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