TECHNICAL MANUAL
WALKIE RIDER
TRUCK
MODEL WRT-40 AND
WRT-60 SERIES LIFT TRUCKS

continued…

b. Replacement of Disc Brake Parts. (Figure 3-6)
1. Disconnect battery.
2. Block the wheels to prevent the truck from moving. 
3. Remove service cover.
4. Remove shoulder bolt (33) from rod end (14) of control handle to disassemble brake.
5. Remove shoulder bolt (24) from brake link (22) and brake lever arm.
6. Remove two bolts and nuts on brake caliper assembly (25) to release brake pads.
7. Insert replacement brake pads in clamp assembly, one pad on each side of disc with linings toward the disc, and secure pads and clamp with two bolts and nuts.

NOTE: Brake disc should be centered between new brake pads. Shims (7) and (9) are available in three thicknesses and may be added or deleted as necessary.

8. Check clearance between brake pads and brake disc and obtain sufficient shims to center the brake disc between the brake pads.
9. If brake disc is closer to one brake pad than the others, perform the following steps to adjust the clearance.
(a) Remove nut (1) and washer (2).
(b) Remove bolts and nuts installed in step 6.
(c) Lift brake disc (3), key (4), and shim (7) off motor shaft.
(d) Add to or remove existing shims (7) or (9) as necessary.
(e) Reinstall brake disc (3), key (4), washer (2), and nut (1).
(f) Install bolts and nuts removed in step 9 (b) and check clearance between brake disc and brake pads by rotating disc by hand. Repeat steps 8 and 9 if clearance is incorrect. 

CAUTION: Overtightening of nuts brake caliper assembly will restrict movement of brake pads and impair brake performance. Both upper and lower brake pads must move freely toward brake disc to engage brake properly.

10. Install shoulder bolt (24) in brake link (22) and brake lever arm. Reinstall rod end (14) in control handle and reassembly with shoulder bolt (33).
11. Release steering arm.
12. Refer to paragraph 3-11a and adjust brake.

Figure  3-6. Disc Brake and Linkage

3-12. Transmission And Drive Wheel Repair.
a. Transmission Removal and Disassembly. (Figure 3-7)

Removal and disassembly of the transmission facilitates inspection and replacement of parts.
1. Disconnect battery.
2. Securely block road wheels so truck cannot move, and remove service cover (2, figure 3-10).
3. Make sure the cables between the battery disconnect plug and the electrical control panel are labeled according to their destinations before they are disconnected.
4. Label the wire connecting the 40-ampere fuse to the dynamic brake and disconnect.
5. Label the wires that lead to the pump and lowering valve solenoids and disconnect.
6. Remove access cover (20, figure 3-10) directly behind the drive wheel by removing the four flat socket head screws.
7. Remove the four screws (17, figure 3-10), lock washers (18) and cable guard weldment (16).
8. Remove the sex hex head screws and lock washer that secure the outer race (22, figure 3-7).

NOTE: Eye bolts may be installed in the four ½-13 tapped holes on the top surface of outer bearing race (22) to lift the complete transmission from the frame.

CAUTION: The  transmission may snag an adjacent electrical cables during the lifting operation. Hoist the transmission slowly and check that it clears all nearby parts.

9. Lift transmission from frame and place in a vertical position for inspection or repair by either putting blocks under pivot bearing or placing on a holding frame.
10. MAke sure the four cables to the drive motor are properly labeled A1, A2, F1, and F2; then disconnect the cables from the drive motor.
11. Remove the hex head cap screw and lock washer that hold the wiring harness and its mounting bracket to the transmission.
12. Remove the four hex head cap screws and lock washers that secure the electrical control panel, and lift off the control panel.
13. Disconnect the mechanical brake by removing the shoulder bolt (24, figure 3-6) and lock nut (23) that secure the brake caliper (25) to the links (22).

14.  Remove drain plugs (27, figure 3-7) and drain the transmission oil into a suitable container.
15. Remove the five socket head cap screws (54) and lock washers (55) and lift out the motor, making sure the spilled coupling (53) is not misplaced. Lay motor and brake parts aside until reassembly.
16. Remove eight screws (25), transmission cover (23) and gasket (51).
17. Remove eight screws (47) and lock washers (48) and pull off drive wheel.

NOTE: Observe the torque requirements listed in table 3-5 when reassembling the transmission.

b. Spiral Bevel Pinion Gear Replacement.
1. Remove and disassemble the transmission, as discussed in pargraph 3-12a.
2. Remove the four socket head screws (4, figure 3-7) and lock washers (5) and remove bearing cap and oil seal.

NOTE: Shim (50) may be lost during disassembly unless special care is taken.

3. Remove spiral bevel pinion assembly and attached parts, making sure to retain shim (50) for use during reassembly.
4. Remove roll pin (7) from bearing locknut (6), this action permitting complete disassembly.

NOTE: If spiral bevel pinion (12) requires replacement, the spiral bevel gear (28) also will require replacement. They must be replaced as a matched set. 

5. Reassemble the spiral bevel pinion gear assembly in the reverse order of disassembly with the following instructions.
(a) Pregrease the upper and lower bearing cones (11) with molybdenum disulfide grease, and place shim into bore first then sprial bevel pinion assembly.
(b) Make sure the spacer shield (39) is installed with the chamfer side down, facing the back face of the spiral pinion.
(c) Tighten the bearing locknut (6) to seven inch/pounds torque before locking in place with roll pin (7).

(d) After reassembly the spiral bevel gear must turn freely. If there is a binding, spiral bevel gear (28) must be removed by removing roll pin from locknut and shims added until gear rotates freely. If there is excessive backlash then the shim must be reduced until the gear rotates freely. Reassemble locknut and tighten to a torque of twelve (12) inch/pounds. Reinstall 3/16 inch roll pin into aligning holes.

c. Spur Pinion, Internal Gear and Bearing Set Replacement.
To replace a spur pinion, internal gear or bearing set proceed as follows: (Fig. 3-7)
1. Remove adjustbale clamp and transmission seal (37, 38)

NOTE: Use care in removing seal so as not to damage material sealing lip.

2. Remove 3/16" roll pin, bearing locknut, spiral bevel gear (28) and shim.
3. Remove four 3/8-16 hex head cap screws and bearing retainer (30).
4. Remove bearing retainer with “O” ring (46) to remove bearing locknut (44) locking tab on bearing lockwasher must be bent outward to allow locknut to be removed.
5. Remove internal spur gear (40) and wheel load bearings. Spur pinion (33) and bearings cannot be removed by applying pressure from wheel hub side. When reassembling, spiral bevel gear (28) must rotate freely with spiral bevel pinion and shims will have to be added or deducted (29) to accomplish this. Reassemble locknut and tighten to a torque value of twelve (12) inch/pounds torque. Reinstall 3/16" roll pin into aligning holes.
After re-assembling internal gear assembly (40) locknut (44) must be tightened to set the end play to zero (0) to .005 end play. Then locking tab on lockwasher (45) bent down into notch on locknut (44) to keep it from rotating loose. Reinstall bearing retainer and “O” ring. Light coating of petroleum jelly should be applied to “O” ring for ease of assembly.
Replace transmission seal and clamp (37, 38) on main housing. The clamp should be tightened only enough to keep seal from rotating on main housing. It is possible with too much torque on locking screw to strip the notched area of clamp.

d. Transmission Pivot Bearing Adjustment. (Figure 3-7)

NOTE: A special spanner wrench for setting bearing preload may be obtained from Big Joe parts and service department. Wrench part number is 900880.

Figure 3-7. Transmission and Drive Wheel (Sheet 1 of 2)

Figure 3-7. Transmission and Drive Wheel (Sheet 2 of 2)

1.Remove screw (31), lock washer (24), flat washer (52) and retainer clip (49).

NOTE: A few of the ½-13 hex head screws that hold the pivot bearing to the frame (33, figure 3-10) and associated lock washers (32) will have to be removed to provide spanner wrench clearance.

CAUTION: Makeshift disassembly procedures may damage the transmission and make accurate preload adjustment impossible. Do not attempt to tighten or loosen the bearing retainers with such methods as hammering against the raised lugs. Use the official Big Joe Spanner wrench, part number 900880.

2. Using the special spanner wrench, set the pivot bearing to 140 foot-pounds torque.
3. Place the retaining clip (49, figure 3-7) into the most convenient notch of the lockout (17) and secure with screw (31), lock washer (24), and flat washer (52).
4. Apply molybdenum disulfide grease with a low pressure grease gun to the two grease fittings (14) in the pivot bearing outer race (22).

e. Transmission Pivot Bearing Replacement.

NOTE: A special spanner wrench for setting bearing preload may be obtained from Big Joe parts and service department. Wrench part number is 900880.

1.Remove steering arm (paragraph 3-10).
2. Remove electrical panel assembly and drive motor assembly (paragraph 3-12a, steps 1 through 12).
3. Block the drive wheel so that it cannot turn left or right.
4. Remove screw (31), lock washer (24), flat washer (52) and retaining clip (49).

NOTE: Makeshift disassembly procedures may damage the transmission and make accurate preload adjustment impossible. Do not attempt to tighten or loosen the bearing retainer by such methods as hammering against the raised lugs. Use the official Big Joe spanner wrench, part number 900880.

CAUTION: Ball bearings (20 and 21) may fall out of raceway (19) when bearing retainer (17) is removed. Take special care to catch all bearings during disassembly.

5. Using the special spanner wrench, remove beraing retainer (17) and felt strips (18).
6. Remove bearing raceway (19) and ball bearings (20 and 21). Outer race (22) now may be removed.

7. Reassemble the pivot bearing in reverse order of disassembly with the following instructions.
(a) When installing th esteel ball bearings (20 and 21) followed by one plain, etc.
(b) Prepack ball bearings with molybdenum disulfide grease and install with bearing raceway (19).
(c) Set pivot bearing preload to 140 foot/pounds torque as discussed in pargraph 3-12d. See table 3-5.

Table 3-5. Transmission Fasteners Torque Requirement

f.  Drive Wheel Replacement
1. Disconnect battery.
2. Securely block the load wheels to prevent the truck from moving.
3. Use a jack to raise the rear of the lift truck so that the drive wheel clears the ground.
4. Lower thr truck on blocks, making certain the drive wheel is still clear of the ground.
5. Remove four screws (13, figure 3-10) and access cover (20).
6. Remove two flat head screws (25) and transmission stop (19).

CAUTION: IF A WHEEL PULLER IS USED, MANY HAVE POINTED CENTER SCREWS WHICH MAY PUNCTURE THE BEARING RETAINER AND CAUSE OIL LEAKAGE. PROTECT THE BEARING RETAINER BY PLACING A PIECE OF METAL BETWEEN THE WHEEL PULLER CENTER POINT AND THE BEARING RETAINER.

8. Remove the eight hex head cap screws (47, figure 3-7) and lock washers (48) that secure the drive wheel to the internal spur gear (40) and then pull off the wheel.
9. Reverse the above procedure to install new drive wheel, making sure the hex head screws (47) are tightened to a torque seting of 90 foot/pounds.

3-13. Load Wheel and Bearing Replacement. (Figure 3-8)

1.Raise forks with hydraulic cylinder.
2. Disconnect battery.
3. Block the drive wheel to prevent the truck from moving.
4. Place a hydraulic jack under each fork at reinforced section behind the load wheel (6) and under the pull rod. Raise the forks until the load wheels clear the floor.
5. Remove locknut (13) securing load wheel to axle shaft.
6. Install new or repaired load wheel assembly.

NOTE: Bearings and spacers are matched sets within the load wheel assembly and should not be mixed with other sets.

CAUTION: Lubricate wheels when reassembling.

7. Reassemble by the following steps 1 through 6 in reverse order. For wheel spindles with Zerk fittings lubricate with gun. For wheel spindles without Zerk fittings, repack before installing.

NOTE: Torque locknut (13) to 100 foot/pounds.

3-14. Load Wheel Housing Replacement. (Figure 3-8)

In order to perform the following procedure, the truck must be placed in a service position, either securely held off the floor, or carefully tipped on its side. If proper joists or jacks are available, lower the forks as far as they will go, raise the truck off the floor and proceed with the service.

1.Place truck in service position. If tipping the truck is necessary, perform the following:
(a) Lower the forks all the way, and then disconnect and remove the battery.
(b) Plug the hydraulic reservoir breather vent with 3/8 NPT pipe plug.
(c) Disconnect the high-pressure hydraulic hose at the pump and place the free end of hose in a clean container to catch the oil that may drain from lift cylinders.
(d) Carefully tip truck onto its side.
2. Loosen nuts (22) away from spring plate (23) to release spring tension from pull rod assembly.
3. Disconnect the extension spring (21).
4. Remove roll pin (18) securing wheel housing pivot shaft (36) and pull shaft out of fork.
5. Remove snap ring (16) and exit roller (15) thrust washer (3) from shaft (14).
6. Remove roll pin (18) securing shaft (14) to wheel housing and pull shaft out of housing.
7. Disassemble load wheel housing assembly (6) as shown in figure 3-8.
8. Install new or repaired load wheel housing assembly by following steps 1 through 7 in reverse sequence.
9. Adjust pull rod length as described in paragraph 3-15a if necessary.

NOTE: If load wheel is disassembled from housing (7), reassembly using torque setting of 100 foot pound onlocknut (13).

3-15. Lift Linkage Repair.

In order to perform the following procedures, the truck must be placed in a service position, either securely held off the floor, or carefully tipped on its side. If proper hoists or jacks are available, lower the forks as far as they will go, raise the truck off the floor and proceed with the service. If you must tip the truck, perform the following steps.
1. Lower the forks all the way, and then disconnect and remove the battery.
2. Plug the hydraulic reservoir breather vent with 3/8 NPT pipe plug.
3. Disconnect the high-pressure hydraulic hose at the pump and place the free end of hose in a clean container to catch the oil that may drain from lift cylinder.
4. Carefully tip truck onto its side.

Figure 3-8. Backrest/Fork Assembly (Sheet 1 of 2)

Figure 3-8. Backrest/Fork Assembly (Sheet 2 of 2)

a. Adjustment of Pull Rod. (Figure 3-8)

NOTE: There can be no upward forces on the backrest/fork when making pull rod adjustments. The backrest/fork must be freely suspended from the frame for the correct adjustment to be made.

To insure even raising and lowering of forks and correct lowered height of forks, the pull rods must be properly adjusted. Follow this procedure to adjust pull rods.
1. Place the truck in a service position.
2. Loosen nuts (22) away from spring plate (23) to release spring tension on the pull rod assembly.
3. Disconnect the extension spring (21).
4. Loosen jam nuts (22 and 19) from against the clevises (17 and 43).
5. Turn the pull rod (20) so that wheel housing assembly (6) backs up against the underside of the fork.

NOTE: A large C-clamp may be used to hold the wheel housing assembly against the underside of the fork.

6. Lock the wheel housing assembly against the underside of the fork.
7. Turn pull rod opposite direction until roller (34) rests snugly against the roller pad portion of the frame (under the battery compartment). Do not overtighten.
8. Replace tension spring plate, and tighten jam nuts (22 and 19) against clevises (17 and 43).
9. Repeat the procedure for the other pull rod.
10. Return truck to normal operating position and restore it to operating condition. Add hydraulic oil if necessary.
11. Select a relatively smooth, flat area free of debris to test the adjustment.
12. Without a load, raise and lower forks several times and watch for rocking or tilting of truck or uneven lifting of forks.
13. Correct lowered height of truck should be approximately 3-1/8 inches. If lowered height exceeds 3-3/8 inches, adjust pull rods following instructions for adjustment of pull rod given in steps 1 through 11.

b. Removal of Pull Rod. (Figure 3-8)

1.Place truck in a service position.
2. Loosen nuts (22) beside spring plate (23) to release spring tension.
3. Disconnect the spring (21).

NOTE: Pull rod (20) has a right-hand thread on one end and a left-hand on the other end.

4. Loosen nut (22) and left-hand nut (19) from against clevises (17 and 43).
5. Unscrew pul l rod from the front by turning clockwise.
6. Unscrew pull rod from the rear clevis by turning counterclockwise.

c. Installation of Replacement Pull Rod Assembly.
Before a new pull rod is installed, inspect old wheel housing shafts (36, figure  3-8) for wear, and replace if necessary. New roll pins should be used to insure snug fit.

To install pull rod assembly refer to figure 3-8, and follow this procedure.

NOTE: Pull rod (20) has a right-hand thread on one end and a left-hand thread on the other end.

1.Place the truck in a service position.
2. Install jam nut (19) on the front (left-hand thread) end of the pull rod.
3. Screw to front end of the pull rod into the front clevis (17).
4. Install the following on the pull rod rear end, one nut (22), spring plate (23), two more nuts (22) and lock washer (24).
5. Install pull rod rear end into rear clevis (43)
6. Connect the spring plate to the boss welded to the underside of the fork with the extension spring (21).
7. Adjust pull rod length as described in paragraph 3-15a.

3-16 Roller Removal
1. Raise the forks.
2. Block the drive wheel to prevent the truck from moving.
3. Provide adequate support for the forks.
4. Disconnect the battery.
5. To remove an entry roller, remove the associated shoulder bolt (5, figure 3-8), roller (4), and nut (2).
6. To remove and exit roller, follow instructions for load wheel housing replacement, paragraph 3-14, steps 1 through 5.

3-17. Caster Bearing Replacement (Figures 3-9 and 3-10)
1.Block the load wheel to prevent truck from moving.
2. Disconnect the battery.
3. Raise the rear of the truck with a jack or a second lift truck and place supports under the frame approximately six inches in front of the caster assemblies.
4. Lower the truck onto the supports.

5. Remove the platforms (44, figure 3-10) by removing screws (42) and washers (32 and 43).
6. Remove the four screws (13) and remove the caster assembly (14) and bearing housing (15).
7. Remove snap ring (1, figure 3-9) and spacer (2) and pull bearing housing off caster assembly.
8. Press out and discard damaged bearing (3) after removing retainer ring (14).
9. Reassemble and reinstall caster assembly with new bearing in place by performing steps 1 through 8 in reverse sequence.

Figure 3-9. Caster Assembly

3.18. Caster Wheel Bearing Replacement. (Figure 3-9)

1.Block the load wheels to prevent the truck from moving.
2. Disconnect the battery.
3. Raise the rear of the truck with jack or a second lift truck and place supports under the frame approximately six inches in front of the caster assemblies.
4. Lower the lift truck onto the supports.
5. Remove snap ring (8) from wheel axle (13). Remove spacer (7) and slide out axle so wheel (11) can be removed.
6. Remove wheel, retaining thrust bearing (9) for inspection and possible reuse.
7. Press out damaged bearing(s) (10) and install new bearing(s).
8. Reassemble and reinstall the caster assembly by performing steps 1 through 7 in reverse sequence.

3-19. Base and Frame. (Figure 3-10)

Figure 3-10 identifies and locates parts associated with the base and frame. No special procedures are required, except the following, which explains removal of the backrest/fork assembly.
In order to perform the following procedures, the truck must be placed in a service position, either securely held off the floor, or carefully tipped on its side. If proper hoists or jacks are available, lower the forks as far as they will go, raise thr truck off the floor and proceed with the service.

WARINING: Before disconnecting any hydraulic lines, make sure the hydraulic system is not under pressure.

1.Place truck in service position. If the truck must be tipped, perform the following:
(a) Lower the forks all the way, and then disconnect and remove the battery.
(b) Plug the hydraulic reservoir breather vent with 3/8 NPT pipe plug.
(c) Disconnect the high-pressure hydraulic hose at the pump and place the free end of hose in a clean container to catch the oil that may drain from lift cylinders.
(d) Carefully tip truck onto its side.
2. Disconnect the hydraulic hose (9, figure 3-25) where it joins swivel connector (12) under the battery compartment.
3. Remove truck from service position and set on floor.
4. Slightly raise the backrest/fork.
5. Install jacks or other adequate supports beneath each fork.
6. Remove the two screws (3, figure 3-25) and lock washers (4) from the backrest/fork brackets above the lift cylinders, and remove the mounting bar (5).
7. Remove the eight screws (3, figure 3-25) and lock washers (4) from the backrest/fork brackets above the lift cylinders, and remove the mounting bar (5).

Figure 3-10. Base and Frame