R6595A

BL-WPT-0118 - 02-27-2018 5-1

WARNING: When removing the control head in thefollowing steps, be sure to hold it in placeuntil the control harness is disconnected.

3. Remove two screws, two lock washers and twoflat washers.

4. Remove the control head.

5-1.2. Control Head Installation

1. Secure control head with two screws two lockwashers and two flat washers.

2. Connect harness to the control head.

3. Install the cap assembly as described in para-graph 5-1.4.

4. Reconnect the batteries and turn on the keyswitch.

Figure 5-2 Control Head

R6596A

5-2 BL-WPT-0118 - 02-27-2018

5-1.3. Cap Assembly Removal.


2. Remove four screws and lift up cap assembly (24)and disconnect harness from harness.

5-1.4. Cap Assembly Installation.

1. Hold cap assembly in place and connect harnessto harness.

2. Position cap assembly on control head andsecure with four screws.

3. Reconnect the batteries and turn on the keyswitch.

5-1.5. Belly-Button Switch Replacement.


2. Disconnect harness from switch assembly.

3. Remove two screws, two lock washers, and twoflat washers and remove switch assembly frombracket.

4. Remove pin, bracket, and spring from button.

5. Remove two pins and switch from bracket.

6. Position the new switch in bracket and securewith two pins.

Figure 5-3 Emergency Reverse Switch Assembly

R6754

BL-WPT-0118 - 02-27-2018 5-3

7. Position bracket in button and install pin.

8. Position switch assembly on bracket and securewith two screws, two lock washers, and two flatwashers.

9. Connect harness to switch assembly.


5-1.6. Horn Switch Replacement.


2. Remove three screws, bracket and spring.

3. Remove two pins and switch from bracket.

4. Position the new switch in bracket and securewith two pins .

5. Position bracket in cover and secure with threescrews .


Figure 5-4 Cap Assembly

R6753

5-4 BL-WPT-0118 - 02-27-2018

5-1.7. Lift and Lower Switch Replacement.


2. Remove pin and switch assembly from the cap

3. Remove two pins, two switches and four springsfrom bracket.

4. Disconnect the harness with switches from theswitch assembly.

5. Position the new switches and four springs inbracket and secure with two pins.

6. Position switch assembly in cover and secure withpin.


Figure 5-5 Left Lift/Lower Switch Assy (Right Similar)

R6753

BL-WPT-0118 - 02-27-2018 5-5

5-1.8. Speed Potentiometer Replacement.


2. Disconnect harness from potentiometer.

3. Remove screw, washer and control knob frompotentiometer.

4. Remove screw, washer and control knob fromother side of potentiometer.

5. Remove two screws, two lock washers and twoflat washers and remove potentiometer frombracket.

6. Position new potentiometer in bracket and securewith two screws, two lock washers and two flatwashers.

7. Install control knob on potentiometer and securewith screw, and washer.

8. Install control knob on the other side of potentiom-eter and secure with screw, and washer.

9. Connect harness to potentiometer.


5-2. STEERING ARM

5-2.1. Return Spring Replacement.

The steering arm gas return spring is replaced whilethe steering arm is in the upright position.

1. Remove the compartment covers as described inparagraph 5-3.

2. Secure the steering arm in the upright position.

3. Remove screw and free the gas return springfrom brake plate.

4. Pull downward on the gas return spring to free itfrom its seat inside steering arm.

5. Position the new gas return spring inside thesteering arm being sure it fully engages its seat.

6. Position the opposite end of the gas return springon brake plate and install screw.

7. Install the compartment covers as described inparagraph 5-3.

5-2.2. Steering Arm Removal.


2. Remove the brake as described in paragraph 6-1.3.

3. Disconnect harness from harness.

4. Attach a hoist to steering arm.

5. Remove screw, shaft and the steering arm.

5-2.3. Steering Arm Installation.

1. Position steering arm over the drive motor andsecure with shaft and screw.

2. Connect harness to harness.

3. Install the brake as described in paragraph 6-1.3.


5-3. COMPARTMENT COVERS

5-3.1. Removal.

1. Turn off the key switch and disconnect the batter-ies

2. Remove two screws and upper cover.

3. Remove screw.

4. Remove middle cover.

5. Remove screw

6. Pull the lower cover up and out.

5-3.2. Installation.

1. Position the lower cover on the frame and securewith screw.

2. Place middle cover around the brake and securewith screw.

3. Install upper cover and secure with two screws.

4. Reconnect the batteries and turn on the key-switch.

5-6 BL-WPT-0118 - 02-27-2018

SECTION 6BRAKE SERVICING

6-1. BRAKES.

The brake system consists of a drive motor mountedbrake. This brake is spring applied and electricallyreleased. Should it become necessary to move a deadtruck, the brake is equipped with an adjusting nut (Fig-ure 6-1) that may be manually loosened to release thebrake.

WARNING: Before returning the truck to operation,be sure to return the brake adjusting nutto its original position and check forproper braking function. Failure to returnadjusting nut to its original positionresults in truck having no braking ability.

6-1.1. Air Gap Adjustment.

The “air gap” is the distance between the magnet bodyand the rotor plate with the brake applied. As the brakepads and rotor wear normally, the air gap will increaseand should be readjusted when it measures more than0.25 mm.

NOTE: If the air gap measures more than 0.25 mm,the brake may not release properly. Air gapadjustment can be performed as long as thebrake pads and rotor function properly or untilthe adjustable spacer threads are fullyengaged (adjustment limit reached).

1. Block load wheels.


3. Using low pressure air, remove any dirt betweenarmatures and magnet body.

4. Using standard feeler gauges, check the gapbetween the magnet body and the rotor plate. Thegap should be 0.25 mm.

5. If necessary, refer to Figure 6-1 and adjust thegap as follows:

a. Loosen the three mounting screws by half aturn.

f. The threaded air gap adjusting nuts can thenbe screwed into Magnet Body by turningcounterclockwise.

g. Turn the three mounting screws clockwiseuntil the gap measures 0.012” (0.25 mm).

h. The threaded air gap adjusting nuts are thenscrewed clockwise until they bottom.

i. Finally tighten the three mounting screws to52 in-lb (6 Nm).

j. Recheck the gap.

11. Remove load wheel blocks and check operation.


Figure 6-1 Brake Assembly

R6625

BL-WPT-0118 - 02-27-2018 6-1

6-1.2. Stopping Distance Adjustment.

The stopping distance of the truck should require mini-mal adjustment. However, this distance should bechecked with each planned maintenance.

Using an unloaded truck, run truck to its top speed onan even dry concrete surface. Move control handleinto the lower braking position. Measure length ofbraking path from the actuation point of the brakesuntil the truck has stopped. The actual length of thebraking path should be between approximately 1.5 -2.5 ft (0.5-0.7 m).

To adjust stopping distance, proceed as follows:



3. Rotate the adjusting nut (Figure 6-1) clockwise toSHORTEN the stopping distance or counterclock-wise to LENGTHEN the stopping distance.



6-1.3. Brake Assembly Replacement



3. Disconnect electric brake from harness.

4. Remove the three mounting screws (Figure 6-1)and the brake.

5. Place the new brake into position and secure withthe three mounting screws.

6. Finally tighten the three mounting screws to 52 in-lb (6 Nm).

7. Reconnect electric brake from harness.



6-2 BL-WPT-0118 - 02-27-2018

SECTION 7TRANSMISSION, DRIVE WHEEL, LOAD WHEEL

7-1. Drive Wheel.



3. Loosen but do not remove the five nuts.

4. Jack up the truck so the drive wheel is off theground; then securely block the truck to preventmovement.

5. Remove the five nuts five washers and drivewheel from the transmission.

6. Install new drive wheel in reverse order ofremoval.



7-2. Transmission.




4. Remove the steering arm as described in para-graph 5-2.2.

5. Disconnect harness from drive motor.

6. Remove the drive motor as described in para-graph 10-4.1.

7. Remove the drive wheel as described in para-graph 7-1.

8. Support the transmission and remove the eightscrews, eight washers and eight flat washers.

9. Slowly lower the transmission out the bottom ofthe frame.

10. Install new transmission by reversing the stepsabove.

Figure 7-1 Transmission, Motor, Brake Assembly

R6601A

BL-WPT-0118 - 02-27-2018 7-1

7-3. Load Wheel.

7-3.1. Removal

1. Raise forks.


3. Block the drive wheel to prevent the truck fromrolling.

4. Jack up the forks to raise the load wheels off thefloor. Securely block the forks in the raised posi-tion by positioning supports under both fork tips.

NOTE: When shaft is removed, load wheel assemblywill drop free.

5. Remove pin securing shaft and remove shaft andload wheel assembly.

NOTE: Inspect the load wheel assembly. If the loadwheel is worn within 1/8" of the metal sleeve,or is cracked or damaged, replace the entireload wheel and bearing assembly. Big LiftLLC recommends that both load wheelassemblies be replaced at the same time.

This ensures level and safe operation of thelift truck.

7-3.2. Repair

6. Remove bearings from wheels.

7. Inspect bearings and replace if necessary.

8. Reassemble bearings in wheels.

7-3.3. Load Wheel Installation

1. Position load wheel assembly in wheel bracket.

2. Install shaft and secure with pin.

3. Remove blocking from under the truck.

4. Lower the forks.


Figure 7-2 Wheel Assembly

R6607

7-2 BL-WPT-0118 - 02-27-2018

SECTION 8ELEVATION SYSTEM SERVICING

8-1. GENERAL.

The elevation system includes the lift linkage, powersection and fork section.

8-2. LIFT LINKAGE

8-2.1. Removal

Refer to Figure 8-1 sheet 1 and 2 for the following pro-cedure.

1. Lift complete truck to height sufficient to permitaccess to lift linkage under forks. Provide blockingunder frame, the rear of fork frame and at tips ofthe forks.


3. Remove screw for link from each side of frame.

4. Support lower link and remove shaft from eachside of link. Lower linkto the floor.

5. Remove screw for pins from each side of forkframe.

6. Support both tension rods and remove shafts.

7. Remove tension rods with attached parts fromunder the fork.

8-2.2. Installation

1. Reverse the steps from 8-2.1

8-3. Power Section and Fork Section

8-3.1. Separating Power Section and Fork Section.

1. Support entire truck on separate blocks so thatfork frame can be fully supported when frame isremoved.



4. Remove the lift cylinder as described in para-graph 9-2.4.


6. Remove the steering arm as described in para-graph 5-2.2.

7. Remove the transmission as described in para-graph 7-2.

8. Attach a suitable hoist to frame.

9. Remove screw and shaft from frame.

10. Remove screw. Support link and remove shafts.Lower link to the floor.

11. Remove frame from fork frame.

8-3.2. Fork Frame Repair.

1. Removal of components mounted on the framemay be necessary to effect repairs/welding.

2. Inspect fork frame for broken welds and weld asnecessary.

3. Replace fork frame if forks have been bentseverely.

8-3.3. Carrier Frame Repair.

1. Removal of components mounted on the frame(20, Figure 8-1 Frame) may be necessary toeffect repairs/welding.

2. Inspect frame for broken welds and weld as nec-essary.

8-3.4. Mating Power Section and Fork Section.

1. With suitable hoist, carefully move frame intoposition.

2. Move link into position on frame and install shaft.Secure shaft with screw.

3. Raise link, install shafts and secure with screws.

4. Remove hoist from frame.

BL-WPT-0118 - 02-27-2018 8-1

Figure 8-1 Frame (Sheet 1)

R6605A

8-2 BL-WPT-0118 - 02-27-2018

Figure 8-1 Linkage (Sheet 2)

R6606A

BL-WPT-0118 - 02-27-2018 8-3

5. Install the transmission as described in paragraph7-2.

6. Install the steering arm as described in paragraph5-2.3.

7. Install the brake as described in paragraph 6-1.

8. Install the lift cylinder as described in paragraph9-2.4.



11. Remove the blocking from under the truck.

8-4 BL-WPT-0118 - 02-27-2018

SECTION 9HYDRAULIC SYSTEM SERVICING

9-1. LINES AND FITTINGS

WARNING: When forks are raised, pressure exists inthe hydraulic system lines and fittings. Toensure release of pressure, forks mustbe fully lowered and the batteries discon-nected before performing any mainte-nance on the hydraulic system.

NOTE: Leaking hydraulic fittings may be remedied bysimply tightening fittings. If this does not rem-edy the leak, the fittings or line must bereplaced.

1. Lower forks fully.



CAUTION: Hydraulic oil can damage parts. Wipe offany oil immediately. Provide a containerunder the line or fitting before discon-necting.

4. Refer to Figure 9-1 and remove leaking line or fit-ting and replace it with a new line or fitting.

5. Check level of hydraulic oil. Hydraulic oil must bebetween the two level marks on the reservoir. Ifrequired, add hydraulic oil to bring to proper level.Use hydraulic oil listed in Table 3-2.


7. Operate the lift and lower buttons to refill the cylinder and lines with hydraulic oil.



9-2. HYDRAULIC PUMP, MOTOR, AND RESER-VOIR ASSY

The hydraulic pump/motor assembly can be disas-sembled and repaired. However, a defective pump,valve or motor requires replacement of that compo-nent.

WARNING: When forks are raised, pressure exists inthe hydraulic system lines and fittings. Toensure release of pressure, forks mustbe fully lowered and the batteries discon-nected before performing any mainte-nance on the hydraulic system.

9-2.1. Removal




4. Tag and disconnect electrical leads from pump/motor assembly and solenoid.

NOTE: The reservoir and hose will be filled withhydraulic oil. Place a container under thepump assembly to catch any hydraulic oil.

5. Disconnect hose from pump/motor assembly.

6. While supporting the pump/motor assembly,remove two screws, two lock washers and two flatwashers.

7. Remove the pump/motor assembly with bracket.

8. Remove two screws, two lock washers, two flatwashers and bracket from pump/motor assembly.

BL-WPT-0118 - 02-27-2018 9-1

Figure 9-1 Hydraulic System

R6608A

9-2 BL-WPT-0118 - 02-27-2018

9-2.2. Disassembly and Reassembly

1. Remove the hydraulic pump/motor assembly asdescribed in paragraph 9-2.1.

2. Refer to Figure 9-2 for disassembly and reassem-bly.

9-2.3. Installation

1. Position bracket on pump/motor assembly andsecure with two screws, two lock washers and twoflat washers.

2. While supporting the pump/motor assembly,install two screws, two lock washers and two flatwashers.

3. Reconnect hose to pump/motor assembly.

4. Connect electrical leads to motor and solenoid.

5. Fill the hydraulic reservoir. Hydraulic oil must bebetween the two level marks on the reservoir. Usehydraulic oil listed in Table 3-2.





9-2.4. Lift Cylinder

9-2.4.1.Removal




4. Ensure that hydraulic pressure has been relievedfrom the lift circuit. Disconnect the hydraulic linefrom the lift cylinder.

5. Disconnect hose from cylinder.

6. Remove screw, lock washer, flat washer andspring plate securing the cylinder.

WARNING: Frame is heavy. Use care while securingand lifting in order to prevent injury.

7. With suitable hoist, carefully raise frame slightlyso the cylinder can be removed.

Figure 9-2 Pump and Motor Assembly

R6609

BL-WPT-0118 - 02-27-2018 9-3

9-2.4.2.Repair

1. Secure the lift cylinder in a vise, clamping lightlyat the base of the cylinder.

2. Withdraw the cylinder rod from the cylinder.

NOTE: If the cylinder tube or piston rod are dam-aged, the entire lift cylinder must be replaced.

3. Replace guide rings, seal ring and wiper ring

4. Coat all parts with hydraulic oil.

5. Insert piston rod (5), with attached parts, into cyl-inder tube (1).

9-2.4.3.Installation

1. Position the cylinder on frame. Then lower theframe onto the cylinder.

2. Reconnect the hose to cylinder with new O-ring.

3. Fill the hydraulic reservoir. Hydraulic oil must bebetween the two level marks on the reservoir. Usehydraulic oil listed in Table 3-2.





Figure 9-3 Lift Cylinder

R6610

9-4 BL-WPT-0118 - 02-27-2018

SECTION 10ELECTRICAL COMPONENTS

10-1.ELECTRICAL CONTROL PANEL

10-1.1.Maintenance

NOTE: Erratic operation of the truck may be causedby defective controller components. Beforeremoving the electrical panel, perform trou-bleshooting procedures per SECTION 4, todetermine corrective action to be taken.

There are no user-serviceable parts inside the control-ler. No attempt should be made to open the controller.Opening the controller may damage it and will void thewarranty.

The controller is programmed at the factory specifi-cally for the truck model on which it is equipped. It isimportant to replace the controller with the correct pre-programmed unit to assure proper performance set-tings intended for that particular truck. See Figure 12-17 for the preprogrammed controller number.

It is recommended that the controller exterior becleaned periodically, and if a Zapi Handset is avail-able, this periodic cleaning provides a good opportu-nity to check the controller’s diagnostic history file. It isalso recommended that the controller’s fault detectioncircuitry be checked whenever the vehicle is serviced.

10-1.2.Cleaning



3. Remove any dirt or corrosion from the bus bararea. The controller should be wiped clean with amoist rag. Allow it to dry before reconnecting thebattery.

4. Make sure the connections to the buss bars aretight. Use two well insulated wrenches for thistask in order to avoid shorting across the bussbars.

10-1.3.Panel Removal.



3. Tag and disconnect all electrical cables whichconnect to the control panel (1).

4. Remove two screws (4), two lock washers (3), twoflat washers (2), horn (14) and control panel (1).

10-1.4.Panel Disassembly.

Refer to Figure 10-2 for location and identity of themajor replacement components mounted on the paneland remove defective parts.

NOTE: Contactor is not repairable and must bereplaced if defective.

10-1.5.Panel Installation.

1. Install the control panel and secure with twoscrews, two lock washers, two flat washers andhorn.

2. Connect all electrical cables to the control panelas noted during removal.



BL-WPT-0118 - 02-27-2018 10-1

Figure 10-1 Electrical System

R6478

R6611A

10-2 BL-WPT-0118 - 02-27-2018

10-2.HORN REPLACEMENT



3. Tag and disconnect all electrical connections fromhorn.

4. Remove screw, lock washer, flat washer, andhorn.

5. Install horn and secure with screw, lock washer,flat washer.



Figure 10-2 Electrical Panel

R6478

R6612A

BL-WPT-0118 - 02-27-2018 10-3

10-3.PUMP MOTOR.

The pump motor is replaceable but not repairable.Refer to paragraph 9-2.

10-4.DRIVE MOTOR.

The drive motor exposed surfaces should be cleanedat least once a month to assure proper cooling ofmotor. Use an air hose to blow dust off of motor sur-faces.

10-4.1.Motor Removal


2. Note routing of cables to ensure proper installa-tion.

3. Tag the cables connected to the drive motor; thendisconnect these cables from the drive motor.

4. Remove the eight screws, eight lock washersand eight flat washers.

5. Lift motor from transmission.

6. Remove nut, gear, and key from the motor .

10-4.2.Motor Repair

1. Refer to Figure 10-4 for motor disassembly.

10-4.3.Motor Installation

1. Position key and gear on the shaft of motor andsecure with nut.

2. Install drive motor on transmission. Make sure toalign the gears.

3. Reinstall eight screws, eight lock washers andeight flat washers.

4. Position cables as noted in removal and recon-nect the cables to the drive motor.

5. Reinstall the brake as described in paragraph 6-1.3.

6. Remove nut, gear, and key from the motor .


R6601A

10-4 BL-WPT-0118 - 02-27-2018

Figure 10-4 Drive Motor

R6478

R6767

BL-WPT-0118 - 02-27-2018 10-5

10-5.LIFT LIMIT SWITCH

10-5.1.Replacement

1. Disconnect wiring from the lift limit switch.

2. Remove the two screws, two lock washers, flatwashers, mounting plate and switch.

3. Remove the two screws, two nuts and mountingplate from switch.

4. Position the new switch on mounting plate andsecure with two screws and two nuts.

5. Position bracket on the frame and secure with twoscrews, two lock washers, flat washers.

6. Adjust the switch as described in paragraph 10-5.2.

10-5.2.Adjustment

1. Raise the forks until switch is aligned with thedetent on the frame.

2. The detent should trigger the lift limit switch andstop the hydraulic pump and motor.

3. If necessary, loosen screws and adjust mountingplate.

4. Tighten screws and recheck.

10-6.DEADMAN SWITCH

10-6.1.Replacement

1. Disconnect harness from the deadman switch.

2. Remove the two screws, and switches frombracket.

3. Position the new switches on bracket and securewith the two screws.

4. Reconnect harness to the deadman switch.

10-6 BL-WPT-0118 - 02-27-2018

SECTION 11OPTIONAL EQUIPMENT

11-1.LOAD BACKREST.

A load backrest is available for addition to the lift truckto allow handling of high loads.

11-2.CASTERS

Casters provide for additional stability. Installation ofthe casters is shown in Figure 12-7 and repair parts asshown in Figure 12-9 or Figure 12-10.

BL-WPT-0118 - 02-27-2018 11-1

NOTES

11-2 BL-WPT-0118 - 02-27-2018

SECTION 12ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the WPT 45 Lift Truck.

BL-WPT-0118 - 02-27-2018 12-1

Figure 12-1 Steering Arm

R6595A

12-2 BL-WPT-0118 - 02-27-2018

Steering Arm

Pos. # Part Number Description Qty. Reqd. Notes

1 1120-340000-00-B CONTROL HEAD ASSEMBLY 1

2 1146-330000-30 STEERING ARM 1

3 1120-320000-00 GAS SPRING ASSEMBLY 1

4 0000-000322-00 SCREW M8×25 1

5 1120-300003-00 SHAFT 1

6 0000-000029-00 BUSHING 2

7 0000-000032-00 SCREW M6×25 1

8 1120-300005-00 BRACKET 1

9 0000-000429-00 SCREW M5×8 1

10 0000-000030-00 SCREW M10×16 1

11 1120-300007-00 BRACKET 1

12 0000-000117-00 SCREW M5×10 1

13 0000-000206-00 LOCKWASHER Ø5 3

14 0000-000390-00 FLATWASHER Ø5 2

15 0000-000004-00 SCREW M5×12 2

16 1120-300004-00 FIXED PLATE 1

17 1120-300001-0A BRAKE BASE 1

18 1120-300006-00 BRACKET 1

19 0000-000088-00 SCREW M4×8 2

20 0000-000122-00 LOCKWASHER Ø4 3

21 0000-000377-00 SCREW M2×20 2

22 0000-000378-00 SCREW M4×16 1

23 0000-000702-00 FLATWASHER Ø4 1

24 0000-000491-00 PLASTIC RING 1

25 0000-000209-00 NUT M4 1

26 0000-000109-00 SCREW M8×16 3

27 0000-000159-00 LOCKWASHER Ø8 3

28 2112-520004-0C WIRING HARNESS 3 PIN 1

29 2112-520003-0C WIRING HARNESS INCLUDING SWITCHES 1

30 0000-000010-00 SCREW M5×6 1

31 0000-000490-00 LINE CLAMP 1

32 1220-560001-00 SWITCH 2

BL-WPT-0118 - 02-27-2018 12-3

Figure 12-2 Control Head

R6596A

12-4 BL-WPT-0118 - 02-27-2018

Control Head


1 1120-342000-00-B CAP ASSEMBLY 1

2 1120-340005-00 CONTROL KNOB 1

3 0000-000038-00 LOCKWASHER Ø3 2

4 0000-000037-00 SCREW M3×12 2

5 0000-000004-00 SCREW M5×12 2

6 0000-000206-00 LOCKWASHER Ø5 4

7 0000-000390-00 FLATWASHER Ø5 4

8 0000-000088-00 SCREW M4×8 2

9 0000-000122-00 LOCKWASHER Ø4 2

10 0000-000702-00 FLATWASHER Ø4 2

11 0000-000322-00 SCREW M8×25 2

12 0000-000159-00 LOCKWASHER Ø8 2

13 0000-000176-00 FLATWASHER Ø8 2

14 1120-340003-00 CONTROL KNOB 1

15 1120-343000-00-B REVERSE BUTTON 1

16 0000-000004-00 SCREW M5×12 2

17 0000-000035-00 SCREW M5×20 4

18 1120-340002-00 COVER 1

19 1120-341000-00 HANDLE 1

20 1120-340001-00 CONNECTOR BRACKET 1

21 1220-520008-0C ACCELERATOR ASSEMBLY 1

22 0000-000010-00 SCREW M5×6 1

BL-WPT-0118 - 02-27-2018 12-5

Figure 12-3 Cap Assembly

R6753

12-6 BL-WPT-0118 - 02-27-2018

Cap Assembly


1 1120-342001-00 UPPER COVER 1

2 1120-342203-00 BUTTON FOR LOWERING(R) 1

3 1120-342202-00 BUTTON FOR LIFTING(R) 1

4 1120-342102-00 SPRING 8

5 1120-342201-00 BUTTON BRACKET(R) 1

6 1120-342105-00 PIN 6

7 1120-342104-00 BUTTON FOR LIFTING(L) 1

8 1120-342103-00 BUTTON FOR LOWERING(L) 1

9 1120-342101-00 BUTTON BRACKET (L) 1

10 1120-342300-00 HORN BUTTON ASSEMBLY 1

11 0000-000039-00 SCREW ST3.5×9.5 6

12 0000-000490-00 HARNESS CLAMP 3

13 1120-342200-00 LIFT AND LOWER BOX(R) ASSEMBLY 1

14 1120-342100-00 LIFT AND LOWER BOX(L) ASSEMBLY 1

15 1220-520006-0C BUTTONS ASSEMBLY 3

16 1220-560002-00 INCHING SWITCH II 5

17 1120-342002-00 HORN BUTTON 1

18 1120-342005-00 PIN 2

19 1120-342003-00 SPRING 2

20 1120-342004-00 BUTTON BRACKET 1

BL-WPT-0118 - 02-27-2018 12-7

Figure 12-4 Emergency Reverse Switch Assembly

R6754

12-8 BL-WPT-0118 - 02-27-2018

Emergency Reverse Switch Assembly


1 1120-343002-00 BUTTON REVERSER 1

2 1120-343003-00 SPRING 2

3 1120-342005-00 PIN 2

4 1120-343001-0A BRACKET 1

5 1120-343004-00 PIN 1

6 1220-520005-0C REVERSING SWITCH WIRE 1

7 1220-560002-00 INCHING SWITCH II 1

BL-WPT-0118 - 02-27-2018 12-9


R6601A

12-10 BL-WPT-0118 - 02-27-2018

Transmission, Motor, Brake Assembly


1 0000-000027-00 SCREW M6×55 3

2 1120-210000-00 BRAKE ASSEMBLY 1 Used up to Serial # 325130008

2a 1120-210000-10 BRAKE ASSEMBLY 1Used from Serial # 325130009

(With Brake Releases)

3 1120-220000-00 MOTOR ASSEMBLY 1

4 0000-000154-00 SCREW M8×35 8

5 0000-000159-00 LOCKWASHER Ø8 8

6 0000-000176-00 FLATWASHER Ø8 8

7 0000-000155-00 SCREW M10×40 6

8 0000-000063-00 LOCKWASHER Ø10 6

9 0000-000007-00 FLATWASHER Ø10 6

10 1120-230000-00 BEARING 1

11 0000-000013-00 GREASE FITTING M8 1

12 1120-240000-00 GEAR BOX,GK10-2 1

Serviceable Gear Box (for internal parts contact Big Lift) Used on trucks with Serial #’s:

E1914041-52, E1915010, E1915022, E1915023, E1915034, E1916003, E1916005 - E1916008, E1916010, E1916017-E1916028, E1916049 - E1916051, E1916053, E1916055, E1916058, E1916061, E1916063, E1918022, E1918023

E1918076 - E1918083, E1919001, E1919002, E1919006 - E1919019

12a 1120-240014-01 GEAR 1Used with Gear Box

1120-240000-00, 25 teeth

12b 0000-000389-00 OUTPUT SHAFT SEAL 1Used with Gear Box

1120-240000-00

12c 1120-240000-10 GEAR BOX, ZF,GK10 1

NO LONGER USED. It was used from Serial # E1919020 to E2214515 (It’s Non Serviceable)

Replace with Part # 1120-240000-30 Gearbox and the

gear set part # 1120-GB30-00

12d 1120-240014-00 GEAR ZF 1Used with Gear Box

1120-240000-10, 31 teeth

12e 1120-240000-30 GEAR BOX III,GK10-3 1Serviceable

Used from Serial # E2214516

13 1120-200001-00 DRIVE WHEEL POLY 1

13a 1120-200001-20 DRIVE WHEEL-POLY TRACTION 1Traction Drive Wheel, Poly

(Diamond X Siped)

13b 506161-11 DRIVE WHEEL-RUBBER 1Non Marking Rubber, Diamond-X (Traction)

14 0000-000025-00 LOCKWASHER Ø12 5

15 0000-000157-00 NUT M12 5

15a 0000-001131-10 NUT M12×1.5 5 For 1120-240000-10, pos 12b

16 0000-000070-00 SCREW M10×25 2

17 1120-210002-00 BRAKE LINING 1

18 1120-240014-30 STUDS 5

18a 4230-210001-00 STUDS 5 For 1120-240000-10, pos 12b

BL-WPT-0118 - 02-27-2018 12-11

Figure 12-6 Transmission - For Serial Numbers: E1914041-52, E1915010, E1915022, E1915023, E1915034, E1916003, E1916005 - E1916008, E1916010, E1916017-E1916028, E1916049 - E1916051, E1916053, E1916055, E1916058, E1916061, E1916063,

E1918022, E1918023 E1918076 - E1918083, E1919001, E1919002, E1919006 - E1919019

CW_0030

12-12 BL-WPT-0118 - 02-27-2018

Transmission - For Serial Numbers:

E1914041-52, E1915010, E1915022, E1915023, E1915034, E1916003, E1916005 - E1916008, E1916010, E1916017-E1916028, E1916049 - E1916051, E1916053, E1916055, E1916058, E1916061, E1916063, E1918022, E1918023 E1918076 - E1918083, E1919001,

E1919002, E1919006 - E1919019


1 1120-240012-00 GEAR CASE 1

2 1120-240007-00 WASHER 1

3 0000-000497-00 BEARING 1

4 0000-000389-00 SEAL WASHER TC52×80×8 1

5 1120-240011-00 FLANGE 1

6 1120-240015-00 BOLT 5

7 0000-000157-00 NUT M12 5

8 0000-000200-00 BEARING 1

9 1120-240003-00 GEAR 1

10 1120-240017-00 WASHER 1

11 1120-240004-00 WASHER 1

12 0000-000285-00 BOLT M12×35 1

13 1120-240009-00 WASHER 1

14 1120-240010-00 GEAR 1

15 1120-240018-00 BEARING 1

16 1120-240002-00 GEAR 1

17 1120-240019-00 WASHER 1

18 1120-240020-00 WASHER 1

19 1120-240016-00 NUT 1

20 1120-240014-00 GEAR 1

21 1120-240001-00 TOP COVER 1

22 0000-000211-00 O-RING 150×3.1( 1

23 0000-000055-00 SCREW M6×16 12

24 1120-240013-00 GAS PLUG 1

25 1120-240008-00 COVER 1

26 0000-000214-00 O-RING 135×3.1 1

27 1120-240021-00 SEAL WASHER 2

28 1120-240006-00 PLUG 1

29 0000-000417-00 PLUG M14×1.5 1

30 0000-000025-00 LOCKWASHER Ø12 5

BL-WPT-0118 - 02-27-2018 12-13

Figure 12-7 Transmission - Used from Serial # E2214516

R6601B

12-14 BL-WPT-0118 - 02-27-2018

Transmission - Used from Serial # E2214516


-- 1120-240000-30 GEAR CASE ASSEMBLY 1 Includes pos. # 1-24

1 1120-240001-30 GEAR CASE 1

2 1120-240002-30 PLUG 1

3 0000-000214-00 O-RING 135×3.1 1

4 1120-240003-30 COVER 1

5 0000-000056-00 LOCKWASHER Ø6 12

6 0000-000259-00 BOLT M6×16 8

7 1120-240019-30 WASHER A.R. As Required

8 0000-000961-00 BEARING 2

9 1120-240005-30 PLUG 1

10 1120-GB30-10 GEAR SET 1 This includes 2 gears

11 1120-240007-30 WASHER 1

12 1120-240008-30 LOCKING PLATE 1

13 0000-000277-00 BOLT M8×25 3

14 0000-001054-00 BEARING 30204 2

15 1120-GB30-00 GEAR SET 1 This includes 2 gears

16 0000-000379-00 FLATWASHER Ø14 1

17 0000-001055-00 WASHER Ø14 1

18 0000-001056-00 NUT M14×1.5 1

19 0000-000211-00 O-RING 150×3.1 1

20 1120-240010-30 COVER 1

21 1120-240011-30 GAS PLUG 1

22 0000-000055-00 SCREW M6×16 4

23 1120-240017-30 SEAL WASHER TC80×65×8 1

24 1120-240013-30 OUTPUT SHAFT 1

BL-WPT-0118 - 02-27-2018 12-15

Figure 12-8 Compartment

R6603A

12-16 BL-WPT-0118 - 02-27-2018

Compartment


1 1120-140000-00 CASTER ASSEMBLY 2 Used up to Serial # E2210274

1a 1118-140000-00 CASTER ASSEMBLY 2 Used from Serial # E2210275

2 0000-000176-00 FLATWASHER Ø8 8

3 0000-000159-00 LOCKWASHER Ø8 8

4 0000-000151-00 SCREW M8×25 8

5a 1120-150003-0A LOWER COVER 1

Standard from Serial # E2221902 and can be used on older trucks without any modification. It has an extra hole at the bottom that will not be used on older trucks.

6 1120-150002-00 MIDDLE COVER 1

7 1120-150001-00 UPPER COVER 1 Used up to Serial # 326110854

7a 1146-151001-30 UPPER COVER 1 Used from Serial # 326110855

8 1120-150004-00 SCREW M6×25 2

9 0000-000126-00 SCREW M6×16 2

10 2214-150002-00 WASHER 2

11 1220-150005-00 NUT M8 1 Used from Serial # E2221902

12 0000-000649-00 SCREW M8×20 1 Used from Serial # E2221902

13 1120-150005-00 INSERT PIECE 1

14 1146-151002-30 MANUAL HOLDER 1

Used from Serial # 32611085515 0000-000119-00 SCREW M5×12 4

16 0000-000546-00 NUT M5 4

BL-WPT-0118 - 02-27-2018 12-17

Figure 12-9 Caster Wheel (Optional) - Used up to Serial # E2210274

R6604A

12-18 BL-WPT-0118 - 02-27-2018

Caster Wheel (Optional) - Used up to Serial # E2210274


-- 1120-140000-00 CASTER ASSEMBLY 1Used up to Serial # E2210274

- 2 per truck needed.

1 1120-140002-00 SCREW M10×25 1

2 1120-140001-00 CASTER HOUSING 1

3 0000-000164-00 BEARING 1

4 0000-000178-00 BEARING 1

5 1120-141000-00 CASTER RIG 1

6 0000-000709-00 BOLT M10×95 1

7 1120-140003-00 RUBBER 1

8 1120-142000-00 WHEEL BRACKET 1

9 0000-000495-00 BOLT M12×85 1

10 1120-143001-00 SHAFT 1

11 0000-000020-00 BEARING 2

12 1120-143003-00 CASTER WHEEL 1

13 0000-000057-00 NUT M12 1

14 1120-140004-00 SPRING 1

15 0000-000174-00 NUT M10 1

16 0000-000426-00 NUT M10 1

17 0000-000175-00 FLATWASHER Ø10 1

18 0000-000296-00 RETAINER PIN Ø2×20 1

19 0000-000172-00 FLATWASHER Ø20 2

20 0000-000222-00 FLATWASHER Ø12 1

21 0000-000060-00 LOCK WASHER Ø12 1

22 0000-000071-00 FLATWASHER Ø10 1

23 0000-000063-00 LOCK WASHER Ø10 1

BL-WPT-0118 - 02-27-2018 12-19

Figure 12-10 Caster Wheel (Optional) - Used from Serial # E2210275

R6604B

12-20 BL-WPT-0118 - 02-27-2018

Caster Wheel (Optional) - Used from Serial # E2210275


-- 1118-140000-00 CASTER ASSEMBLY 1Used from Serial # E2210275-

2 per truck needed.

1 0000-000985-00 SCREW M10×20 1

2 1118-140003-00 PLATE 1

3 1118-140001-00 CASTER SUPPORT 1

4 0000-000986-00 BEARING 1

5 1118-140002-00 CASTER SUPPORT 1

6 0000-000168-00 BOLT M10×90 1

7 1120-140003-00 RUBBER BLOCK 1

8 1120-142000-00 WHEEL BRACKET 1

9 0000-000495-00 BOLT M12×85 1

10 1120-143001-00 SHAFT 1

11 0000-000020-00 BEARING 2

12 1120-143003-00 PU WHEEL 1

13 0000-000426-00 NUT M10 1

14 1120-140004-00 SPRING 1

15 0000-000987-00 ELASTIC COLLAR Φ80 1

16 0000-000165-00 NUT M12 1

17 0000-000063-00 LOCKWASHER Ø10 1

18 0000-000007-00 FLATWASHER Ø10 1

19 0000-000435-00 FLATWASHER Ø20 2

20 0000-000060-00 LOCKWASHER Ø12 1

BL-WPT-0118 - 02-27-2018 12-21

Figure 12-11 Frame

R6605A

12-22 BL-WPT-0118 - 02-27-2018

Frame


1 0000-000055-00 SCREW M6×16 8

2 0000-000056-00 LOCKWASHER Ø6 8

3 1120-134000-0A PIN 2

4 0000-000014-00 GREASE FITTING M8 2

5 0000-000016-00 SCREW M6×8 7

19 1144-110000-00-02 FORK FRAME 27” X 45” 1Fork width (8” Battery Box):

27” (685mm) x 45” (1150mm)

19a 1144-110000-00-04 FORK FRAME 27” X 48” 1Fork width (8” Battery Box):

27” (685mm) x 48” (1220mm)

19b 1144-110000-00-05 FORK FRAME 27” X 36” 1Fork width (8” Battery Box): 27” (685mm) x 36” (850mm)

19c 1144-110000-00-09 FORK FRAME 27” X 45” (WITH ENTRY ROLLERS) 1Fork width (8” Battery Box):

27” (685mm) x 45” (1150mm) (With Entry Rollers)

19d 1144-110000-10-02 FORK FRAME 21” X 45” 1Fork width (8” Battery Box):

21” (540mm) x 45” (1150mm)

19e 1144-110000-10-04 FORK FRAME 21” X 48” 1Fork width (8” Battery Box):

21” (540mm) x 48” (1220mm)

19f 1144-110000-10-05 FORK FRAME 21” X 36” 1Fork width (8” Battery Box): 21” (540mm) x 36” (850mm)

19g 1144-110000-10-09 FORK FRAME 21” X 45” (WITH ENTRY ROLLERS) 1Fork width (8” Battery Box):


19h 1146-110000-00-01 FORK FRAME 27” X 45” 1Fork width (9” Battery Box):

27” (685mm) x 45” (1150mm)

19i 1146-110000-00-02 FORK FRAME 27” X 36” 1Fork width (9” Battery Box): 27” (685mm) x 36” (850mm)

19j 1146-110000-00-06 FORK FRAME 27” X 45” (WITH ENTRY ROLLERS) 1Fork width (9” Battery Box):


19k 1146-110000-10-01 FORK FRAME 21” X 45” 1Fork width (9” Battery Box):

21” (540mm) x 45” (1150mm)

19l 1146-110000-10-02 FORK FRAME 21” X 36” 1Fork width (9” Battery Box): 21” (540mm) x 36” (850mm)

19m 1146-110000-10-06 FORK FRAME 21” X 45” (WITH ENTRY ROLLERS) 1Fork width (9” Battery Box):


19n 1144-110000-20-04 FORK FRAME 18” X 36” 1Fork width (8” Battery Box): 18” (460mm) x 36” (850mm)

19o 1146-110000-20-01 FORK FRAME 18” X 36” 1Fork width (9” Battery Box): 18” (460mm) x 36” (850mm)

19p 1144-110000-00-08 FORK FRAME 27” X 60” 1Fork width (8” Battery Box):

27” (685mm) x 60” (1450mm) - Fork length is really 57"

19q 1144-110000-10-08 FORK FRAME 21” X 60” 1Fork width (8” Battery Box):


19r 1146-110000-00-05 FORK FRAME 27” X 60” 1Fork width (9” Battery Box):


19s 1146-110000-10-05 FORK FRAME 21” X 60” 1Fork width (9” Battery Box):


BL-WPT-0118 - 02-27-2018 12-23

Figure 12-11 Frame - Continued

R6605A

12-24 BL-WPT-0118 - 02-27-2018

Frame - Continued


20 1145-120000-00 TRUCK FRAME 1For Fork Width:

21” (540mm) and 27” (685mm)

20a 1146-120000-20 TRUCK FRAME 1For Fork Width:

18” (460mm)

22 SEE POS. # 35 LOAD BACKREST 1 SEE POS. # 35

23 0000-000373-00 FLATWASHER Ø12 4

24 0000-000060-00 LOCKWASHER Ø12 4

25 0000-000228-00 BOLT M12×25 4

27 0000-000177-00 SCREW M8×12 2

28 1145-101003-00 BOLT 3

29 1145-101002-00 ROLLER 3

30 1145-101001-00 ROLLER BRACKET 1

31 0000-000278-00 BOLT M8×30 4

32 0000-000159-00 LOCKWASHER Ø8 4

33 1144-171004-00 PLATE 2

34 0000-000196-00 NUT M8 4

35 1144-170000-00 LOAD BACKREST 48” TALL 1 (1248mm)

35a 1144-170000-10 LOAD BACKREST 60” TALL 1 (1552mm)

36 0000-000176-00 FLATWASHER Ø8 4

BL-WPT-0118 - 02-27-2018 12-25

Figure 12-12 Linkage - Used up to serial number E2115502

R6606A

12-26 BL-WPT-0118 - 02-27-2018

Linkage - Used up to serial number E2115502


1 0000-000055-00 SCREW M6×16 8

2 0000-000056-00 LOCKWASHER Ø6 8

5 0000-000016-00 SCREW M6×8 7

6 1120-130001-00 LINK 1

7 1120-130002-0A PIN 1

8 0000-000011-00 BUSHING 22

9 1120-132000-1A LONG LINK - FORK LENGTH 45” AND 48” 1Used with 8” Battery Box and With or Without Entry Rollers

9a 1120-132000-5A LONG LINK - FORK LENGTH 36” 1Used with 8” Battery Box and With or Without Entry Rollers

9b 1146-132000-0A LONG LINK - FORK LENGTH 45” AND 48” 1Used with 9” Battery Box and With or Without Entry Rollers

9c 1146-132000-1A LONG LINK - FORK LENGTH 36” 1Used with 9” Battery Box and With or Without Entry Rollers

10 1220-133000-10 LOWER LINK - FOR FORK WIDTH 27” 1

10a 1220-133000-00 LOWER LINK - FOR FORK WIDTH 21” 1

10b 1146-133000-20 LOWER LINK - FOR FORK WIDTH 18” 1

11 1120-130004-00 PIN 2

Used on trucks before April 2011 and with Serial #:

E2012166, E2012172-173-174-175-176-177, E2012182,

E20120183, E20120185, E2012188, E2012155

11a 1120-135000-00 PIN 2

12 0000-000013-00 GREASE FITTING M8 2

13 1120-131000-0A PIN 2

14 1120-130006-0A PIN 4

15 1120-130007-0A PIN 2

16 1120-130008-00 WHEEL BRACKET 2 Used up to Serial # E2018193

16a 1120-130008-0A WHEEL BRACKET 2 Used between Serial # E2018194 and E2115502

17 0000-000015-00 SCREW M6X10 2 Used up to Serial # E2018193

17a 0000-000414-00 PIN 6×50 2 Used between Serial # E2018194 and E2115502

18 1120-133000-10 LOAD WHEEL ASSEMBLY - SINGLE WHEEL 2 Single Wheel

21 1120-130010-10 SHAFT - WITH SET SCREW 2Used up to Serial # E2018193

(With Set Screw)

21a 1120-130010-1A SHAFT - WITH ROLL PIN 2Used between Serial #

E2018194 and E2115502 (With Roll Pin)

26 1120-100005-10 PLATE 1

37 0000-001034-00 BUSHING 4

38 0000-000012-00 GREASE FITTING M8 9

BL-WPT-0118 - 02-27-2018 12-27

Figure 12-13 Linkage - Used from serial number E2115503

R8485

12-28 BL-WPT-0118 - 02-27-2018

Linkage - Used from serial number E2115503


1 0000-000055-00 SCREW M6×16 6

2 0000-000056-00 LOCKWASHER Ø6 8

5 0000-000016-00 SCREW M6×8 11

6 1120-130001-00 LINK 1

7 1120-130002-0A PIN 1

8 0000-000011-00 BUSHING 10

9 1221-132000-00-03 LONG LINK ASSEMBLY- FORK LENGTH 45” AND 48” 2

9a 1221-132000-00-01 LONG LINK ASSEMBLY- FORK LENGTH 36” 2

9b 1221-132000-00-05 LONG LINK ASSEMBLY- FORK LENGTH 60” 2

10 1220-133000-10 LOWER LINK - FOR FORK WIDTH 27” 1

10a 1220-133000-00 LOWER LINK - FOR FORK WIDTH 21” 1

10b 1146-133000-20 LOWER LINK - FOR FORK WIDTH 18” 1

11 1120-135000-00 PIN 2

12 0000-000013-00 GREASE FITTING M8 2

13 1120-131000-0A PIN 2

14 1120-130006-0A PIN 4

15 1120-130007-0A PIN 2

16 1120-130008-0A WHEEL BRACKET 2

17 0000-000414-00 PIN 6×50 2

18 1120-133000-10 SINGLE LOAD WHEEL 4

21 1120-130010-1A PIN 2

26 1120-100005-10 PLATE 1

37 0000-001034-00 BUSHING 16

38 0000-000012-00 GREASE FITTING M8 9

39 1221-132003-00 CONNECTING SEAT 2

40 0000-000688-00 NUT M22×1.5 L 2

41 1221-132002-00-03 LONG LINK - FORK LENGTH 45” AND 48” 2

41a 1221-132002-00-01 LONG LINK - FORK LENGTH 36” 2

41b 1221-132002-00-05 LONG LINK - FORK LENGTH 60” 2

42 0000-000687-00 NUT M22×1.5 2

43 1221-132001-00 CONNECTING SEAT 2

BL-WPT-0118 - 02-27-2018 12-29

Figure 12-14 Load Wheel

R6607

12-30 BL-WPT-0118 - 02-27-2018

Load Wheel


-- 1120-133000-10 LOAD WHEEL ASSEMBLY 1

1 0000-000100-00 BEARING 2

2 1120-133003-10 LOAD WHEEL 1

BL-WPT-0118 - 02-27-2018 12-31

Figure 12-15 Hydraulic System

R6608A

12-32 BL-WPT-0118 - 02-27-2018

Hydraulic System


1 1120-420000-00 HYDRAULIC PUMP ASSEMBLY 1 Used up to Serial # E2319233

1a 1120-430000-00 HYDRAULIC PUMP ASSEMBLY 1 Used from Serial # E2319234

2 0000-000176-00 FLATWASHER Ø8 8

3 0000-000159-00 LOCKWASHER Ø8 8

4 0000-000255-00 BOLT M8×20 2

5 1120-410000-00 CYLINDER 1

6 1120-400001-00 SOFT OIL PIPE 1

7 1120-400002-00 SETTING PLATE 1 Used up to Serial # E2319233

7a 1120-400003-00 SETTING PLATE 1 Used from Serial # E2319234

8 0000-000634-00 WASHER Ø18 1

9 2701-141400-00 CONNECTOR 1

10 0000-000514-00 WASHER Ø14 1

11 2702-381400-00 CONNECTOR 1

12 0000-000255-00 BOLT M8×20 4

13 1120-100006-00 CYLINDER BAFFLE R 1 Used up to 04-24-2011

13a 1120-180000-00 CYLINDER BAFFLE R 1 Used from 04-25-2011

14 1120-100002-00 CYLINDER BAFFLE L 1

15 1120-100001-00 SPRING PLATE 1

16 0000-000390-00 FLATWASHER Ø5 1

17 0000-000206-00 LOCKWASHER Ø5 1

18 0000-000004-00 SCREW M5×12 1

19 0000-000321-00 SCREW M8×20 2

BL-WPT-0118 - 02-27-2018 12-33

Figure 12-16 Pump & Motor Assy - Used up to Serial # E2319233

R6609

12-34 BL-WPT-0118 - 02-27-2018

Pump & Motor Assy - Used up to Serial # E2319233


-- 1120-420000-00 HYDRAULIC PUMP ASSEMBLY 1

1 1120-420001-00 VALVE ASSEMBLY 1

2 1120-420002-00 MOTOR 1

3 1120-420003-00 PLUG 1

4 1120-420004-00 CLAMP 1

5 1120-420005-00 CLAMP 1

6 1120-420006-00 TUBE 1

7 1120-420007-00 TUBE 1

8 1120-420008-00 FILTER 1

9 1120-420009-00 RELIEF VALVE 1

10 1120-420010-00 CARTRIDGE 1

11 1120-420011-00 SOLENOID VALVE LOWERING 1

12 1120-420012-00 PUMP 1

13 1120-420013-00 SHAFT 1

14 1120-420014-00 PIN 2

15 1120-420015-00 SCREW 4

16 1120-420016-00 RESERVOIR 1

17 1120-420017-00 CONTACTOR 1

18 1120-420018-00 CABLE 1

19 1120-420019-00 WIRE ASSY 1 Used up to Serial # E2017171

20 1120-420020-00 PLUG 1

21 1120-420021-00 BRUSH 1

BL-WPT-0118 - 02-27-2018 12-35

Figure 12-17 Pump & Motor Assy - Used from Serial # E2319234

R8031

12-36 BL-WPT-0118 - 02-27-2018

Pump & Motor Assy - Used from Serial # E2319234


-- 1120-430000-00 HYDRAULIC PUMP ASSEMBLY 1

1 1115-560001-00 HOSE CLAMPS D80 2

2 1120-430002-00 WIRE HARNESS 1

3 1115-560003-00 MOTOR 1

4 1115-560002-00 SOLENOID 1

5 1115-560008-00 SCREW M8×8 1

6 1115-560007-00 BALL 1

7 1120-430007-00 VALVE PLATE 1

8 1115-560006-00 SAFETY VALVE 1

9 1115-560005-00 THROTTLE 1

10 1115-560025-00 O-RING 1

11 1115-560026-00 SCREW 1

12 1115-560016-00 CHECK VALVE 1

13 1115-560017-00 SOLENOID VALVE 1

14 1120-430014-00 RETURN PIPE 1

15 1115-560017-00 CONNECTING SHAFT 1

16 1115-560011-00 GEAR PUMP 1

17 1115-560012-00 FLATWASHER Ø5 2

18 1115-560013-00 SCREW M5×70 2

19 1115-560015-00 OIL FILTER 1

20 1120-430020-00 SUCTION PIPE 1

21 1120-430021-00 O-RING 1

22 1120-430022-00 OIL TANK 1

23 1120-430023-00 O-RING 1

24 1115-560024-00 AIR FILTER 1

25 1115-561001-00 BRUSH ASSEMBLY 2

BL-WPT-0118 - 02-27-2018 12-37

Figure 12-18 Lift Cylinder

R6610

12-38 BL-WPT-0118 - 02-27-2018

Lift Cylinder


-- 1120-410000-00 LIFT CYLINDER ASSY. 1

-- 1120-SK SEAL KIT 1 Includes pos. # 3 & 4

1 1120-411000-00 CYLINDER TUBE 1

2 1120-410002-00 GUIDE RING 9.7×2.5 2

3 0000-000046-00 YX RING 55×65×6 1

4 0000-000045-00 DUST RING DH55×63×5-6.5 1

5 1120-410001-00 PISTON ROD 1

BL-WPT-0118 - 02-27-2018 12-39

Figure 12-19 Electrical System

R6611A

12-40 BL-WPT-0118 - 02-27-2018

er

er

s. lift.

2

er

er

s. lift.

l

e

Electrical System


1 -- SEE ELECTRICAL PANEL SECTION 1

2 0000-000194-00 FLATWASHER Ø8 5

3 0000-000159-00 LOCKWASHER Ø8 5

4 0000-000321-00 SCREW M8×20 5

5 0000-000208-00 SCREW M4×25 2

6 1120-500006-00 LIFTING LIMIT SWITCH 1

7 1120-500016-00 KEYS FOR 2 WAY KEY SWITCH (SET OF 2 KEYS) 2 Used up to Serial numbE2118215

7a 1120-500016-10 KEYS FOR 2 WAY KEY SWITCH (SET OF 2 KEYS) 2 Used from serial numbE2118216

7b 1115-500008-00 KEYS FOR 3 WAY KEY SWITCH (SET OF 2 KEYS) 2 Only used on a few truckif not sure check with big

8 1120-500002-00 BRACKET 1

9 1220-520007-0C BATTERY INDICATOR (BDI) 3 PIN - WITH HARNESS 1 Used from July 2010 to 04-14-201

9a 1220-520007-0B BATTERY INDICATOR (BDI) 4 PIN - WITH HARNESS 1 Used up to July 2010

9b 1220-520007-0D BATTERY INDICATOR HARNESS 1 Used from 04-15-2012

10 0000-000126-00 SCREW M6×16 2

11 1120-500013-00 NUT M6 2

12 0000-000209-00 NUT M4 3

13 1120-500008-00 SETTING PLATE 1

14 1120-500003-00 HORN 1

15 1220-520002-0C 2 WAY SWITCH ASSEMBLY 1 Used up to Serial numbE2118215

15a 1220-520002-1C 2 WAY SWITCH ASSEMBLY 1 Used from Serial numbE2118216

15b 1115-520003-00 3 WAY SWITCH ASSEMBLY 1 Only used on a few truckif not sure check with big

16 1120-540004-00 ALARM LAMP 1 Used from May 2012

17 1115-510006-20 BATTERY INDICATOR (BDI) 1

Set the BDI dial to thefollowing: M = IndustriaBattery, Q = Maint.Fre

Battery

BL-WPT-0118 - 02-27-2018 12-41

Figure 12-20 Electrical Panel

R6612A

12-42 BL-WPT-0118 - 02-27-2018

Electrical Panel


1 1120-500001-00 SETTING BOARD 1

2 0000-000128-00 FLATWASHER Ø5 5

3 0000-000206-00 LOCKWASHER Ø5 5

4 0000-000004-00 SCREW M5×12 4

5 1120-500004-00-10 CONTROLLER 1

6 1120-530007-00 COPPER CONDUCTOR ? 1

7 0000-000123-00 FLATWASHER Ø6 7

8 0000-000056-00 LOCKWASHER Ø6 7

9 0000-000166-00 NUT M6 5

10 1120-500005-00 CONTACTOR 1

11 0000-000077-00 SCREW M6×12 2

12 1120-540001-00-B FUSE HOLDER 1

13 0000-000074-00 SCREW M6×20 2

14 0000-000196-00 NUT M8 4

15 0000-000210-00 FLATWASHER Ø8 5

16 1120-540002-00 FUSE 1

17 1120-530006-00 COPPER CONDUCTOR? 1

18 1120-540003-00 BUSHING 1

BL-WPT-0118 - 02-27-2018 12-43

Figure 12-21 Drive Motor

R6767

12-44 BL-WPT-0118 - 02-27-2018

Drive Motor


-- 1120-220000-00 DRIVE MOTOR 1

1 0000-000293-00 RETAINING RING 2

2 0000-000226-00 KEY 6×6×16 1

3 1120-220001-00 TERMINAL BLOCK 1

4 0000-000206-00 LOCKWASHER Ø5 17

5 0000-000117-00 SCREW M5×10 2

6 0000-000166-00 NUT M6 6

7 0000-000056-00 LOCKWASHER Ø6 6

8 1120-220002-00 BEARING 1

9 0000-000204-00 KEY 3×5×13 1

10 0000-000409-00 O-RING 1

11 0000-000436-00 NUT M12×1.5 1

12 0000-000323-00 SCREW M5×16 15

BL-WPT-0118 - 02-27-2018 12-45

Figure 12-22 Wiring Harness

R6613A

12-46 BL-WPT-0118 - 02-27-2018

BL-WPT-0118 - 02-27-2018 12-47

Wiring Harness


1 1120-520001-00 MAIN WIRING HARNESS 1

Only few units with this har-ness, it’s without AMP connec-tors. Only used on some trucks made in 2009. No longer avail-

able need to replace a lot of items. Call for instructions

1a 1120-520001-0B MAIN WIRING HARNESS 1

Only few units with this har-ness, Only used on some

trucks made before July 2010. No longer available need to

replace a lot of items. Call for instructions

1b 1120-520001-0C WITH LOW POWER PROTECTION MAIN WIRING 1

Only used when 3-way key switch. No longer available please replace with 1120-520001-0D and also 1220-

520002-1C Keyswitch

1c 1120-520001-0D WITH LOW POWER PROTECTION MAIN WIRE 1 From Serial # E2017171

2 1120-500010-00 FUSE 10A 1

Figure 12-23 Wiring Cables

R6614A

12-48 BL-WPT-0118 - 02-27-2018

Wiring Cables


1 1120-530009-00 PUMP POWER LINE + 1

2 1120-530008-00 PUMP POWER LINE - 1

3 1120-530004-00 MOTOR LINE V 1

4 1120-530003-00 MOTOR LINE U 1

5 1120-530005-00 MOTOR LINE W 1

6 1120-112008-00 PLATE 1

7 1120-531000-00 CONNECTOR BATTERY GRAY 1

8 0000-000056-00 LOCKWASHER Ø6 4

9 0000-000170-00 SCREW M6×30 2

BL-WPT-0118 - 02-27-2018 12-49

Figure 12-24 Battery Assy. Used from Serial # E1922226 to E2410519 (Factory Installed Batt. Packs Only)

R6969A

12-50 BL-WPT-0118 - 02-27-2018

Battery Assembly Used from Serial # E1922226 to E2410519 (Factory Installed Battery Packs Only)


1 0000-000055-00 SCREW M6×16 6

2 0000-000056-00 LOCKWASHER Ø6 6

3 0000-000380-00 FLATWASHER Ø6 4

4 1145-550003-20 WASHER RUBBER 4 Used up to 02-27-2012

5 1145-550001-20 BLOCK 4

6 0000-000119-00 SCREW M5×12 2

7 0000-000206-00 LOCKWASHER Ø5 2

8 1145-552000-2C BATTERY COVER 1 Used up to Serial # E2221158

8a 1145-552000-2D BATTERY COVER 1Used from Serial # E2221159 to E2410519

9 003232 BATTERY 4

10 0000-000550-00 NUT M8 8 Used up to 03-09-2013

10a 0000-000242-00 BOLT M8×16 8 Used from 03-10-2013

11 1145-553002-2L M2 CABLE 1

12 1145-553001-20 M1 CABLE 1

13 1145-553003-2L M3 CABLE 1

14 1145-553100-20 BATTERY CONNECTOR ASSEMBLY 1

15 0000-000498-00 SCREW M6×30 2

16 1120-510001-00 PULLER 1

17 0000-000166-00 NUT M6 2

18 1145-551000-2C BATTERY FRAME 1 Used up to Serial # E2221158

18a 1145-551000-2D BATTERY FRAME 1Used from Serial # E2221159 to E2410519

19 1120-560000-00 CHARGER 20A 1

No longer available: If replacing old charger you have to order Kit part # 1145-EP25-20, Charger 1120-560000-00-01 and Cord 1120-560002-00 (see Figure 12-23)

20 1145-550002-20 PLUG 2

21 1120-560001-00 CHARGER CABLE 1

21a 1115-500006-11 EXTENSION CABLE 1 Not in picture

22 0000-000851-00 SCREW M8×12 2

23 0000-000390-00 FLATWASHER Ø5 2

24 0000-000119-00 SCREW M5×12 2 Used up to Serial # E2221158

24a 0000-000700-00 SCREW M8×16 2Used from Serial # E2221159 to E2410519

25 0000-000206-00 LOCKWASHER Ø5 2 Used up to Serial # E2221158

25a 0000-000159-00 LOCKWASHER Ø8 2Used from Serial # E2221159 to E2410519

26 0000-000176-00 FLATWASHER Ø8 2Used from Serial # E2221159 to E2410519

BL-WPT-0118 - 02-27-2018 12-51

Figure 12-25 Battery Assy. Used from Serial # E2410520 to B24130126 (Factory Installed Batt. Packs Only)

R8079

12-52 BL-WPT-0118 - 02-27-2018

Battery Assembly Used from Serial # E2410520 to B24130126 (Factory Installed Battery Packs Only)


1 0000-000055-00 SCREW M6×16 6

2 0000-000056-00 LOCKWASHER Ø6 8

3 0000-000380-00 FLATWASHER Ø6 4

4 1145-550011-00 PLATE 1

5 1145-550001-20 BLOCK 4

6 0000-000119-00 SCREW M5×12 2

7 0000-000206-00 LOCKWASHER Ø5 6

8 1145-552000-2D BATTERY COVER 1

9 003232 BATTERY 4

10 0000-000242-00 BOLT M8×16 8

11 1145-553002-2L M2 CABLE 1

12 1145-553001-20 M1 CABLE 1

13 1145-553003-2L M3 CABLE 1


15 0000-000498-00 SCREW M6×30 4

16 1120-510001-00 PULLER 1

17 0000-000166-00 NUT M6 2

18 1145-551000-2D BATTERY FRAME 1

19 1120-560000-00-01 CHARGER, 25A 1

20 1145-550002-20 INSERTION 2

21 1120-560002-00 CHARGER CABLE USA 1

22 1115-500009-00 CHARGER HOOP 2

23 0000-000390-00 FLATWASHER Ø5 6

24 0000-000700-00 SCREW M8×16 4

25 0000-000159-00 LOCKWASHER Ø8 4

26 0000-000176-00 FLATWASHER Ø8 4

27 0000-000117-00 SCREW M5×10 4

28 1120-112008-00 PLATE 1

29 1145-EP25-20 KIT FOR CHARGER INSTALLATION 1 Charger not included

BL-WPT-0118 - 02-27-2018 12-53

Figure 12-26 Battery Assembly Used from Serial # B24130127 (Factory Installed Batt. Packs Only)

R8080

12-54 BL-WPT-0118 - 02-27-2018

Battery Assembly Used from Serial # B24130127 (Factory Installed Battery Packs Only)


1 0000-000055-00 SCREW M6×16 6

2 0000-000056-00 LOCKWASHER Ø6 8

3 0000-000380-00 FLATWASHER Ø6 4

4 1120-112008-00 PLATE 1

5 1145-550001-20 BLOCK 4

6 0000-000119-00 SCREW M5×12 2

7 0000-000206-00 LOCKWASHER Ø5 6


9 003232 BATTERY 4

10 0000-000242-00 BOLT M8×16 8

11 1145-553002-2L M2 CABLE 1

12 1145-553001-20 M1 CABLE 1

13 1145-553003-2L M3 CABLE 1


15 0000-000498-00 SCREW M6×30 4

16 1120-510001-00 PULLER 1

17 0000-000166-00 NUT M6 2

18 1145-551000-2E BATTERY FRAME 1

19 1120-560000-00-01 CHARGER, 25A 1

20 1145-550002-20 INSERTION 2


22 1115-500009-00 CHARGER HOOP 2

23 0000-000390-00 FLATWASHER Ø5 6

24 0000-000700-00 SCREW M8×16 2

25 0000-000159-00 LOCKWASHER Ø8 2

26 0000-000176-00 FLATWASHER Ø8 2

27 0000-000117-00 SCREW M5×10 4

BL-WPT-0118 - 02-27-2018 12-55

Figure 12-27 Battery Assy. Used from Serial # E1922226 to B2410095 (Factory Installed Batt. Packs Only)

R8081

12-56 BL-WPT-0118 - 02-27-2018

-

Battery Assembly Used from Serial # E1922226 to B2410095 (Factory Installed Battery Packs Only)


1 0000-000077-00 SCREW M6×12 1

2 0000-000056-00 LOCKWASHER Ø6 1

3 0000-000380-00 FLATWASHER Ø6 1

4 1145-550001-30 BLOCK 1

5 0000-000550-00 NUT M8 4

6 0000-000119-00 SCREW M5×12 2

7 0000-000206-00 LOCKWASHER Ø5 2

8 0000-000055-00 SCREW M6×16 2

9 1145-552000-2C BATTERY COVER 1 Used up to Serial # E2221158

9 1145-552000-2D BATTERY COVER 1Used from Serial # E2221159 to B24140095

10 1145-551000-2C BATTERY FRAME 1 Used up to Serial # E2221158

10 1145-551000-2D BATTERY FRAME 1Used from Serial # E2221159 to B24140095

11 1145-550002-20 INSERTION 2

12 1145-533001-30 M1 CABLE 1

13 1145-553100-30 CONNECTOR BATTERY ASSEMBLY 1

14 0000-000206-00 LOCKWASHER Ø5 2

15 1145-550006-30 BATTERY 2

16 0000-000006-00 SCREW M6×30 2

16 0000-000498-00 SCREW M6×30 2

17 1120-510001-00 PULLER 1

18 0000-000166-00 NUT M6 2

19 1120-560000-00 CHARGER 20A, 110V 1

No longer available: If replacing old charger you have to order Kit part # 1145-EP25-20, Charger 1120-56000000-01 and Cord 1120-560002-00

20 1120-560001-00 CHARGER CABLE 1

20A 1115-500006-11 EXTENSION CABLE 1

21 0000-000493-00 SCREW M5×8 2

22 0000-000851-00 SCREW M8×12 2

23 0000-000390-00 FLATWASHER Ø5 2

24 0000-000119-00 SCREW M5×12 2 Used up to Serial # E2221158

24 0000-000700-00 SCREW M8×16 2Used from Serial # E2221159 to B24140095

25 0000-000206-00 LOCKWASHER Ø5 2 Used up to Serial # E2221158

25 0000-000159-00 LOCKWASHER Ø8(??) 2Used from Serial # E2221159 to B24140095

26 0000-000176-00 FLATWASHER Ø8(??) 2Used from Serial # E2221159 to B24140095

BL-WPT-0118 - 02-27-2018 12-57

Figure 12-28 Battery Assembly Used from Serial # B2410096 (Factory Installed Batt. Packs Only)

R8082

12-58 BL-WPT-0118 - 02-27-2018

Battery Assembly Used from Serial # B2410096 (Factory Installed Battery Packs Only)


1 0000-000077-00 SCREW M6×12 1

2 0000-000056-00 LOCKWASHER Ø6 5

3 0000-000380-00 FLATWASHER Ø6 1

4 1145-550001-30 BLOCK 1

5 1120-112008-00 PLATE 1

6 0000-000119-00 SCREW M5×12 2

7 0000-000206-00 LOCKWASHER Ø5 6

8 0000-000055-00 SCREW M6×16 2


10 1145-551000-2E BATTERY FRAME 1

11 1145-550002-20 INSERTION 2

12 1145-533001-30 M1 CABLE 1

13 1145-553100-30 CONNECTOR BATTERY ASSEMBLY 1

14 1115-500009-00 CHARGER HOOP 2

15 1145-550006-30 BATTERY 2

16 0000-000498-00 SCREW M6×30 4

17 1120-510001-00 PULLER 1

18 0000-000166-00 NUT M6 2

19 1118-560006-00-01 CHARGER 1


21 0000-000117-00 SCREW M5×10 4

22 1115-520013-Z0 LED WIRE HARNESS 1

23 0000-000390-00 FLATWASHER Ø5 6

24 0000-000700-00 SCREW M8×16 2

25 0000-000159-00 LOCKWASHER Ø8 2

26 0000-000176-00 FLATWASHER Ø8 2

27 1115-510009-00 LAMP HOLDER 1

BL-WPT-0118 - 02-27-2018 12-59

Figure 12-29 Cold Conditioning Parts (Optional)

R6868

12-60 BL-WPT-0118 - 02-27-2018

Cold Conditioning Parts (Optional)


1 1120-500001-LK MOUNTING PLATE 1

2 1120-520003-LK TEMPERATURE DETECT SWITCH 1

3 1120-520004-LK HEATING FAN 1

4 1120-520002-LK WIRE HARNESS 1

5 1120-520005-LK HEATER BAND 1

6 0000-000009-00 SCREW M4×12 4

7 0000-000122-00 LOCKWASHER Ø4 4

8 0000-000702-00 FLATWASHER Ø4 4

9 1120-520001-LK MAIN HARNESS 1

10 1120-500010-00 FUSE 10A 1

BL-WPT-0118 - 02-27-2018 12-61

Big Lift LLC

wpt 45 series lift llc manual no. bl-wpt-0118 - 02-27-2018 wpt 45 series self-propelled, pallet lift...

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