Home

DP WPT 45 SERIES SELF-PROPELLED, PALLET LIFT TRUCK OPERATION MAINTENANCE REPAIR PARTS LIST [(TW UP) WPT-45] 2/3

This article provides a comprehensive list of operation, maintenance, repair, and parts for the DP WPT 45 Series Self-Propelled, Pallet Lift Truck (TW UP) model, allowing users to easily find the information they need for the proper functioning and upkeep of the equipment.

Written by Nash Bernardo

Updated at November 1st, 2024

+ More

OPERATION
MAINTENANCE
REPAIR PARTS LIST
WPT 45 SERIES
SELF-PROPELLED
PALLET LIFT TRUCK

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
SECTION		PAGE	SECTION		PAGE
1.DESCRIPTION		1-1	6. BRAKE SERVICING		6-1
1-1.	INTRODUCTION	1-1	6-1.	BRAKES	6-1
1-2.	GENERAL DESCRIPTION	1-1	6-1.1.	AIR GAP ADJUSTMENT	6-1
1-3.	SAFETY FEATURES	1-2	6-1.2.	STOPPING DISTANCE ADJUSTMENT	6-2
2. OPERATION		2-1	6-1.3.	BRAKE ASSEMBLY REPLACEMENT	6-2
2-1.	GENERAL	2-1	7. TRANSMISSION, DRIVE WHEEL, LOAD WHEEL		7-1
2-2.	OPERATING PRECAUTIONS	2-1	7-1.	DRIVE WHEEL	7-1
2-3.	BEFORE OPERATION	2-1	7-2.	TRANSMISSION	7-1
2-4.	GENERAL CONTROL OPERATION	2-4	7-3.	LOAD WHEEL	7-2
2-5.	DRIVING AND STOPPING PROCEDURES	2-4	7-3.1.	REMOVAL	7-2
2-6.	BELLY-BUTTON SWITCH	2-4	7-3.2.	REPAIR	7-2
2-7.	STEERING ARM GAS SPRING	2-5	7-3.3.	LOAD WHEEL INSTALLATION	7-2
2-8.	LIFT AND LOWER CONTROLS	2-5	8. ELEVATION SYSTEM SERVICING		8-1
2-9.	LOADING AND UNLOADING	2-5	8-1.	GENERAL	8-1
2-10.	PARKING	2-5	8-2.	LIFT LINKAGE	8-1
3. PLANNED MAINTENANCE		3-1	8-2.1.	REMOVAL	8-1
3-1.	GENERAL	3-1	8-2.2.	INSTALLATION	8-2
3-2.	MONTHLY AND QUARTERLY CHECKS	3-1	8-3.	POWER SECTION AND FORK SECTION	8-2
3-3.	BATTERY CARE	3-1	8-3.1.	SEPARATING POWER SECTION AND FORK SECTION	8-2
3-3.1.	GENERAL	3-1	8-3.2.	FORK FRAME REPAIR	8-2
3-3.2.	SAFETY RULES	3-2	8-3.3.	CARRIER FRAME REPAIR	8-2
3-3.3.	BATTERY CARE AND CHARGING	3-2	8-3.4.	MATING POWER SECTION AND FORK SECTION	8-2
3-3.4.	BATTERY CLEANING	3-2	9. HYDRAULIC SYSTEM SERVICING		9-1
3-3.5.	MAINTENANCE FREE BATTERIES	3-3	9-1.	LINES AND FITTINGS	9-1
3-4.	CHARGING BATTERIES	3-3	9-2.	HYDRAULIC PUMP, MOTOR, AND RESERVOIR ASSY	9-2
3-5.	LUBRICATION	3-4	9-2.1.	REMOVAL	9-2
4. TROUBLESHOOTING		4-1	9-2.2.	DISASSEMBLY AND REASSEMBLY	9-2
4-1.	GENERAL	4-1	9-2.3.	INSTALLATION	9-2
4-2.	CONTROLLER TROUBLESHOOTING	4-4	9-2.4	LIFT CYLINDER	9-4
4-2.1.	ZAPI HANDSET	4-4	10. ELECTRICAL COMPONENTS		10-1
4-2.2.	FAULT DETECTION	4-4	10-1.	ELECTRICAL CONTROL PANEL	10-1
4-2.3.	TESTING TRUCK OPERATION	4-4	10-1.1.	MAINTENANCE	10-1
4-2.4.	SETTINGS AND ADJUSTMENTS	4-5	10-1.2.	CLEANING	10-1
5. STEERING ARM, CONTROL HEAD AND COMPARTMENT		5-1	10-1.3.	PANEL REMOVAL	10-1
5-1.	CONTROL HEAD	5-1	10-1.4.	PANEL DISASSEMBLY	10-1
5-1.1.	CONTROL HEAD REMOVAL	5-1	10-1.5.	PANEL INSTALLATION	10-1
5-1.2.	CONTROL HEAD INSTALLATION	5-2	10-2	HORN REPLACEMENT	10-3
5-1.3.	CAP ASSEMBLY REMOVAL	5-3	10-3	PUMP MOTOR	10-4
5-1.4.	CAP ASSEMBLY INSTALLATION	5-3	10-4	DRIVE MOTOR	10-4
5-1.5.	BELLY-BUTTON SWITCH REPLACEMENT	5-3	10-4.1.	MOTOR REMOVAL	10-4
5-1.6.	HORN SWITCH REPLACEMENT	5-4	10-4.2	MOTOR INSTALLATION	10-4
5-1.7.	LIFT AND LOWER SWITCH REPLACEMENT	5-5	10-5	LIFT LIMIT SWITCH	10-4
5-1.8.	DIRECTIONAL POTENTIOMETER REPLACEMENT	5-6	10-5.1.	REPLACEMENT	10-4
5-2.	STEERING ARM	5-6	10-5.2.	ADJUSTMENT	10-4
5-2.1.	RETURN SPRING REPLACEMENT	5-6	10-6	DEADMAN SWITCH	10-5
5-2.2.	STEERING ARM REMOVAL	5-6	10-6.1.	REPLACEMENT	10-5
5-2.3.	STEERING ARM ISNTALLATION	5-6	11. OPTIONAL EQUIPMENT		11-1
5-3.	COMPARTMENT COVERS	5-6	11-1.	LOAD BACKREST	11-1
5-3.1.	REMOVAL	5-6	11-2.	CASTERS	11-1
5-3.2.	INSTALLATION	5-6	12	ILLUSTRATED PARTS BREAKDOWN	12-1

LIST OF ILLUSTRATIONS
Figure		Page	Figure		Page
1-1	NAME PLATE	1-1	10-3	TRANSMISSION, MOTOR, BRAKE ASSEMBLY	10-4
1-2	WOT 45 LIFT TRUCK	1-1	12-1	STEERING SYSTEM	12-2
2-1	SAMPLE OF OPERATOR CHECK LIST	2-3	12-2	STEERING ARM	12-3
-2	FORWARD/REVERSE CONTROL	2-4	12-3	CONTROL HEAD	12-4
2-3	PUSHBUTTON SWITCHES	2-4	2-4	CAP ASSEMBLY	12-5
2-4	BRAKE ACTUATION	2-4	12-5	LIF/LOWERING SWITCH ASSY, LEFT	12-6
2-5	BELLY-BUTTON SWITCH	2-5	12-6	LIF/LOWERING SWITCH ASSY, RIGHT	12-7
3-1	LUBRICATION DIAGRAM	3-5	12-7	EMERGENCY REVERSE SWITCH ASSEMBLY	12-8
4-1	CONNECTING THE HANDSET	4-4	12-8	TRANSMISSION, MOTOR, BRAKE MOUNTING	12-9
4-2	ZAPI HANDSET	4-5	12-9	TRANSMISSION, MOTOR , BRAKE ASSEMBLY	12-10
4-3	ZAPI HANDSET	4-9	12-10	TRANSMISSION, MOTOR , BRAKE ASSEMBLY	12-11
4-4	THROTTLE REGULATION	4-10	12-11	COMPARTMENT	12-12
4-5	ZAPI HANDSET	4-11	12-12	CASTER WHEEL (OPTIONAL)	12-13
4-6	ZAPI CONTROLLER CONNECTIONS	4-13	12-13	FRAME	12-14
5-1	STEERING ARM	5-1	12-14	LIFT LINK ASSEMBLY	12-15
5-2	CONTROL HEAD	5-2	12-15	LOAD WHEEL	12-16
5-3	EMERGENCY REVERSE SWITCH ASSEMBLY	5-3	12-16	HYDRAULIC SYSTEM	12-17
5-4	CAP ASSEMBLY	5-4	12-17	PUMP & MOTOR ASSY	12-18
5-5	LEFT LIFT/LOWER SWITCH ASSY (RIGHT SIMILAR)	5-5	12-18	LIFT CYLINDER	12-19
6-1	BRAKE ASSEMBLY	6-1	12-19	ELECTRICAL SYSTEM	12-20
7-1	TRANSMISSION, MOTOR, BRAKE ASSEMBLY	7-1	12-20	ELECTRICAL PANEL	12-21
7-2	WHEEL ASSEMBLY	7-2	12-21	WIRING HARNESS	12-22
8-1	FRAME	8-1	12-22	WIRING CABLES	12-24
8-2	LIFT LINKAGE ASSEMBLY	8-3	12-23	BATTERY COMPARTMENT	12-24
9-1	HYDRAULIC SYSTEM	9-1	12-24	BATTTERIES	12-26
9-2	PUMP AND MOTOR ASSEMBLY	9-3
10-1	ELECTRICAL SYSTEM	10-2
10-2	ELECTRICAL PANEL	10-3
LIST OF TABLES
Table		Page	Table		Page
2-1	OPERATOR CHECKS	2-2	4-1	TROUBLESHOOTING CHART	4-1
3-1	MONTHLY AND QUARTERLY INSPECTION AND SERVICE CHART	3-1	4-2	SET OPTIONS	4-5
3-2	RECOMMENDED LUBRICANTS	3-4	4-3	ADJUSTMENTS	4-9
3-3	LUBRICATION CHART	3-5	4-4	PARAMETER ADJUSTMENTS	4-11
			4-5	ZAPI CONTROLLER CONNECTOR PINS	4-13

continued…

Figure 4-6 Zapi Controller Connections

Table 4-5 Zapi Controller Connector Pins

CNA Connector
PIN	ABBREVATION	DESCRIPTION
CAN#1	NMC	Negative of main contactor coil.
CAN#2	PMC	Positive of main contactor coil.
CAN#3	NEB	Output for driving the electromechanical brake coil; drives the load to -Batt. Maximum current: 3 A.
CAN#4	NPC	Negative of pump contactor soil.
CAN#5	PPC/PEV	Positive of pump contactor coil and lowering electrovalve coil.
CAN#6	NEV	Negative of the lowering electrovalve coil.
CAN#7	CAN LOW	Low level CAN-BUS voltage I/O.
CAN#8	-BAT	-Bat.
CAN#9	ENC+	Encoder Positive Supply (+5 or +12 Vdc)
CAN#10	ENX-	Encoder Negative Supply (GND to minus battery)
CAN#11	HM(+B)	Output for driving an hourmeter; when the hourmeter is active this output provides a +Batt signal; 3 maximum current.
CAN#12	-BATT	-Batt.
CAN#13	MOT TH	Motor thermal sensor input. The internal pull-up is a fixed 2mA (Max 5V) source current.
CAN#14	SR2	Speed reduction 2 input. Active low (switch opened).
CAN#15	SR1	Speed reduction 1 input. Active low (switch opened).
CAN#16	+12V	This output provides a +12V signal for the MDI PRC, it present; mA maximum current.
CAN#17	CAN HIGH	High level CAN-BUS voltage I/O.
CAN#18	CPOTB	Brake potentiometer wiper.
CAN#19	ENC A	Encoder Channel A.
CAN#20	ENC B	Encoder Channel B.
CNB 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 >1kΩ.
CNC 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).

SECTION 5
STEERING ARM, CONTROL HEAD AND COMPARTMENT

5-1. CONTROL HEAD
5-1.1. ControlHeadRemoval

1. Turn off the key switch (7, Figure 12-19) and disconnect the batteries.

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

2. Remove two screws (2, Figure 5-1), two washers (3) and two flat washers (4).

Figure 5-1 Steering Arm

WARNING: When removing the control head in the following steps, be sure to hold it in place until the control harness is disconnected.

3. Remove two screws (6, Figure 5-2), two washers (7) and two flat washers (8).

4. Disconnect harness (10, Figure 12-21) from har- ness (13) and remove the control head and han- dle (15, Figure 5-2).

5-1.2. Control Head Installation

1. Hold control head in place and connect harness (10, Figure 12-21) to harness (13).

2. Secure control head and handle (15, Figure 5-2) with two screws (6), two washers (7) and two flat washers (8).

3. Install two screws (2, Figure 5-1), two washers (3) and two flat washers (4).

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

5. Reconnect the batteries and turn on the key switch (7, Figure 12-19).

Figure 5-2 Control Head

5-1.3. Cap Assembly Removal.

1.Turn off the key switch (7, Figure 12-19) and dis- connect the batteries.

2. Remove four screws (6, Figure 5-2) and lift up cap assembly (1) and disconnect harness (10, Figure 12-21) from harness (9).

5-1.4. Cap Assembly Installation.

1.Hold cap assembly (1, Figure 5-2) in place and connect harness (10, Figure 12-21) to harness (9).

2. Position cap assembly (1, Figure 5-3) on control head and secure with four screws (6).

3. Reconnect the batteries and turn on the key switch (7, Figure 12-19).

5-1.5. Belly-Button Switch Replacement.

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

2. Disconnect harness (8, Figure 12-21) from har- ness (10).

3. Remove two screws (13, Figure 5-2) and remove switch assembly (12) from bracket (10).

4. Remove pin (6, Figure 5-3), bracket (5), and spring (3) from button (1).

5. Remove two pins (4) and switch (2) from bracket (5).

6. Disconnect harness (8, Figure 12-21) from switch (2, Figure 5-3) and connect it to the new switch.

7. Position the new switch (2, Figure 5-3) in bracket (5) and secure with two pins (4).

Figure 5-3 Emergency Reverse Switch Assembly

8. Position bracket (5) in button (1) and install pin (6).
9. Position switch assembly (12, Figure 5-2) on bracket (10) and secure with two screws (13).
10. Connect harness (8, Figure 12-21) to harness (10).
11. Install the cap assembly as described in paragraph 5-1.4.
5-1.6. Horn Switch Replacement.
1. Remove the cap assembly as described in paragraph 5-1.3.

2. Remove three screws (8, Figure 5-4), bracket (7) and spring (9).
3. Remove two pins (10) and switch (6) from bracket (7).
4. Disconnect harness (9, Figure 12-21) from switch (6, Figure 5-2) and correct it to the new switch.
5. Position the new switch (6) in bracket (7) and secure with two pins (10).
6. Position bracket (7) in cover (1) and secure with three screws (8).
7. Install the cap assembly as described in paragraph 5-1.4.

Figure 5-4 Cap Assembly

5-1.7. Lift and Lower Switch Replacement.

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

2.Disconnect harness (9, Figure 12-21) from switch assembly (2 or 4, Figure 5-4).

3. Remove pin (3, Figure 5-5) and switch assembly (2 or 4, Figure 5-4) from the cap (1)

4. Remove two pins (3, Figure 5-5), two switches (2) and four springs (5) from bracket (4).

5. Position the new switches (2) and four springs (5) in bracket (4) and secure with two pins (3).

6. Position switch assembly (2 or 4, Figure 5-4) in cover (1) and secure with pin (3, Figure 5-5).

7. Connect harness (9, Figure 12-21) to switch (2 or 4, Figure 5-4).

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

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

5-1.8. Speed Potentiometer Replacement.

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

2. Disconnect harness (10, Figure 12-21) from potentiometer (2, Figure 5-2).

3. Remove screw (5), washer (4) and control knob (3) from potentiometer (2).

4. Remove screw (5), washer (4) and control knob (11) from other side of potentiometer (2).

5. Remove two screws (13) and remove potentiome- ter (2) from bracket (10).

6. Position new potentiometer (2) in bracket (10) and secure with two screws (13).

7. Install control knob (3) on potentiometer (2) and secure with screw (5), and washer (4).

8. Install control knob (11) on the other side of potentiometer (2) and secure with screw (5), and washer (4).

9. Connect harness (10, Figure 12-21) to potentiom- eter (2, Figure 5-2).

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

5-2. STEERING ARM
5-2.1. ReturnSpringReplacement.

The steering arm gas return spring (6, Figure 5-1) is replaced while the steering arm (5) is in the upright position.

1.Remove the compartment covers as described in paragraph 5-3.

2. Secure the steering arm (5, Figure 5-1) in the upright position.

3. Remove screw (7), flat washer (25), washer (26) and free the gas return spring (6) from brake plate (16).

4. Pull downward on the gas return spring (6) to free it from its seat inside steering arm (5).

5. Position the new gas return spring (6) inside the steering arm being sure it fully engages its seat.

6. Position the opposite end of the gas return spring (6) on brake plate (16) and install screw (7), flat washer (25), washer (26).

7. Install the compartment covers as described in paragraph 5-3.

5-2.2. Steering Arm Removal.

1. Remove the compartment covers as described in paragraph 5-3.

2. Remove the brake as described in paragraph

3. Disconnect harness (6, Figure 12-21) and harness (10) from harness (13).

4. Attach a hoist to steering arm (1, Figure 12-1).

5. Remove the three screws (4), three washers (5) and the steering arm (1).

5-2.3. Steering Arm Installation.

1.Position steering arm (1, Figure 12-1) over the drive motor and secure with three screws (4), three washers (5).

2. Connect harness (6, Figure 12-21) and harness (10) to harness (13).

3. Install the brake as described in paragraph

4. Install the compartment covers as described in paragraph 5-3.

5-3. COMPARTMENT COVERS

5-3.1. Removal.

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

2. Remove two screws (10, Figure 12-11) and upper cover (9).

3. Remove two screws (3, Figure 12-1). 4. Remove middle cover (8).
5. Pull the lower cover (7) up and out.

5-3.2. Installation.

1.Position the lower cover (7, Figure 12-11) on the frame.

2. Place middle cover (8) around the brake and secure with two screws (3, Figure 12-1).

3. Install upper cover (9, Figure 12-11) and secure with two screws (10).

4. Reconnect the batteries and turn on the keyswitch.

SECTION 6
BRAKE SERVICING

6-1.2. Stopping Distance Adjustment.

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

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

To adjust stopping distance, proceed as follows:

1.Block load wheels.

2. Remove the compartment covers as described in paragraph 5-3.

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

4. Remove load wheel blocks and check operation.

5. Install the compartment covers as described in paragraph 5-3.

6-1.3. BrakeAssemblyReplacement
1.Block load wheels.
2. Remove the compartment covers as described in paragraph 5-3.
3. Disconnect electric brake (12, Figure 12-21) from harness (13).

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

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

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

7. Reconnect electric brake (12, Figure 12-21) from harness (13).

8. Remove load wheel blocks and check operation.

9. Install the compartment covers as described in paragraph 5-3.

SECTION 7
TRANSMISSION, DRIVE WHEEL, LOAD WHEEL

7-3. Load Wheel.

7-3.1. Removal

1.Raise forks.

2. Turn off the key switch (7, Figure 12-19) and disconnect the batteries.

3. Block the drive wheel to prevent the truck from rolling.

4. Jack up the forks to raise the load wheels off the floor. Securely block the forks in the raised position by positioning supports under both fork tips.

NOTE: When shaft (10, Figure 12-14) is removed, load wheel assembly (11) will drop free.

5. Remove screw (4) securing pin (10) and remove pin (10) and load wheel assembly (11).

NOTE: Inspect the load wheel assembly. If the load wheel is worn within 1/8" of the metal sleeve, or is cracked or damaged, replace the entire load wheel and bearing assembly. Big Lift LLC recommends that both load wheel assemblies be replaced at the same time. This ensures level and safe operation of the lift truck.

7-3.2. Repair

6. Remove bearings (1, Figure 7-2) from wheels (2).

7. Inspect bearings (1) and replace if necessary.

8. Reassemble bearings (1) in wheels (2).

7-3.3. LoadWheelInstallation

1.Position load wheel assembly (11, Figure 12-14) in wheel bracket (12).

2. Install pin (10) and secure with screw (4).

3. Remove blocking from under the truck.

4. Lower the forks.

5. Reconnect the batteries and turn on the keyswitch (9, Figure 12-19).

Figure 7-2 Wheel Assembly

SECTION 8
ELEVVATION SYSTEM SERVICING

8-1. GENERAL.

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

8-2. LIFT LINKAGE 8-2.1. Removal

1. Lift complete truck to height sufficient to permit access to lift linkage under forks. Provide blocking under frame (3, Figure 8-1), the rear of fork sec- tion (1) and at tips of the forks.

2. Turn off the key switch (7, Figure 12-19) and disconnect the batteries.

3. Remove screw (9, Figure 8-1) from each side of frame (3). Support tension rod (14, Figure 8-2) and remove pin (2) from each side of link (5). Lower link (5) to the floor.

4. Support both tension rods (14) and remove pins (9).

5. Remove tension rods (14) with attached parts from under the fork.

Figure 8-1 Frame

8-2.2. Installation

1.Position tension rods (14, Figure 8-2) with attached parts under the fork.

2. Position bracket (12) in the fork and install pin (9).

3. Raise each tension rod (14) into position and install pin (2) through the frame. Secure Pin (2) with screw (9, Figure 8-1).

4. Remove blocking and lower the truck to the ground.

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

6. Reconnect the batteries and turn on the keyswitch (7, Figure 12-19).

8-3. Power Section and Fork Section

8-3.1. SeparatingPowerSectionandFork Section.

1.Support entire truck on blocking, providing sepa- rate blocks so that fork section (1, Figure 8-1) can be fully supported when frame (3) is removed.

2. Turn off the key switch (7, Figure 12-19) and dis- connect the batteries.

3. Remove the compartment covers as described in paragraph 5-3.

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

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

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

7. Remove the transmission as described in paragraph 7-2.

8. Attach a suitable hoist to frame (3, Figure 8-1).

9. Remove screw (9) and shaft (8) from frame (3).

10. Remove screw (9). Support link (5, Figure 8-2) and remove pins (2). Lower link (5) to the floor.

11. Remove frame (3) from fork section (1).

8-3.2. Fork Frame Repair.

1.Removal of components mounted on the frame (1) may be necessary to effect repairs/welding.

2. Inspect fork section (1) for broken welds and weld as necessary.

3. Replace fork section (1) if forks have been bent severely.

8-3.3. CarrierFrameRepair.

1.Removal of components mounted on the frame (3) may be necessary to effect repairs/welding.

2. Inspect frame (3) for broken welds and weld as necessary.

8-3.4. Mating Power Section and Fork Section.

1.With suitable hoist, carefully move frame (3, Fig- ure 8-1) into position.

2. Move link (14) into position on carrier frame (3) and install shaft (8). Secure shaft with screw (9).

3. Raise link (5, Figure 8-2) and install pins (2) and secure with screws (9, Figure 8-2).

4. Remove hoist from carrier frame (3).
5. Install the transmission as described in paragraph 7-2.

6. Install the steering arm as described in paragraph 5-2.3.

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

8. Install the lift cylinder as described in paragraph 9-2.4.

9. Install the compartment covers as described in paragraph 5-3.

10. Reconnect the batteries and turn on the keyswitch (9, Figure 12-19).

11. Remove the blocking from under the truck.

Figure 8-2 Lift Linkage Assembly

SECTION 9
HYDRAULIC SYSTEM SERVICING

9-1. LINES AND FITTINGS

WARNING:

When forks are raised, pressure exists in the hydraulic system lines and fittings. To ensure release of pressure, forks must be fully lowered and the batteries disconnected before performing any maintenance on the hydraulic system.

NOTE:

Leaking hydraulic fittings may be remedied by simply tightening fittings. If this does not rem- edy the leak, the fittings or line must be replaced.

1. Lower forks fully.

2. Turn off the key switch (7, Figure 12-19) and dis- connect the batteries.

3. Remove the compartment covers as described in paragraph 5-3.

CAUTION: Hydraulic oil can damage parts. Wipe off any oil immediately. Provide a container under the line or fitting before disconnecting.

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

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

Figure 9-1 Hydraulic System

6. Reconnect the batteries and turn on the keyswitch (7, Figure 12-19).

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

8. Check level of hydraulic oil. Hydraulic oil must be between the two level marks on the reservoir. If required, add hydraulic oil to bring to proper level. Use hydraulic oil listed in Table 3-2.

9. Install the compartment covers as described in paragraph 5-3.

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 component.

WARNING: When forks are raised, pressure exists in the hydraulic system lines and fittings. To ensure release of pressure, forks must be fully lowered and the batteries disconnected before performing any maintenance on the hydraulic system.

9-2.1. Removal

1.Lower forks fully.

2. Turn off the key switch (7, Figure 12-19) and dis- connect the batteries.

3. Remove the compartment covers as described in paragraph 5-3.

4. Tag and disconnect electrical leads from motor (2, Figure 9-2) and solenoid (17).

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

5. Disconnect hose (6, Figure 9-1) from pump/motor assembly (1).

6. While supporting the pump/motor assembly (1), remove two screws (4), two washers (3) and two flat washers (2).

7. Remove the pump/motor assembly (1) with bracket (7).

8. Remove two screws (4), two washers (3) and two flat washers (2) and bracket (7) from pump/motor assembly (1).

9-2.2. Disassembly and Reassembly

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

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

9-2.3. Installation

1. Position bracket (7, Figure 9-1) on pump/motor assembly (1) and secure with two screws (4), two washers (3) and two flat washers (2).

2. While supporting the pump/motor assembly (1), install two screws (4), two washers (3) and two flat washers (2).

3. Reconnect hose (6, Figure 9-1) to pump/motor assembly (1).

4. Connect electrical leads to motor (2, Figure 9-2) and solenoid (17).

5. Fill the hydraulic reservoir. Hydraulic oil must be between the two level marks on the reservoir. Use hydraulic oil listed in Table 3-2.

6. Reconnect the batteries and turn on the keyswitch (7, Figure 12-19).

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

8. Check level of hydraulic oil. Hydraulic oil must be between the two level marks on the reservoir. If required, add hydraulic oil to bring to proper level. Use hydraulic oil listed in Table 3-2.

9. Install the compartment covers as described in paragraph 5-3.

Figure 9-2. Pump and Motor Assembly

9-2.4. LiftCylinder

9-2.4.1.Removal

1.Lower forks fully.

2. Turn off the key switch (7, Figure 12-1) and dis- connect the batteries.

3. Remove the compartment covers as described in paragraph 5-3.

4. Ensure that hydraulic pressure has been relieved from the lift circuit. Disconnect the hydraulic line from the lift cylinder.

5. Disconnect hose (6, Figure 9-1) from cylinder (5).

6. Remove screw (6, Figure 12-13), washer (5) and spring plate (4) securing the cylinder to frame (3).

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

7. With suitable hoist, carefully raise frame (1) slightly so the cylinder can be removed.

9-2.4.2.Repair

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

2. Withdraw the cylinder rod (5) from the cylinder.

NOTE: If the cylinder tube (1) or piston rod (5) are damaged, the entire lift cylinder must be replaced.

3. Replace guide rings (2), seal ring (3) and wiper ring (4)

4. Coat all parts with hydraulic oil (Table 3-2).
5. Insert piston rod (5), with attached parts, into cylinder tube (1).

9-2.4.3.Installation

1.Position the cylinder on frame (3, Figure 12-13). Then lower the frame (1) onto the cylinder.

2. Reconnect the hose (3, Figure 9-1) to cylinder (1) with new O-ring (2).

3. Fill the hydraulic reservoir. Hydraulic oil must be between the two level marks on the reservoir. Use hydraulic oil listed in Table 3-2.

4. Reconnect the batteries and turn on the keyswitch (7, Figure 12-19).

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

6. Check level of hydraulic oil. Hydraulic oil must be between the two level marks on the reservoir. If required, add hydraulic oil to bring to proper level. Use hydraulic oil listed in Table 3-2.

7. Install the compartment covers as described in paragraph 5-3.

SECTION 10
ELECTRICAL COMPONENTS

10-1.ELECTRICAL CONTROL PANEL

10-1.1. Maintenance

NOTE: Erratic operation of the truck may be caused by defective controller components. Before removing the electrical panel, perform trou- bleshooting procedures per SECTION 4, to determine corrective action to be taken.

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

The controller is programmed at the factory specifi- cally for the truck model on which it is equipped. It is important to replace the controller with the correct pre- programmed unit to assure proper performance settings intended for that particular truck. See Figure 12- 20 for the preprogrammed controller number.

It is recommended that the controller exterior be cleaned 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 is also recommended that the controller’s fault detection circuitry be checked whenever the vehicle is serviced.

10-1.2. Cleaning

1.Turn off the key switch (7, Figure 12-19) and dis- connect the batteries.

2. Remove the compartment covers as described in paragraph 5-3.

3. Remove any dirt or corrosion from the bus bar area. The controller should be wiped clean with a moist rag. Allow it to dry before reconnecting the battery.

4. Make sure the connections to the buss bars are tight. Use two well insulated wrenches for this task in order to avoid steering the buss bars.

10-1.3.Panel Removal.

1. Turn off the key switch (7, Figure 12-19) and dis- connect the batteries.

2. Remove the compartment covers as described in paragraph 5-3.

3. Tag and disconnect all electrical cables which connect to the control panel (1, Figure 10-1).

4. Remove two screws (4), two washers (3), two flat washers (2) and control panel (1).

10-1.4.Panel Disassembly.

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

NOTE: Contactor (12) is not repairable and must be replaced if defective.

10-1.5.Panel Installation.

1.Install the control panel (1, Figure 10-1) and secure with two screws (4), two washers (3), two flat washers (2).

2. Refer to Figure 12-22 and connect all electrical cables to the control panel as noted during removal.

3. Install the compartment covers as described in paragraph 5-3.

4. Reconnect the batteries and turn on the keyswitch (7, Figure 12-19).

Figure 10-1 Electrical System

10-2.HORN REPLACEMENT

1.Turn off the key switch (7, Figure 12-19) and dis- connect the batteries.

2. Remove the compartment covers as described in paragraph 5-3.

3. Tag and disconnect all electrical connections from horn (19, Figure 10-1).

4. Remove screw (7), washer (8), flat washer (9), and horn (19).

5. Install horn (19) and secure with screw (7), washer (8), flat washer (9).

6. Install the compartment covers as described in paragraph 5-3.

7. Reconnect the batteries and turn on the keyswitch (7, Figure 12-19).

Figure 10-2 Electrical Panel

10-5.2.Adjustment

1.Raise the forks until switch (6, Figure 10-1) is aligned with the detent on the frame.

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

3. If necessary, loosen screws (4) and adjust mount- ing plate (13).

4. Tighten screws (4) and recheck.

10-6.DEADMAN SWITCH 10-6.1. Replacement

1.Disconnect wiring from the deadman switch (19, Figure 12-2).

2. Remove the two screws (20), and switches (19) from bracket (18).

3. Position the new switches (19) on bracket (18) and secure with the two screws (20).

SECTION 11
OPTIONAL EQUIPMENT

11-1.LOAD BACKREST.

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

11-2.CASTERS

Casters provide for additional stability. Installation of the casters is shown in Figure 12-11 and repair parts as shown in Figure 12-12.

SECTION 12
ILLUSTRATED PARTS BREAKDOWN

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

Figure 12-1 Steering System

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
1	---	STEERING ARM (FIGURE 12-2)	REF	3	0000-000090-00	SCREW	2
2	---	TRANSMISSION, MOTOR, BRAKE ASSY (FIGURE 12-8)	REF	4	0000-000322-00	SCREW	3
				5	0000-000159-00	WASHER	3

Figure 12-2 Steering Arm

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
1	---	CONTROL HEAD (FIGURE 12-3)	REF	14	0000-000117-00	SCREW	1
2	0000-000322-00	SCREW	2	15	0000-000031-00	SCREW	2
3	0000-000159-00	WASHER	2	16	1120-300004-00	FIXED PLATE	1
4	0000-000194-00	FLAT WASHER	2	17	1120-300001-0A	BRAKE PLATE	1
5	1120-330000-00	CONTROL ARM	1	18	1120-300006-00	BRACKET	1
6	1120-320000-00	GAS SPRING	1	19	1120-310002-00	DEADMAN SWITCH	2
7	1120-300002-00	SCREW	1	20	0000-000207-00	SCREW	2
8	0000-000033-00	SCREW	1	21	0000-000016-00	SCREW	1
9	0000-000056-00	WASHER	1	22	0000-000028-00	SCREW	2
10	1120-300005-00	BRACKET	1	23	1120-300003-00	SHAFT	1
11	0000-000030-00	SCREW	1	24	0000-000029-00	BUSHING	2
12	---	BRACKET	1	25	0000-000071-00	FLATWASHER	2
13	0000-000206-00	WASHER	1	26	0000-000063-00	WASHER	2

*Click on link to see original document:

https://static.helpjuice.com/helpjuice_production/uploads/upload/image/14012/3736353/1704263570914-_TW%2BUP_%2BWPT-45.pdf

Contact Us

DP WPT 45 SERIES SELF-PROPELLED, PALLET LIFT TRUCK OPERATION MAINTENANCE REPAIR PARTS LIST [(TW UP) WPT-45] 2/3

Contact Us

Related Articles