Self-Propelled, Pallet Lift Truck: Operation Maintenance Repair Parts List
Self-Propelled, Pallet Lift Truck: Operation Maintenance Repair Parts List
Self-Propelled, Pallet Lift Truck: Operation Maintenance Repair Parts List
SELF-PROPELLED,
PALLET LIFT TRUCK
Operation
Maintenance
Repair Parts List
Do not operate this truck unless you have been autho- Always look in direction of travel. Keep a clear view,
rized and trained to do so, and have read all warnings and when load interferes with visibility, travel with load
and instructions in Operator’s Manual and on this trailing.
truck.
Use special care when operating on ramps travel
Do not operate this truck until you have checked its slowly, and do not angle or turn. Travel with load
condition. Give special attention to tires, horn, battery, downhill.
controller, lift system, brakes, steering mechanism,
Do not handle loads which are higher than the load
guards and safety devices.
backrest or load backrest extension unless load is
Operate truck only from designated operating position. secured so that no part of it could fall backward.
Do not carry passengers. Keep feet clear of truck and Before lifting, be sure load is centered, forks are com-
wear foot protection. pletely under load, and load is as far back as possible
Observe applicable traffic regulations. Yield right of against load backrest.
way to pedestrians. Slow down and sound horn at When leaving truck, neutralize travel control, fully
cross aisles and wherever vision is obstructed. lower lifting mechanism and set brake. When leaving
truck unattended, also shut off power.
Start, stop, travel, steer and brake smoothly. Slow
down for turns and on uneven or slippery surfaces that
could cause truck to slide or overturn. Use special
care when traveling without load as the risk of overturn
may be greater.
TABLE OF CONTENTS
BL-WPT-0916 - 02-23-2018 1
1-2 BL-WPT-0916 - 02-23-2018
SECTION 1
DESCRIPTION
1-1. INTRODUCTION. speed range. The WPT 60 lift truck can be driven with
This publication describes the 24 volt WPT 60 lift truck forks raised or lowered. The lift truck must be pro-
distributed by Big Lift LLC. Included are operating tected from the elements.
instructions, maintenance instructions, lubrication pro- The model number will be found on the name plate
cedures, corrective maintenance procedures and a (Figure 1-1) along with the serial number, lifting capac-
complete parts list with part location illustrations. ity, and load center. Figure 1-2 shows the locations of
Users shall comply with all requirements indicated in the truck’s main components and controls.
applicable OSHA standards and current edition of
A.N.S.I. B56.1 Part II. By following these requirements MODEL NO. SERIAL NO.
from your WPT 60 lift truck. ALT CAP LB/ KG LOAD CTR IN/ MM LIFT HGT IN/ MM
1-2. GENERAL DESCRIPTION. TRUCK WT LESS BATTERY LB/ KG BATTERY MIN WT LB/ KG
The self-propelled WPT 60 truck, Figure 1-2, lifts and TRUCK WT WITH BATTERY LB/ KG BATTERY MAX WT LB/ KG
Lift and Lower is controlled by pushbuttons on the con- AUSTRALIAN PATENT NO. 537,987
R7048
• Do not operate this truck until you have checked its CAUTION: A QUALIFIED SERVICE TECHNICIAN
condition. Give special attention to Tires, Horn, Bat- should check the truck monthly for
tery, Controller, Lift System, Brakes, Steering Mech- proper lubrication, proper fluid levels,
anism, Guards and Safety Devices brake maintenance, motor maintenance
• Operate truck only from designated operation posi- and other areas specified in the SEC-
TION 3.
tion. Wear foot protection. Do not carry passengers.
• Observe applicable traffic regulations. Yield right of WARNING: If the truck is found to be unsafe and in
way to pedestrians. Slow down and sound horn at need of repair, or contributes to an
cross aisles and wherever vision is obstructed. unsafe condition, report it immediately to
the designated authority. Do not operate
• Start, stop, travel, steer and brake smoothly. Slow
it until it has been restored to a safe
down for turns and on uneven or slippery surfaces
operating condition. Do not make any
that could cause truck to slide or overturn. Use spe-
unauthorized repairs or adjustments. All
cial care when traveling without load as the risk of
service must be performed by a qualified
overturn may be greater.
maintenance technician.
• Always look in direction of travel. Keep a clear view,
and when load interferes with visibility, travel with
load or lifting mechanism trailing.
2-4.2. Travel
Move the control arm to the travel position. The speed
control (See Figure 2-3 & Figure 2-4 located on each
side of the control head provides fingertip control for
driving the truck. Rotate the control in the direction you
want to travel. The farther you rotate the control from
the neutral position, the faster the truck will travel.
R6801
The WPT 60 may be equipped with maintenance free A voltage check from battery connector terminal to
or industrial wet cell battery. battery case should indicate near zero volts. Typically,
however, the sum of the voltages at both terminals will
The care and maintenance of the battery is very equal battery volts. This leakage voltage will discharge
important to obtain efficient truck operation and maxi- the battery. As battery cleanliness deteriorates, the
mum battery life. usable charge of the battery decreases due to this self
discharge.
Table 3-1 Monthly and Quarterly Inspection and Service Chart
VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check electrical 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.
5-1. CONTROL HEAD 2. Remove the screws and lift up cover and discon-
nect handle harness from control head switch har-
5-1.1. Cover Removal. ness.
1. Turn off the key switch and disconnect the battery.
R7050 R8236
R7051
3. Remove horn, lift and lower switches from their 9. Reconnect the battery and turn on the key switch.
brackets by releasing the two tabs of the bracket
5-2.2. Steering Arm Removal.
and pulling up on the switch.
1. Turn off the key switch and disconnect the battery.
4. Replace switch harness as an assembly.
2. Remove the compartment covers as described in
5. Press the new switches into their brackets until
paragraph 5-3.
they lock in place. Refer to the tags added in the
remove process. 3. Disconnect handle harness from main harness.
6. Install the cover as described in paragraph 5-1.2. 4. Disconnect brake switch from main harness.
5. Attach a hoist to steering arm.
5-1.7. Speed Potentiometer Replacement.
6-1. BRAKE - Used up to S/N 324200414. 11. Remove load wheel blocks and check operation.
The brake system consists of a drive motor mounted 12. Install the compartment covers as described in
brake. This brake is spring applied and electrically paragraph 5-3.
released.
7-2. Transmission.
1. Turn off the key switch and disconnect the battery.
2. Block the load wheels securely.
3. Remove the compartment covers as described in
paragraph 5-3.
4. Remove the brake as described in paragraph 6-
1.3.
5. Remove the drive motor as described in para-
graph 10-4.
6. Using a suitable means, raise the truck frame
enough to provide clearance for removal of the
transmission/motor/brake.
7. Support the transmission and remove six screws,
six lock washers and six flat washers.
8. Slowly lower the transmission out the bottom of
the frame.
9. Install new transmission by reversing the steps
above. R6783
8-1. LIFT LINKAGE 3. Remove pin and shaft. Free roller from bracket.
4. Inspect bushings in roller. If necessary, remove
8-1.1. Removal
and replace the bushings.
1. Lift complete truck to height sufficient to permit
5. Remove pin and shaft. Free bar from link.
access to lift linkage under forks. Provide blocking
under frame, the rear of fork frame and at tips of 6. Inspect bushings in link. If necessary, remove and
the forks. replace the bushings.
2. Turn off the key switch and disconnect the battery. 7. Reassembly by reversing the steps above.
3. Remove pin and remove shaft. Lower the front of 8-1.3. Installation
link to the floor.
1. Position the link assembly from under the fork.
4. Remove pin and remove shaft. Free the front of
link from the fork frame. 2. Position the rear of link in the main frame and
install shaft and two pins.
5. Remove two pins and remove shaft. Free the rear
of link from the main frame. 3. Position the front of link in fork frame. and install
shaft and pin.
6. Remove the link assembly from under the fork.
4. Position link in the fork and install shaft and pin.
8-1.2. Repair 5. Remove blocking and lower the truck to the
1. Remove pin and shaft. Free bracket from bar end. ground.
2. Inspect bushings in bar end. If necessary, remove 6. Reconnect the battery and turn on key switch.
and replace the bushings.
1. While supporting the pump/motor assembly , 3. Remove the compartment covers as described in
install two screws, two lock washers and two flat paragraph 5-3.
washers. 4. Ensure that hydraulic pressure has been relieved
2. Reconnect hose to pump/motor assembly. from the lift circuit.
3. Connect electrical leads to motor and solenoid. 5. Disconnect hose from cylinder.
4. Fill the hydraulic reservoir to 1 inch below open- 6. Remove connector and seal from cylinder.
ing. Use hydraulic oil listed in Table 3-2. 7. Remove screw, lock washer and shaft securing
5. Reconnect the battery and turn on the keyswitch. the top of cylinder.
6. Operate the lift and lower buttons to refill the WARNING: Frame is heavy. Use care while securing
cylinder and lines with hydraulic oil. and lifting in order to prevent injury.
7. Check level of hydraulic oil. If required, add 8. With suitable hoist, carefully raise frame slightly to
hydraulic oil to bring to 1 inch below opening. Use relieve pressure from the cylinder mounts.
hydraulic oil listed in Table 3-2.
9. Remove screw, lock washer and shaft securing
8. Install the compartment covers as described in the bottom of cylinder and remove the cylinder.
paragraph 5-3.
9-2.4.3.Installation
1. Position the cylinder in the frame and secure the
bottom of the cylinder with shaft, screw and lock
washer.
2. Secure top of cylinder with shaft, screw and lock
washer.
3. Using a suitable hoist. carefully lower frame.
4. Reconnect the hose to cylinder.
5. Fill the hydraulic reservoir to 1 inch below open-
ing. Use hydraulic oil listed in Table 3-2.
6. Reconnect the battery and turn on the keyswitch.
R6791
7. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil. Figure 9-3 Lift Cylinder
8. Check level of hydraulic oil. If required, add
hydraulic oil to bring to 1 inch below opening. Use
hydraulic oil listed in Table 3-2.
10-1.ELECTRICAL CONTROL PANEL 4. Make sure the connections to the buss bars are
tight. Use two well insulated wrenches for this
10-1.1.Maintenance task in order to avoid steering the buss bars.
NOTE: Erratic operation of the truck may be caused 10-1.3.Panel Removal.
by defective controller components. Before
removing the electrical panel, perform trou- 1. Turn off the key switch and disconnect the battery.
bleshooting procedures per SECTION 4, to 2. Remove the compartment covers as described in
determine corrective action to be taken. paragraph 5-3.
There are no user-serviceable parts inside the control- 3. Tag and disconnect all electrical cables which
ler. No attempt should be made to open the controller. connect to the control panel.
Opening the controller may damage it and will void the 4. Remove four screws, four lock washers, four flat
warranty. washers, and control panel.
The controller is programmed at the factory specifi-
10-1.4.Panel Disassembly.
cally for the truck model on which it is equipped. It is
important to replace the controller with the correct pre- Refer to Figure 10-2 for location and identity of the
programmed unit to assure proper performance set- major replacement components mounted on the panel
tings intended for that particular truck. See Figure 12- and remove defective parts.
21 for the preprogrammed controller number.
NOTE: Contactor is not repairable and must be
It is recommended that the controller exterior be replaced if defective.
cleaned periodically, and if a Zapi Can Console kit and
laptop computer are available, this periodic cleaning 10-1.5.Panel Installation.
provides a good opportunity to check the controller’s 1. Install the control panel and secure with four
diagnostic history file. It is also recommended that the screws, four lock washers, four flat washers.
controller’s fault detection circuitry be checked when-
2. Refer to Figure 12-22 and Figure 12-23 and con-
ever the vehicle is serviced.
nect all electrical cables to the control panel as
10-1.2.Cleaning noted during removal.
1. Turn off the key switch and disconnect the battery. 3. If controller was replaced, the Vacc will need to be
programmed as follows:
2. Remove the compartment cover as described in
paragraph 5-3. a. Connect the Zapi Smart Console and follow
the instructions as described in paragraph 4-
3. Remove any dirt or corrosion from the bus bar
2.1.1.
area. The controller should be wiped clean with a
COnsole kit
R7057
R6794A
10-4.DRIVE MOTOR.
The drive motor exposed surfaces should be cleaned
at least once a month to assure proper cooling of
motor. Use an air hose to blow dust off of motor sur-
faces.
10-4.1.Motor Removal
1. Remove the brake as described in paragraph
6-1.3.
2. Note routing of cables to ensure proper installa-
tion.
3. Tag the cables connected to the drive motor; then
disconnect these cables from the drive motor.
4. Remove the four screws and lift motor from the
transmission.
10-4.2.Motor Installation
5. Install drive motor on the transmission. Make sure
to align the gears.
6. Reinstall four screws.
7. Position cables as noted in removal and recon-
nect the cables to the drive motor.
8. Reinstall the brake as described in paragraph
6-1.3.
10-5.1.Replacement
1. Disconnect wiring from the lift limit switch.
2. Remove the two screws, two lock washers, flat
washers and switch.
3. Remove the two nuts, two screws, two lock wash-
ers, flat washers, and mounting plate from the
switch. R6783
11-1.LOAD BACKREST.
A load backrest is available for addition to the lift truck
to allow handling of high loads.
Following is an illustrated parts breakdown of assemblies and parts associated with the WPT 60 Lift Truck.
Figure 12-3 Steering Arm - Used from serial number E2318058 - Continued
Figure 12-8 Drive Assembly - Used between serial number 324200415 and 325150487
Figure 12-11 Drive Wheel Assembly - Used from serial number 325150488
Figure 12-12 Transmission Assembly - Used between serial number 324200415 and 326140212
Figure 12-12 Transmission Assembly - Continued - Used between serial number 324200415 and 326140212