DO NOT INSTALL, OPERATE OR SERVICE THIS PRODUCT UNLESS YOU HAVE READ AND
FULLY UNDERSTAND THE ENTIRE CONTENTS OF THIS MANUAL. FAILURE TO DO SO MAY
RESULT IN PROPERTY DAMAGE, BODILY INJURY OR DEATH.
OWNER’S MANUAL
OPERATION
MAINTENANCE
PARTS LIST
SELF-PROPELLED, PALLET LIFT TRUCK
WPT 45 SERIES
�������
WPT 45 SERIES Self-Propelled, Pallet Lift Truck. Issue Date: Sept.17, 2010. Rev.1 (Manual# BG-WPT-0610)
www.totalwarehouse.com
833-868-2500
WARNING
Do not operate this truck unless you have been autho-
rized and trained to do so, and have read all warnings
and instructions in Operator’s Manual and on this
truck.
Do not operate this truck until you have checked its
condition. 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 and
wear foot protection.
Observe applicable traffic regulations. Yield right of
way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision is obstructed.
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.
Always look in direction of travel. Keep a clear view,
and when load interferes with visibility, travel with load
trailing.
Use special care when operating on ramps travel
slowly, and do not angle or turn. Travel with load
downhill.
Do not handle loads which are higher than the load
backrest or load backrest extension unless load is
secured 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 possible
against load backrest.
When leaving truck, neutralize travel control, fully
lower lifting mechanism and set brake. When leaving
truck unattended, also shut off power.
TABLE OF CONTENTS
BG-WPT-0610
Section
Page
Section
Page
DESCRIPTION............................................................1-1
1-1.
INTRODUCTION..............................................1-1
1-2.
GENERAL DESCRIPTION...............................1-1
1-3.
SAFETY FEATURES. ......................................1-2
OPERATION ...............................................................2-1
2-1.
GENERAL. .......................................................2-1
2-2.
OPERATING PRECAUTIONS. ........................2-1
2-3.
BEFORE OPERATION.....................................2-1
2-4.
GENERAL CONTROL OPERATION................2-4
2-5.
DRIVING AND STOPPING PROCEDURES....2-4
2-6.
BELLY-BUTTON SWITCH. ..............................2-4
2-7.
STEERING ARM GAS SPRING.......................2-5
2-8.
LIFT AND LOWER CONTROLS. .....................2-5
2-9.
LOADING AND UNLOADING. .........................2-5
2-10.
PARKING. ........................................................2-5
PLANNED MAINTENANCE ........................................3-1
3-1.
GENERAL. .......................................................3-1
3-2.
MONTHLY AND QUARTERLY CHECKS. .......3-1
3-3.
BATTERY CARE.............................................3-1
3-3.1. GENERAL ........................................................3-1
3-3.2. SAFETY RULES ..............................................3-2
3-3.3. BATTERY CARE AND CHARGING.................3-2
3-3.4. BATTERY CLEANING......................................3-2
3-3.5. MAINTENANCE FREE BATTERIES................3-3
3-4.
CHARGING BATTERIES .................................3-3
3-5.
LUBRICATION. ................................................3-4
TROUBLESHOOTING ................................................4-1
4-1.
GENERAL ........................................................4-1
4-2.
CONTROLLER TROUBLESHOOTING............4-4
4-2.1. ZAPI HANDSET ...............................................4-4
4-2.2. FAULT DETECTION. .......................................4-4
4-2.3. TESTING TRUCK OPERATION. .....................4-4
4-2.4. SETTINGS AND ADJUSTMENTS ...................4-5
STEERING ARM, CONTROL HEAD AND
COMPARTMENT ........................................................5-1
5-1.
CONTROL HEAD.............................................5-1
5-1.1. CONTROL HEAD REMOVAL ..........................5-1
5-1.2. CONTROL HEAD INSTALLATION ..................5-2
5-1.3. CAP ASSEMBLY REMOVAL. ..........................5-3
5-1.4. CAP ASSEMBLY INSTALLATION. ..................5-3
5-1.5. BELLY-BUTTON SWITCH REPLACEMENT. ..5-3
5-1.6. HORN SWITCH REPLACEMENT....................5-4
5-1.7. LIFT AND LOWER SWITCH
REPLACEMENT...............................................5-5
5-1.8. DIRECTIONAL POTENTIOMETER
REPLACEMENT...............................................5-6
5-2.
STEERING ARM ..............................................5-6
5-2.1. RETURN SPRING REPLACEMENT................5-6
5-2.2. STEERING ARM REMOVAL............................5-6
5-2.3. STEERING ARM INSTALLATION....................5-6
5-3.
COMPARTMENT COVERS............................. 5-6
5-3.1. REMOVAL. ...................................................... 5-6
5-3.2. INSTALLATION. .............................................. 5-6
BRAKE SERVICING ................................................... 6-1
6-1.
BRAKES. ......................................................... 6-1
6-1.1. AIR GAP ADJUSTMENT. ................................ 6-1
6-1.2. STOPPING DISTANCE ADJUSTMENT.......... 6-2
6-1.3. BRAKE ASSEMBLY REPLACEMENT ............ 6-2
TRANSMISSION, DRIVE WHEEL, LOAD WHEEL .... 7-1
7-1.
DRIVE WHEEL. ............................................... 7-1
7-2.
TRANSMISSION. ............................................ 7-1
7-3.
LOAD WHEEL. ................................................ 7-2
7-3.1. REMOVAL ....................................................... 7-2
7-3.2. REPAIR .......................................................... 7-2
7-3.3. LOAD WHEEL INSTALLATION....................... 7-2
ELEVATION SYSTEM SERVICING ........................... 8-1
8-1.
GENERAL........................................................ 8-1
8-2.
LIFT LINKAGE................................................. 8-1
8-2.1. REMOVAL ....................................................... 8-1
8-2.2. INSTALLATION ............................................... 8-2
8-3.
POWER SECTION AND FORK SECTION...... 8-2
8-3.1. SEPARATING POWER SECTION AND
FORK SECTION.............................................. 8-2
8-3.2. FORK FRAME REPAIR................................... 8-2
8-3.3. CARRIER FRAME REPAIR............................. 8-2
8-3.4. MATING POWER SECTION AND FORK
SECTION......................................................... 8-2
HYDRAULIC SYSTEM SERVICING........................... 9-1
9-1.
LINES AND FITTINGS .................................... 9-1
9-2.
HYDRAULIC PUMP, MOTOR, AND
RESERVOIR ASSY ......................................... 9-2
9-2.1. REMOVAL ....................................................... 9-2
9-2.2. DISASSEMBLY AND REASSEMBLY ............. 9-2
9-2.3. INSTALLATION ............................................... 9-2
9-2.4. LIFT CYLINDER .............................................. 9-4
10 ELECTRICAL COMPONENTS................................. 10-1
10-1.
ELECTRICAL CONTROL PANEL ................. 10-1
10-1.1.MAINTENANCE............................................. 10-1
10-1.2.CLEANING .................................................... 10-1
10-1.3.PANEL REMOVAL. ....................................... 10-1
10-1.4.PANEL DISASSEMBLY................................. 10-1
10-1.5.PANEL INSTALLATION. ............................... 10-1
10-2.
HORN REPLACEMENT ................................ 10-3
10-3.
PUMP MOTOR. ............................................. 10-4
10-4.
DRIVE MOTOR. ............................................ 10-4
10-4.1.MOTOR REMOVAL....................................... 10-4
10-4.2.MOTOR INSTALLATION............................... 10-4
10-5.
LIFT LIMIT SWITCH ...................................... 10-4
10-5.1.REPLACEMENT............................................ 10-4
10-5.2.ADJUSTMENT............................................... 10-5
10-6.
DEADMAN SWITCH...................................... 10-5
10-6.1.REPLACEMENT............................................ 10-5
TABLE OF CONTENTS - Continued
ii
BG-WPT-0610
11 OPTIONAL EQUIPMENT ......................................... 11-1
11-1.
LOAD BACKREST......................................... 11-1
11-2.
CASTERS...................................................... 11-1
12 ILLUSTRATED PARTS BREAKDOWN ....................12-1
LIST OF ILLUSTRATIONS
Figure
Page
Figure
Page
1-1
NAME PLATE ................................................... 1-1
1-2
WPT 45 LIFT TRUCK ....................................... 1-1
2-1
SAMPLE OF OPERATOR CHECK LIST .......... 2-3
-2
FORWARD/REVERSE CONTROL................... 2-4
2-3
PUSHBUTTON SWITCHES ............................. 2-4
2-4
BRAKE ACTUATION ........................................ 2-4
2-5
BELLY-BUTTON SWITCH................................ 2-5
3-1
LUBRICATION DIAGRAM ................................ 3-5
4-1
CONNECTING THE HANDSET........................ 4-4
4-2
ZAPI HANDSET ................................................ 4-5
4-3
ZAPI HANDSET ................................................ 4-9
4-4
THROTTLE REGULATION............................. 4-10
4-5
ZAPI HANDSET .............................................. 4-11
4-6
ZAPI CONTROLLER CONNECTIONS ........... 4-13
5-1
STEERING ARM............................................... 5-1
5-2
CONTROL HEAD.............................................. 5-2
5-3
EMERGENCY REVERSE SWITCH
ASSEMBLY....................................................... 5-3
5-4
CAP ASSEMBLY .............................................. 5-4
5-5
LEFT LIFT/LOWER SWITCH ASSY
(RIGHT SIMILAR) ............................................. 5-5
6-1
BRAKE ASSEMBLY.......................................... 6-1
7-1
TRANSMISSION, MOTOR, BRAKE
ASSEMBLY....................................................... 7-1
7-2
WHEEL ASSEMBLY ......................................... 7-2
8-1
FRAME.............................................................. 8-1
8-2
LIFT LINKAGE ASSEMBLY.............................. 8-3
9-1
HYDRAULIC SYSTEM...................................... 9-1
9-2
PUMP AND MOTOR ASSEMBLY .................... 9-3
10-1
ELECTRICAL SYSTEM .................................. 10-2
10-2
ELECTRICAL PANEL ..................................... 10-3
10-3
TRANSMISSION, MOTOR, BRAKE
ASSEMBLY ..................................................... 10-4
12-1
STEERING SYSTEM ...................................... 12-2
12-2
STEERING ARM ............................................. 12-3
12-3
CONTROL HEAD............................................ 12-4
2-4
CAP ASSEMBLY............................................. 12-5
12-5
LIFT/LOWERING SWITCH ASSY, LEFT........ 12-6
12-6
LIFT/LOWERING SWITCH ASSY, RIGHT...... 12-7
12-7
EMERGENCY REVERSE SWITCH
ASSEMBLY ..................................................... 12-8
12-8
TRANSMISSION, MOTOR, BRAKE
MOUNTING..................................................... 12-9
12-9
TRANSMISSION, MOTOR, BRAKE
ASSEMBLY ................................................... 12-10
12-10
TRANSMISSION, MOTOR BRAKE
ASSEMBLY ................................................... 12-11
12-11
COMPARTMENT .......................................... 12-12
12-12
CASTER WHEEL (OPTIONAL)..................... 12-13
12-13
FRAME.......................................................... 12-14
12-14
LIFT LINK ASSEMBLY.................................. 12-15
12-15
LOAD WHEEL............................................... 12-16
12-16
HYDRAULIC SYSTEM.................................. 12-17
12-17
PUMP & MOTOR ASSY................................ 12-18
12-18
LIFT CYLINDER............................................ 12-19
12-19
ELECTRICAL SYSTEM................................. 12-20
12-20
ELECTRICAL PANEL.................................... 12-21
12-21
WIRING HARNESS....................................... 12-22
12-22
WIRING CABLES.......................................... 12-24
12-23
BATTERY COMPARTMENT......................... 12-25
12-24
BATTERIES................................................... 12-26
LIST OF TABLES
Table
Page
Table
Page
2-1
OPERATOR CHECKS ....................................... 2-2
3-1
MONTHLY AND QUARTERLY INSPECTION
AND SERVICE CHART ..................................... 3-1
3-2
RECOMMENDED LUBRICANTS ...................... 3-4
3-3
LUBRICATION CHART...................................... 3-5
4-1
TROUBLESHOOTING CHART..........................4-1
4-2
SET OPTIONS ...................................................4-5
4-3
ADJUSTMENTS.................................................4-9
4-4
PARAMETER ADJUSTMENTS........................4-11
4-5
ZAPI CONTROLLER CONNECTOR PINS ......4-13
BG-WPT-0610
1-1
SECTION 1
DESCRIPTION
1-1. INTRODUCTION.
This publication describes the 24 volt transistor
WPT 45 lift truck distributed by Big Joe by Blue Giant.
Included are operating instructions, planned mainte-
nance instructions, lubrication procedures, corrective
maintenance procedures and a complete parts list with
part location illustrations.
Users shall comply with all requirements indicated in
applicable OSHA standards and current edition of
A.N.S.I. B56.1 Part II. By following these requirements
and the recommendations contained in this manual,
you will receive many years of dependable service
from your WPT 45 lift truck.
1-2. GENERAL DESCRIPTION.
The self-propelled WPT 45 truck, Figure 1-2, lifts and
transports payloads up to 4500 pounds on rigid forks.
The forward and reverse motion is controlled by either
of 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 and
without exhaust fumes.
The reversible AC motor propels the lift truck in for-
ward or reverse direction throughout the available
speed 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 of
the truck’s main components and controls.
Figure 1-1 Name Plate
Figure 1-2 . WPT 45 Lift Truck
R6209
COMPLIES WITH THE APPLICABLE REQUIRE-
MENTS OF ANSI B56.1 AND OSHA STANDARDS
BIG LIFT LLC
WISCONSIN DELLS, WISCONSIN 53965
AUSTRALIAN PATENT NO. 537,987
U.S. PATENT NO. 4,444,284
TRUCK
TYPE
MODEL NO.
SERIAL NO.
VOLTAGE
BATTERY
TYPE
CERTIFIED
MAX CAP LB/
LOAD CTR IN/
LIFT HGT IN/
LOAD CTR IN/
LIFT HGT IN/
ALT CAP LB/
BATTERY MIN WT LB/
TRUCK WT LESS BATTERY LB/
BATTERY MAX WT LB/
TRUCK WT WITH BATTERY LB/
KG
MM
MM
MM
MM
KG
KG
KG
KG
KG
R6622
1-2
BG-WPT-0610
1-3. SAFETY FEATURES.
The WPT 45 is designed and engineered to provide
maximum safety for operator and payload. Some of
the safety features incorporated into the design are:
• Dead-man brake to apply the brake and cut off drive
power when the steering arm is released.
• Belly-button switch to reverse truck should the oper-
ator accidentally pin himself against a wall or
obstruction when backing up in slow speed.
• All control functions automatically return to “OFF”
when released.
• Externally accessible quick-disconnect battery plug
within 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 lowering
speed within prescribed limits.
• Relief valve maintains hydraulic pressure within pre-
scribed limits.
• High visibility color scheme of truck provides visual
alert of truck’s presence.
• Battery Indicator
• Casters
BG-WPT-0610
2-1
SECTION 2
OPERATION
2-1. GENERAL.
This section gives detailed operating instructions for
the WPT 45 lift truck. The instructions are divided into
the various phases of operations, such as operating
lift, driving, and stopping. Routine precautions are
included for safe operation.
2-2. OPERATING PRECAUTIONS.
WARNING: Improper operation of the lift truck may
result in operator injury, or load and/or lift
truck damage. Observe the following
precautions when operating the WPT 45
lift truck.
The following safety precautions must be adhered to
at all times.
• Do not operate this truck unless you have been
trained and authorized to do so and have read all
warnings and instructions in this manual and on the
truck.
• All warnings and instructions must be read and
understood before using the equipment.
• Equipment must be inspected by a qualified person
on a regular basis.
• Do not operate this truck until you have checked its
condition. Give special attention to Tires, Horn, Bat-
teries, Controller, Lift System, Brakes, Steering
Mechanism, 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 of
way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision is obstructed.
• 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 spe-
cial care when traveling without load as the risk of
overturn may be greater.
• Always look in direction of travel. Keep a clear view,
and when load interferes with visibility, travel with
load or lifting mechanism trailing.
• Do not overload truck. Check nameplate for load
weight and load center information.
• Before lifting, be sure load is centered, forks are
completely under load, and load is as far back as
possible against load backrest.
• Do not handle loads which are higher than the load
backrest unless load is secured so that no part of it
could fall backward.
• When leaving truck, neutralize travel control. Fully
lower lifting mechanism and set brake. When leaving
truck unattended, turn off key switch and disconnect
switch, remove key and disconnect battery.
2-3. BEFORE OPERATION
Table 2-1 covers important inspection points on the
WPT 45 lift truck which should be checked prior to
operation. Depending on use, some trucks may
require additional checks.
Figure 2-1 shows a sample format for an Operator
Checklist, which can be modified as necessary to fit
your operation.
WARNING: Periodic maintenance of this truck by a
QUALIFIED TECHNICIAN is required.
CAUTION:
A QUALIFIED SERVICE TECHNICIAN
should check the truck monthly for
proper lubrication, proper fluid levels,
brake maintenance, motor maintenance
and other areas specified in the SEC-
TION 3.
WARNING: If the truck is found to be unsafe and in
need of repair, or contributes to an
unsafe condition, report it immediately to
the designated authority. Do not operate
it until it has been restored to a safe
operating condition. Do not make any
unauthorized repairs or adjustments. All
service must be performed by a qualified
maintenance technician.
2-2
BG-WPT-0610
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
BG-WPT-0610
2-3
Figure 2-1 Sample of Operator Check List
R6479
Electric Truck
Daily Operator Check-Off List
Date
Big Joe Manufacturing Company
Operator
Truck No.
Model No.
Dept.
Check
Tires
Load Wheels
Horn
Lift
Lower Control
Need Maintenance
O.K. (
Shift
Hour Meter
Reading
Drive
Hoist
Attachment Operation
Forward & Reverse Controls
Steering
Brakes
Hydraulic Leaks, Cylinders,
Valves, Hoses, Etc.
2-4
BG-WPT-0610
2-4. GENERAL CONTROL OPERATION.
The speed control (See Figure 2-2) 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.
Figure 2-2 Forward/Reverse Control
The pushbutton switches (See Figure 2-3), located on
the 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 the
steering arm. (See Figure 2-4) All traction control
power is shut off when the brake is engaged. When
the steering arm is in the upright position, the brake
acts as a parking brake. Deadman braking occurs
when the handle is released and spring action raises
steering 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 the
speed control can be comfortably operated by
either thumb.
2.
Lower the steering arm to a comfortable position
above horizontal to disengage the brake and to
energize the electrical circuits. If the truck is not
moved, the electrical circuits will time out and will
deenergize. See Figure 2-4.
3.
To move forward (with load in front), slowly press
the speed control forward. See Figure 2-2. Press
the forward speed control farther to increase
speed.
4.
To slow down or stop, release the speed control
and lower or raise the steering arm to the horizon-
tal or vertical position. See Figure 2-4. In those
positions, the brake engages, slowing or stopping
the truck.
5.
Procedures for movement in reverse are the
same as in the forward direction except slowly
press the speed control backward. See Figure 2-
2.
2-6. BELLY-BUTTON SWITCH.
The belly-button switch (Figure 2-5) minimizes the
possibility of the driver being pinned by the steering
arm while driving the lift truck in slow speed. If the
switch presses against the operator while the lift truck
is being driven toward the operator, the switch
changes the direction of the lift truck.
R6617
R6618
R6620