WRT 60

SELF-PROPELLED,
RIDER PALLET LIFT TRUCK

Operation
Maintenance
Repair Parts List

Big Lift LLC MANUAL NO. BL-WRT-0816 - 10-19-2018

www.bigjoeforklifts.com
 WARNING

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

Section Page Section Page

1 DESCRIPTION ............................................................1-1 6 BRAKE SERVICING ................................................... 6-1
1-1 INTRODUCTION ..........................................1-1 6-1 BRAKE - UP TO S/N 324200414 ................. 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
6-1.3 BRAKE ASSEMBLY REPLACEMENT......... 6-2
2 OPERATION ...............................................................2-1 6-2. BRAKE - USED FROM S/N 324200415. ..... 6-2
2-1 GENERAL.....................................................2-1
2-2 OPERATING PRECAUTIONS......................2-1 7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL .... 7-1
2-3 BEFORE OPERATION .................................2-1 7-1 DRIVE WHEEL ............................................ 7-1
2-4 TRAVEL ........................................................2-4 7-2 TRANSMISSION .......................................... 7-1
2-4.1 BRAKE..........................................................2-4 7-3 LOAD WHEEL.............................................. 7-3
2-4.2 TRAVEL ........................................................2-4 7-3.1 REMOVAL.................................................... 7-3
2-4.3 BELLY-BUTTON SWITCH............................2-4 7-3.2 REPAIR ........................................................ 7-3
2-5 STEERING ARM GAS SPRING ...................2-5 7-3.3 LOAD WHEEL INSTALLATION ................... 7-3
2-6 LIFT AND LOWER CONTROLS...................2-5 7-4 CASTERS .................................................... 7-3
2-7 LOADING AND UNLOADING.......................2-5
2-8 PARKING......................................................2-5 8 ELEVATION SYSTEM SERVICING ........................... 8-1
8-1 LIFT LINKAGE ............................................. 8-1
3 MAINTENANCE ..........................................................3-1 8-1.1 REMOVAL.................................................... 8-1
3-1 GENERAL.....................................................3-1 8-1.2 REPAIR ........................................................ 8-1
3-2 MONTHLY AND QUARTERLY CHECKS.....3-1 8-1.3 INSTALLATION............................................ 8-1
3-3 BATTERY CARE ..........................................3-1
3-3.1 GENERAL.....................................................3-1 9 HYDRAULIC SYSTEM SERVICING........................... 9-1
3-3.2 SAFETY RULES ...........................................3-2 9-1 LINES AND FITTINGS ................................. 9-1
3-3.3 BATTERY CARE AND CHARGING .............3-2 9-2 HYDRAULIC PUMP, MOTOR,
3-3.4 BATTERY CLEANING ..................................3-2 AND RESERVOIR ASSY ............................. 9-1
3-3.5 MAINTENANCE FREE BATTERY................3-3 9-2.1 REMOVAL.................................................... 9-1
3-4 CHARGING BATTERY .................................3-3 9-2.2 DISASSEMBLY AND REASSEMBLY .......... 9-3
3-5 LUBRICATION..............................................4-4 9-2.3 INSTALLATION............................................ 9-3
9-2.4 LIFT CYLINDER........................................... 9-3
4 TROUBLESHOOTING ................................................4-1 9-2.4.1 REMOVAL.................................................... 9-3
4-1 GENERAL.....................................................4-1 9-2.4.2 REPAIR ........................................................ 9-5
4-2 CONTROLLER TROUBLESHOOTING ........4-4 9-2.4.3 INSTALLATION............................................ 9-5
4-2.1 ZAPI SMART CONSOLE..............................4-4
4-2.1.1 ZAPI SMART 10 ELECTRICAL COMPONENTS ................................. 10-1
CONSOLE INSTRUCTIONS ........................4-5 10-1 ELECTRICAL CONTROL PANEL.............. 10-1
10-1.1 MAINTENANCE ......................................... 10-1
5 STEERING ARM, CONTROL HEAD 10-1.2 CLEANING ................................................. 10-1
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 COVER REMOVAL.......................................5-1 10-1.5 PANEL INSTALLATION ............................. 10-1
5-1.2 COVER INSTALLATION...............................5-2 10-2 HORN REPLACEMENT............................. 10-4
5-1.3 CONTROL HEAD REMOVAL.......................5-3 10-3 PUMP MOTOR .......................................... 10-5
5-1.4 CONTROL HEAD INSTALLATION...............5-3 10-4 DRIVE MOTOR .......................................... 10-5
5-1.5 BELLY-BUTTON SWITCH 10-4.1 MOTOR REMOVAL ................................... 10-5
REPLACEMENT ...........................................5-3 10-4.2 MOTOR INSTALLATION ........................... 10-5
5-1.6 HORN, LIFT AND LOWER 10-5 LIFT LIMIT SWITCH .................................. 10-5
SWITCH REPLACEMENT............................5-3 10-5.1 REPLACEMENT ........................................ 10-5
5-1.7 SPEED POTENTIOMETER 10-5.2 ADJUSTMENT ........................................... 10-5
REPLACEMENT ...........................................5-3 10-6 DEADMAN SWITCH .................................. 10-6
5-2 STEERING ARM...........................................5-3 10-6.1 REPLACEMENT ........................................ 10-6
5-2.1 RETURN SPRING REPLACEMENT ............5-3
5-2.2 STEERING ARM REMOVAL ........................5-3 11 OPTIONAL EQUIPMENT ........................................ 11-1
5-2.3 STEERING ARM INSTALLATION ................5-4 11-1 LOAD BACKREST ..................................... 11-1
5-3 COMPARTMENT COVERS..........................5-4
5-3.1 REMOVAL ....................................................5-4 12 ILLUSTRATED PARTS BREAKDOWN .................... 12-1
5-3.2 INSTALLATION ............................................5-4

BL-WRT-0816 - 10-19-2018 1
1-2 BL-WRT-0816 - 10-19-2018
 SECTION 1
DESCRIPTION

1-1. INTRODUCTION. speed range. The WRT lift truck can be driven with
This publication describes the 24 volt WRT 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.

and the recommendations contained in this manual,

you will receive many years of dependable service MAX CAP LB/ KG LOAD CTR IN/ MM LIFT HGT IN/ MM

from your WRT 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

transports payloads up to 6000 pounds on rigid forks. TRUCK BATTERY

CERTIFIED VOLTAGE
TYPE TYPE

The truck can be operated from the walking position

using the control head or from the riding position using COMPLIES WITH THE APPLICABLE REQUIRE-
MENTS OF ANSI B56.1 AND OSHA STANDARDS
the grab bar. U.S. PATENT NO. 4,444,284
AUSTRALIAN PATENT NO. 537,987

The battery powered lift truck is quiet and without BIG LIFT LLC
WISCONSIN DELLS, WISCONSIN 53965
exhaust fumes. R6209

The reversible AC motor propels the lift truck in for-

Figure 1-1 Name Plate
ward or reverse direction throughout the available

R6800A

Figure 1-2 WRT Lift Truck

BL-WRT-0816 - 10-19-2018 1-1

1-3. SAFETY FEATURES. • Separately fused control circuits and power circuits.
The WRT is designed and engineered to provide max- • Readily accessible horn button.
imum safety for operator and payload. Some of the
• Handle to provide a firm hand hold for operator.
safety features incorporated into the design are:
• Flow control valve regulates maximum lowering
• Dead-man brake to apply the brake and cut off drive
speed within prescribed limits.
power when the steering arm is released.
• Relief valve maintains hydraulic pressure within pre-
• Belly-button switch to reverse truck should the oper-
scribed limits.
ator accidentally pin himself against a wall or
obstruction when backing up in slow speed. • High visibility color scheme of truck provides visual
alert of truck’s presence.
• All control functions automatically return to “OFF”
when released. • Battery Indicator
• Externally accessible quick-disconnect battery plug • Casters
within operator's reach.

1-2 BL-WRT-0816 - 10-19-2018

 SECTION 2
OPERATION

2-1. GENERAL. • Do not overload truck. Check nameplate for load

This section gives detailed operating instructions for weight and load center information.
the WRT lift truck. The instructions are divided into the • Before lifting, be sure load is centered, forks are
various phases of operations, such as operating lift, completely under load, and load is as far back as
driving, and stopping. Routine precautions are possible against load backrest.
included for safe operation.
• Do not handle loads which are higher than the load
backrest unless load is secured so that no part of it
2-2. OPERATING PRECAUTIONS.
could fall backward.
WARNING: Improper operation of the lift truck may • When leaving truck, neutralize travel control. Fully
result in operator injury, or load and/or lift lower lifting mechanism and set brake. When leaving
truck damage. Observe the following truck unattended, turn off key switch and disconnect
precautions when operating the WRT lift switch, remove key and disconnect battery.
truck.
2-3. BEFORE OPERATION
The following safety precautions must be adhered to
at all times. Table 2-1 covers important inspection points on the
WRT lift truck which should be checked prior to opera-
• Do not operate this truck unless you have been
tion. Depending on use, some trucks may require
trained and authorized to do so and have read all
additional checks.
warnings and instructions in this manual and on the
truck. Figure 2-1 shows a sample format for an Operator
Checklist, which can be modified as necessary to fit
• All warnings and instructions must be read and
your operation.
understood before using the equipment.
• Equipment must be inspected by a qualified person WARNING: Periodic maintenance of this truck by a
on a regular basis. QUALIFIED TECHNICIAN is required.

• 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.

BL-WRT-0816 - 10-19-2018 2-1

 Table 2-1 Operator Checks

ITEM PROCEDURE ITEM PROCEDURE

Transmission Check for signs of fluid leakage. Wheels Check drive wheel for cracks or
and hydraulic damage. Move truck to check
systems. load for freedom of rotation.
Forks Check for cracks and damage. Hydraulic Check operation of lift and lower
Safety signs Check that warning labels, controls to their maximum positions.
nameplate, etc., are in good Brakes Check that brakes actuate when
condition and legible. steering arm is raised to upright
Horn Check that horn sounds when position, and when lowered to
operated. horizontal position.
Steering Check for binding or looseness in Deadman/ Check that steering arm raises to
steering arm when steering. Parking brake upright position when released
and brake applies.
Travel controls Check that speed controls on
control head operate in all Battery Check that battery can be
speed ranges in forward and disconnect disconnected and recon-
reverse and that belly button nected. Check for connector
switch functions. damage.
Battery charge Check the battery indicator.

2-2 BL-WRT-0816 - 10-19-2018

R6479

Figure 2-1 Sample of Operator Check List

BL-WRT-0816 - 10-19-2018 2-3

2-4. TRAVEL. while the lift truck is being driven toward the operator,
the switch changes the direction of the lift truck.
2-4.1. Brake
In an emergency, pull out battery connector, all electri-
The brake is fully applied by lowering or raising the cal functions are cut out and the truck automatically
steering arm. (See Figure 2-2) All travel control power brakes.
is shut off when the brake is engaged. When the steer-
ing 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.

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.

2-4.3. Belly-Button Switch

R6802
The belly-button switch (Figure 2-3 & Figure 2-4) mini-
mizes the possibility of the driver being pinned by the
steering arm while driving the lift truck in the walking Figure 2-2 Brake Actuation
position. If the switch presses against the operator

R6801

Figure 2-3 Control Head - Up To S/N E2318057 (except E2315544 & E2315546)

Figure 2-4 Control Head - From S/N E2318058 (and E2315544 & E2315546)

2-4 BL-WRT-0816 - 10-19-2018

 R6803

Figure 2-5 Grab Bar

2-7. LOADING AND UNLOADING.
2-5. STEERING ARM GAS SPRING. 1. Move truck to location where load is to be picked
The steering arm gas spring automatically raises the up.
steering arm to the upright position when the steering 2. Move the truck into position so forks are within
arm is released. If the steering arm does not return pallet or skid, and the load is centered over the
fully, the steering arm gas spring requires replace- forks and as far back as possible.
ment. Return truck to maintenance for repair.
3. Raise forks to lift load.
2-6. LIFT AND LOWER CONTROLS. 4. Drive to area where load is to be placed.

Lift/Lower Control buttons are located on the steering 5. Move truck to align load with its new position.
control head. (Figure 2-3 & Figure 2-4) and the grab 6. Lower the load until it rests squarely in place and
bar (Figure 2-5). the forks are free.
To lift forks, push in either LIFT button and hold until 7. Slowly move the truck out from under the load.
forks reach desired height. To lower forks, push in
either LOWER button and hold until forks descend to 2-8. PARKING.
desired height. When finished with moving loads, return the truck to its
maintenance or storage area. Turn off the key switch
and disconnect the battery. Charge battery as neces-
sary. Refer to battery care instructions, SECTION 3.

BL-WRT-0816 - 10-19-2018 2-5

 NOTES

2-6 BL-WRT-0816 - 10-19-2018

 SECTION 3
MAINTENANCE

3-1. GENERAL. CAUTION: Gases produced by a battery can be

Maintenance consists of periodic visual and opera- explosive. Do not smoke, use an open
tional checks, parts inspection, lubrication, and sched- flame, create an arc or sparks in the
uled maintenance designed to prevent or discover vicinity of the battery. Ventilate an
malfunctions and defective parts. The operator per- enclosed area well when charging.
forms the checks in SECTION 2, and refers any CAUTION: Battery contain sulfuric acid which may
required servicing to a qualified maintenance techni- cause severe burns. Avoid contact with
cian who performs the scheduled maintenance and eyes, skin or clothing. In case of contact,
any required servicing. flush immediately and thoroughly with
clean water. Obtain medical attention
3-2. MONTHLY AND QUARTERLY CHECKS. when eyes are affected. A baking soda
Table 3-1 is a monthly and quarterly inspection and solution (one pound to one gallon of
service chart based on normal usage of equipment water) applied to spilled acid until bub-
eight hours per day, five days per week. If the lift truck bling stops, neutralizes the acid for safe
is used in excess of forty hours per week, the fre- handing and disposal.
quency of inspection and service should be increased
Leakage voltage from battery terminals to battery case
accordingly. These procedures must be performed by
can cause misleading trouble symptoms with the truck
a qualified service technician or your Big Lift LLC Ser-
electrical system. Since components of the truck elec-
vice Representative.
trical system are insulated from truck frame, leakage
voltage will not normally affect truck operation unless a
3-3. BATTERY CARE.
short circuit or breakdown of circuit wire insulation to
3-3.1. General truck frame occurs.

The WRT may be equipped with maintenance free or A voltage check from battery connector terminal to
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.

BL-WRT-0816 - 10-19-2018 3-1

Although a leakage voltage reading of zero volts may 1. Charge the battery only in areas designated for
not be possible, a cleaner battery will have more that use.
usable charge for truck operation and not affect opera- 2. Make certain the charger being used matches the
tion of electronic devices on the unit. voltage and amperage of the truck battery.
3-3.2. Safety Rules 3. Before disconnecting or connecting battery to a
charger, make sure the charger is “OFF”. If an
• Wear protective clothing, such as rubber apron,
attempt is made to do this while the charger is
gloves, boots and goggles when performing any
“ON”, serious injury to you, the battery and the
maintenance on battery. Do not allow electrolyte to
charger could result.
come in contact with eyes, skin, clothing or floor. If
electrolyte comes in contact with eyes, flush immedi- 4. Before connecting the battery cable to the trucks
ately and thoroughly with clean water. Obtain medi- receptacle, make sure the key switch is off. The
cal attention immediately. Should electrolyte be battery cable must be fully connected before the
spilled on skin, rinse promptly with clean water and truck is used. If the plug is not making good con-
wash with soap. A baking soda solution (one pound tact, heat will weld the two parts of the battery
to one gallon of water) will neutralize acid spilled on connector together, making it difficult to remove
clothing, floor or any other surface. Apply solution and necessary to replace.
until bubbling stops and rinse with clean water. 5. Battery terminals should be checked and cleaned
• If truck is equipped with wet cell battery, keep vent of corrosion regularly. Good battery terminal con-
plugs firmly in place at all times except when adding tact is essential not only for operation, but also for
water or taking hydrometer readings. Do not allow proper charging of the battery.
dirt, cleaning solution or other foreign material to 6. The charging requirements will vary depending on
enter cells. Impurities in electrolyte has a neutraliz- the use of the truck. The battery should be given
ing effect reducing available charge. as equalizing charge on a weekly basis. This
• Do not bring any type of flame, spark, etc., near the charge should normally be an additional three
battery. Gas formed while the battery is charging, is hours at the finish rate.
highly explosive. This gas remains in cell long after 7. Make certain battery used meets weight and size
charging has stopped. requirements of truck. NEVER operate truck with
• Do not lay metallic or conductive objects on battery. an undersized battery.
Arcing will result. 3-3.4. Battery Cleaning
• Do not touch non-insulated parts of DC output con- Always keep vent plugs tightly in place when cleaning
nector or battery terminals to avoid possible electri- battery. When properly watered and charged, the bat-
cal shock. tery will remain clean and dry. All that is necessary is
• De-energize all AC and DC power connections to brush or blow off any dust or dirt that may accumu-
before servicing battery. late on them. However, if electrolyte is spilled or over-
flows from a cell, it should be neutralized with a
• Do not charge a frozen battery.
solution of baking soda and water, brushing the soda
• Do not use charger if it has been dropped or other- solution beneath the connectors and removing grime
wise damaged. from the covers. Then rinse the battery with cool water
from a low pressure supply to remove the soda and
3-3.3. Battery Care and Charging loosen dirt. If battery stay wet consistently, it may be
CAUTION: Never smoke or bring open flame near either overcharged or over filled. This condition should
the battery. Gas formed during charging be investigated and corrected.
is highly explosive and can cause seri-
ous injury.

3-2 BL-WRT-0816 - 10-19-2018

3-3.5. MAINTENANCE FREE BATTERY 3-4. CHARGING BATTERY
Some trucks may be equipped with maintenance free Charging requirements will vary depending on depth of
battery. The battery is completely sealed, will not discharge and temperature. Follow safety rules when
require any watering and have a full 80% discharge placing a battery on charge.
available.
Proceed as follows:
Sealed Maintenance Free battery contain a pressure
1. Park truck at charging station with carriage low-
release valve and under normal operating conditions
ered and turn the key switch off.
do not require any special ventilation.
2. Check the condition of the AC cord, the battery
CAUTION: Do not try to open this battery or remove connector and battery cables. If there are any cuts
the pressure release valve. in the cable, any exposed wires, loose plugs or
connectors, DO NOT attempt to charge the bat-
Only under severe overcharging, such as connected
tery. Contact appropriate personnel for repairs to
to an improperly sized charger, will any significant
be made.
amount of gasses be released from the battery. Also,
being a valve regulated battery, it never requires 3. Disconnect the battery from the truck and connect
watering. the battery to the charger. Make sure connectors
are mated properly.
4. Connect the charger to the appropriate power
supply.
5. Follow the instructions for the charger being used.

BL-WRT-0816 - 10-19-2018 3-3

3-5. LUBRICATION. Table 3-2 Recommended Lubricants
Refer to Table 3-2 for the recommended types of (See Table 3-3 for Application)
grease and oil. Table 3-3 in conjunction with Figure 3-1 No. 1 Transmission oil—EP SAE 80W-90
identifies the items requiring lubrication. Transmission oil—EP SAE 10W-30 (Note)

No. 2 Grease—Lithium base, general purpose.

No. 3 Hydraulic oil-Heavy duty with a viscosity of

150 SUS foam suppressing agent and
rust and oxidation inhibitors
Hydraulic oil-Heavy duty with a viscosity of
100 SUS foam suppressing agent and
rust and oxidation inhibitors (Note)

No. 4 SAE 30 or 40 Engine lubricating oil

NOTE: USED ON COLD CONDITIONED TRUCKS

3-4 BL-WRT-0816 - 10-19-2018

 R6805

Figure 3-1 Lubrication Diagram

Table 3-3 Lubrication Chart
FIG 3-2 LOCATION METHOD OF TYPE APPLICATION
INDEX APPLICATION (Table OF
NO. 3-3) LUBRICANT
1 Transmission Can No. 1 Fill to level plug opening
Capacity 2 pints
2 Hydraulic Reservoir Can No. 3 With lift carriage fully lowered, fill
Capacity-1 quarts reservoir with hydraulic oil to 1
inch below opening
3 Lift Linkage Fittings Gun No. 2 Pressure lubricate.
4 Lift Linkage Fittings* Gun No. 2 Pressure lubricate.
* Raise lift carriage to gain access to grease fittings.

BL-WRT-0816 - 10-19-2018 3-5

 NOTES

3-6 BL-WRT-0816 - 10-19-2018

 SECTION 4
TROUBLESHOOTING

4-1. GENERAL ate: Truck Does Not Operate Forward or Reverse:

Use Table 4-1 as a guide to determine possible Trouble With Braking: Trouble With Lifting Or Lower-
causes of trouble. The table is divided into five main ing, and Miscellaneous malfunctions.
categories: Truck and Hydraulic System Will Not Oper-
Table 4-1 Troubleshooting Chart
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TRUCK AND HYDRAULIC
SYSTEM WILL NOT OPERATE
Truck will not travel nor will lift sys- a. Fuses blown. Check fuses and replace if
tem operate. necessary.
b. Battery dead or disconnected. Check battery quick-disconnect
plug and check battery voltage.
c. Keyswitch defective. Bypass keyswitch to determine if it
is malfunctioning.
d. Defective wiring. Check for open circuit. Repair as
required.
TRUCK DOES NOT OPERATE
FORWARD OR REVERSE
Truck does not travel forward or a. Check all wiring. A loose con- Tighten all loose connections
reverse. All other functions oper- nection may be the cause of before further troubleshooting.
ate normally. malfunction.
b. Defective deadman switch. Check and replace switch if
defective.
c. Defective main contactor. Check for proper operation and
replace if necessary.
d. Defective potentiometer. Check and replace potentiometer
if defective.
Truck travels forward but not in Defective potentiometer in control Check and replace potentiometer
reverse. head. if defective.
Truck travels reverse but not in Defective potentiometer in control Check and replace potentiometer
forward. head. if defective.
Truck travels forward and in Defective potentiometer in control Check and replace potentiometer
reverse at lower speeds; will not head. if defective.
travel at high speed.
TROUBLE WITH BRAKING
Truck does not slow with brake, or a. Defective deadman switch. Check deadman switch for
brake does not engage. continuity. If none found when
the control arm is in the brake
position, replace switch.
b. Defective electric brake. Adjust or replace brake.

BL-WRT-0816 - 10-19-2018 4-1

 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH BRAKING -
Continued
Brake will not release. a. Air gap more than 0.01 in Adjust
(0.25mm).
b. Brake temperature above Allow to cool and check air gap.
281F (140 C).
c. Open brake circuitry or wiring. Make voltage checks.
Brake drags. a. Air gap more than 0.01 in Adjust
(0.25mm).
b. Defective electric brake. Replace.
Brake grabs. a. Air gap more than 0.01 in Adjust
(0.25mm).
b. Defective electric brake. Replace.
Abnormal noise and chatter when Defective electric brake. Replace.
brake is applied.
TROUBLE WITH LIFTING OR
LOWERING
Oil sprays or flows from the top of Defective packing in lift cylinder Repair lift cylinder.
the lift cylinder.
Squealing sounds when lifting a. Oil level too low. Identify oil leak.
forks. b. Lift linkage binding. Apply grease.
Forks do not lift to top. Oil level too low. Add oil to reservoir.
Weak, slow or uneven action of a. Defective pump or relief valve. Check pressure. Adjust as
hydraulic system. necessary.
b. Worn lift cylinder. Replace cylinder.
c. Load larger than capacity. Refer to I.D.plate for capacity.
d. Defective lift motor solenoid. Replace solenoid on electrical
panel.
e. Battery charge low. Charge battery.
Forks do not lift, pump motor does a. Battery is dead or discon- Check and recharge if required.
not run. nected.
b. Defective wiring. Check and repair as required.
c. Defect in electrical system for Check lift switch in control head,
operating pump motor. as well as the solenoid.
Forks do not lift, motor runs. Defect in hydraulic system. Check the oil level in the reservoir
and the oil lines to the lift cylin-
der, and repair as required. If
normal, check the hydraulic
pump, and relief valve. Repair, or
adjust.

4-2 BL-WRT-0816 - 10-19-2018

 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH LIFTING OR
LOWERING - Continued
Forks lift, but will not go down. Defect in hydraulic system Check lowering control switch in
control head and lowering sole-
noid on valve assembly. Replace
as required.
Load will not hold a. Oil bypassing internally in con- Replace valve assembly.
trol valve
b. Worn lift cylinder or packing. Repack cylinder.
Platform does not lift to top. Pump a. Oil level too low. Add oil to reservoir.
motor runs. b. Load larger than capacity. Refer to nameplate on side of
mast for maximum load capacity.
c. Battery needs charging. Change battery.
Forks creep downward under load Leak in hydraulic system, lift cylin- Check for leaking fitting in hydrau-
when in a raised position. der or lowering valve. lic line and repair as required.
Repack lift cylinder or replace
valve assembly.
MISCELLANEOUS
Steering arm does not return to a. Week return spring. Replace spring.
the upright position.
b. Binding. Check and free the binding item.
Verify that the cable has not
been damaged. Repair or
replace as needed.
Truck moves forward when arm is a. Belly-button switch defective. Check for short, and repair or
pulled down. replace as necessary.
b. Short in control head. Check wiring and repair as
required.
Steering arm jerks excessively Drive wheel worn. Replace drive wheel if worn to
starting or stopping the truck. within 3/4 inch of hub.
Drive motor is jerky. Motor internally damaged or worn. Replace motor.

BL-WRT-0816 - 10-19-2018 4-3

4-2. CONTROLLER TROUBLESHOOTING.
An internal microcontroller automatically maintains surveillance over the functioning of the controller.
If the fault is critical, the controller is disabled. More typically, teh fault is a remediable condition - for example - an
undervoltage fault is cleareed when the condition is removed.

4-2.1. Zapi Smart Console (pn# 907225)

A Zapi Smart Console kit is available that is designed specifically for use with the Zapi controller. It serves multiple
functions of reading diagnostic data, testing truck operation, setting options, adjustments and parameter changes
of the controller. The Zapi Smart Console kit contains of two Dongle Cables. The kit is available through your Big
Lift LLC dealer. If you require dealer location information, contact Big Lift LLC.

4-4 BL-WRT-0816 - 10-19-2018

4-2.1.1. Zapi Smart Console Instructions

BL-WRT-0816 - 10-19-2018 4-5

 ZAPI SMART CONSOLE

4-6 BL-WRT-0816 - 10-19-2018

 ZAPI SMART CONSOLE

BL-WRT-0816 - 10-19-2018 4-7

 ZAPI SMART CONSOLE

4-8 BL-WRT-0816 - 10-19-2018

 ZAPI SMART CONSOLE

BL-WRT-0816 - 10-19-2018 4-9

 ZAPI SMART CONSOLE

4-10 BL-WRT-0816 - 10-19-2018

 Table 4-2 Adjustment Settings
Code Function Setting
0 ACCELER. DELAY 24
11 RELEASE BRAKING 20
220 TILLER BRAKING 3
12 INVERS. BRAKING 20
237 DECEL. BRAKING 90
30 MAX SPEED FORW 100
31 MAX SPEED BACK 69

Table 4-3 Factory Setting

Code Name Position Menu Value Scaled Code Node
Value Open
0 ACCELER. DELAY 0 0 24 2.4 0 2
165 BACKING ACCEL. 1 0 10 1 0 2
11 RELEASE BRAKING 2 0 20 2 0 2
220 TILLER BRAKING 3 0 3 0.3 0 2
12 INVERS. BRAKING 4 0 20 2 0 2
237 DECEL. BRAKING 5 0 90 9 0 2
13 PEDAL BRAKING 6 0 3 0.3 0 2
16 SPEED LIMIT BRK. 7 0 28 2.8 0 2
164 BACKING DECEL. 8 0 10 1 0 2
30 MAX SPEED FORWARD 9 0 10 100% 0 2
31 MAX SPEED BACK 10 0 69 69% 0 2
29 CURVE CUTBACK 11 0 100 100% 0 2
252 DEAD ANGLE 12 0 2 LEVEL=2 0 2
48 HYD SPEED FINE 13 0 16 16% 0 2
49 HYDRO COMPENS. 14 0 10 10% 0 2
21 CUTBACK SPEED 1 15 0 58 58% 0 2
181 H&S CUTBACK/CB2 16 0 18 18% 0 2
217 FREQUENCY CREEP 17 0 12 1.20 Hz 0 2
63 MAXIMUM CURRENT 18 0 100 100% 0 2
209 ACC SMOOTH 19 0 10 1 0 2
210 INV SMOOTH 20 0 10 1 0 2
211 STOP SMOOTH 21 0 10 10Hz 0 2
213 BRK SMOOTH 22 0 10 1 0 2

BL-WRT-0816 - 10-19-2018 4-11

 Table 4-3 Factory Setting-Continued
Code Name Position Menu Value Scaled Code Node
Value Open
215 STOP BRK SMOOTH 23 0 10 10Hz 0 2
253 BACKING SPEED 24 0 27 27% 0 2
59 BACKING TIME 25 0 10 10 0 2
56 AUXILIARY TIME 26 0 30 3 0 2
57 HYDRO TIME 27 0 3 1.5 0 2
65 PUMP IMAX 28 0 9 LEVEL=9 0 2
1 PU. ACCELER. DEL 29 0 15 15 0 2
6 PU. DECELER. DEL 30 0 15 1.5 0 2
26 SPEED LIMIT 31 0 100 100% 0 2
27 CREEP SPEED 32 0 10 10% 0 2
53 COMPENSATION 33 0 10 10% 0 2
246 MIN EVP 34 0 16 6.3 0 2
245 MAX EVP 35 0 249 97.6 0 2
244 MIN EVP2 36 0 16 6.3 0 2
243 MAX EVP2 37 0 249 97.6 0 2
250 EVP OPEN DELAY 38 0 16 0.8 0 2
249 EVP CLOSE DELAY 39 0 16 0.8 0 2
248 EVP OPEN DELAY2 40 0 16 0.8 0 2
247 EVP CLOSE DELAY2 41 0 16 0.8 0 2
190 TILLER SWITCH 0 1 1 SEAT 0 2
251 EPS 1 1 0 OFF 0 2
125 HOUR COUNTER 2 1 0 RUNNING 0 2
230 EVP TYPE 3 1 1 DIGITAL 0 2
235 EVP2 TYPE 4 1 0 NONE 0 2
121 BATTERY CHECK 5 1 1 LEVEL=1 0 2
233 STOP ON RAMP 6 1 0 OFF 0 2
100 QUICK INVERSION 7 1 2 TIMED 0 2
241 SET MOT. TEMPERAT 8 1 2 ANALOG 0 2
212 EVI-5 9 1 1 DIGITAL 0 2
218 EV2 10 1 0 ABSENT 0 2
219 EV3 11 1 0 ABSENT 0 2
216 EV4 12 1 0 ABSENT 0 2
183 DIAG PED WIRE KO 13 1 0 ABSENT 0 2
236 INVESION MODE 14 1 1 ON 0 2
170 H&S FUNCTION 15 1 1 PRESENT 0 2
180 HYDRO FUNCTION 16 1 0 NONE 0 2
185 M.C. FUNCTION 17 1 1 PRESENT 0 2

4-12 BL-WRT-0816 - 10-19-2018

 Table 4-3 Factory Setting-Continued
Code Name Position Menu Value Scaled Code Node
Value Open
239 AUX OUT FUNCTION 18 1 1 PRESENT 0 2
182 CONNECTED TO 0 2 2 TRACTION 0 2
145 SET BATTERY TYPE 0 3 0 24V 0 2
140 ADJUST BATTERY 1 3 139 23.66V 0 2
221 THROTTLE 0 ZONE 2 3 5 5% 0 2
224 THROTTLE X POINT 3 3 40 40% 0 2
225 THROTTLE Y POINT 4 3 60 60% 0 2
178 BAT. MIN ADJ. 5 3 0 LEVEL=0 0 2
177 BAT. MAX ADJ. 6 3 2 LEVEL=2 0 2
234 LOAD HM FROM MDI 7 3 0 OFF 0 2
228 CHECK UP DONE 8 3 0 OFF 0 2
229 CHECK UP TYPE 9 3 0 NONE 0 2
184 MC EB VOLT 10 3 100 100% 0 2
186 MC EB RID 11 3 85 85% 0 2
188 PWM ON MAIN CONT 12 3 1 ON 0 2
189 PWM ON AUX OUT 13 3 1 ON 0 2
159 ADJUSTMENT #01 0 131 56 90% 0 2
158 ADJUSTMENT #02 1 131 57 91% 0 2
142 SET CURRENT 2 131 32 320A 0 2
141 SET TEMPERATURE 3 131 107 38 0 2
157 ADJUSTMENT #3 4 131 50 50% 0 2
242 SET CURRENT PUMP 5 131 28 280A 0 2
214 HIGH ADDRESS 6 131 0 0 0 2
232 DITHER AMPLITUDE 7 131 2 2.50% 0 2
231 DITHER FREQUENCY 8 131 5 32.2 Hz 0 2
187 POSITIVE E.B. 0 129 0 LEVEL=0 0 2
179 TOP MAX SPEED 1 129 135 135 Hz 0 2
240 TRUCK TYPE 2 129 0 LEVEL=0 0 2
53 COMPENSATION 3 129 1 ON 0 2
277 CLIP CONTROL 4 129 1 ON 0 2
171 DC-LINK COMPENS. 5 129 1 ON 0 2
172 SAT FREQUENCY 6 129 80 80 Hz 0 2
14 BRAKING MODUL. 7 129 80 80 Hz 0 2
226 MINIMUM VOLTAGE 8 128 4 1.60% 0 2
222 BOOST AT LO FREQ 9 129 20 20% 0 2
173 BOOST AT HI FREQ 10 129 50 50% 0 2
174 BOOST CORNER FRE 11 129 40 40 Hz 0 2

BL-WRT-0816 - 10-19-2018 4-13

 Table 4-3 Factory Setting-Continued
Code Name Position Menu Value Scaled Code Node
Value Open
175 BRAKING BOOSTER 12 129 0 0% 0 2
238 MOTORRESISTANCE 13 129 0 LEVEL=0 0 2
176 SLIP COEFFICIENT 14 129 0 LEVEL=0 0 2
233 MAXSLIP RESET 15 129 6 0.60 Hz 0 2
191 MAXSLIP 0 16 129 25 2.5 Hz 0 2
192 MAXSLIP 1 17 129 25 2.5 Hz 0 2
166 MAXSLIP 1 REV 18 129 25 2.5 Hz 0 2
196 FREQSLIP 1 19 129 30 30 Hz 0 2
193 MAXSLIP 2 20 129 30 3.0 Hz 0 2
167 MAXSLIP 2 REV. 21 129 22 2.2 Hz 0 2
197 FREQSLIP 2 22 129 55 55 Hz 0 2
194 MAXSLIP 3 23 129 47 4.7 Hz 0 2
168 MAXSLIP 3 REV. 24 129 22 2.2 Hz 0 2
198 FREQSLIP 3 25 129 80 80 Hz 0 2
195 MAXSLIP 4 26 129 47 4.7 Hz 0 2
169 MAXSLIP 4 REV. 27 129 22 2.2 Hz 0 2
199 FREQSLIP 4 28 129 130 130 Hz 0 2
200 MAXSLIP 0 BRK 2 129 25 2.5 Hz 0 2
201 MAXSLIP 1 BRK 30 129 25 2.5 Hz 0 2
205 FREQSLIP 1 BRK 31 129 30 30 Hz 0 2
202 MAXSLIP 2 BRK 23 129 30 3.0 Hz 0 2
206 FREQSLIP 2 BRK 33 129 60 60 Hz 0 2
203 MAXSLIP 3 BRK 34 129 40 4.0 Hz 0 2
207 FREQSLIP 3 BRK 35 129 100 100 Hz 0 2
204 MAXSLIP 4 BRK 36 129 40 4.0 Hz 0 2
208 FREQSLIP 4 BRK 37 129 130 130 Hz 0 2
93 OPTION 07 38 129 1 LEVEL=1 0 2
92 OPTION 08 39 129 6 LEVEL=6 0 2
94 OPTION 06 40 129 6 LEVEL=6 0 2

4-14 BL-WRT-0816 - 10-19-2018

 SECTION 5
STEERING ARM, CONTROL HEAD AND COMPARTMENT

5-1. CONTROL HEAD 2. Remove two screws the screws for the cover and
lift it up and disconnect handle wire harness from
5-1.1. Cover Removal. control head switch harness.
1. Turn off the key switch and disconnect the battery.

Used up to S/N E2318057 (except E2315544 & E2315546) Used from S/N E2318058 (and E2315544 & E2315546)

R6778B R8225

Figure 5-1 Steering Arm

BL-WRT-0816 - 10-19-2018 5-1

5-1.2. Cover Installation. 2. Position cover on control head and secure with
cover screws.
1. Hold cover in place and connect handle wire har-
ness to control head switch harness. 3. Reconnect the battery and turn on the key switch.

Used up to S/N E2318057 (except E2315544 & E2315546) Used from S/N E2318058 (and E2315544 & E2315546)

R8226
R6780A

Figure 5-2 Control Head

5-2 BL-WRT-0816 - 10-19-2018

5-1.3. Control Head Removal 1. Remove the cover as described in paragraph 5-
1.1.
1. Turn off the key switch and disconnect the battery.
2. Disconnect harness from potentiometer.
2. Remove the cap assembly as described in para-
graph 5-1.1. 3. Remove screw, lock washer and control knob
from potentiometer.
3. Disconnect harness from switch and potentiome-
ter. 4. Remove screw, lock washer and control knob
from other side of potentiometer.
WARNING: When removing the control head in the
5. Remove potentiometer from cover.
following steps, be sure to hold it in place
until the control harness is disconnected. 6. Position new potentiometer in cover.
7. Install control knob on potentiometer and secure
4. Remove four screws, four lock washers, four flat
with screw.
washers and control head.
8. Install control knob on the other side of potentiom-
5-1.4. Control Head Installation eter and secure with screw.
1. Secure control head with four screws, four lock 9. Connect harness to potentiometer .
washers and four flat washers. 10. Install the cover as described in paragraph 5-1.2.
2. Connect harness to switch and potentiometer.
3. Install the cap assembly as described in para- 5-2. STEERING ARM
graph 5-1.2.
5-2.1. Return Spring Replacement.
4. Reconnect the battery and turn on the key switch.
The steering arm gas return spring is replaced while
5-1.5. Belly-Button Switch Replacement. the steering arm is in the upright position.
1. Remove the cover as described in paragraph 5- 1. Turn off the key switch and disconnect the battery.
1.1. 2. Remove three screws, three lock washers, three
2. Disconnect harness from switch. flat washers and cover.
3. Remove switch from bracket by releasing the two 3. Secure the steering arm in the upright position.
tabs of the bracket and pulling up on the switch.
CAUTION: Use caution when removing the mount-
4. Press the new switch in bracket until it locks in ing screw and the gas return spring. The
place. spring is under tension.
5. Connect harness to switch.
4. Remove screw and free the gas return spring
6. Install the cover as described in paragraph 5-1.2. from bracket.
5-1.6. Horn, Lift and Lower Switch Replacement. 5. Pull downward on the gas return spring to free it
from its seat inside steering arm.
1. Remove the cover as described in paragraph 5-
1.1. 6. Position the new gas return spring inside the
steering arm being sure it fully engages its seat.
2. Before removing the five switches of switch har-
ness from their brackets tag they with their func- 7. Position the opposite end of the gas return spring
tional position. on bracket and install screw .

3. Remove horn, lift and lower switches from their 8. Install cover and secure with three screws, three
brackets by releasing the two tabs of the bracket lock washers and three flat washers.
and pulling up on the switch. 9. Reconnect the battery and turn on the key switch.
4. Replace switch harness as an assembly.
5. Press the new switches into their brackets until
they lock in place. Refer to the tags added in the
remove process.
6. Install the cover as described in paragraph 5-1.2. 5-2.2. Steering Arm Removal.

5-1.7. Speed Potentiometer Replacement. 1. Turn off the key switch and disconnect the battery.

BL-WRT-0816 - 10-19-2018 5-3

2. Remove the compartment covers as described in 4. Reconnect brake switch from main harness.
paragraph 5-3. 5. Install the compartment covers as described in
3. Disconnect handle harness from main harness. paragraph 5-3.
4. Disconnect brake switch from main harness. 6. Reconnect the battery and turn on the key switch.
5. Attach a hoist to steering arm.
5-3. COMPARTMENT COVERS
6. Remove four screws lock washers, flat washers
and nuts securing the steering arm assembly to 5-3.1. Removal.
the frame.
1. Turn off the key switch and disconnect the battery.
7. Remove eight screws, lock washers and flat
2. Remove mat.
washers securing the steering arm assembly to
the transmission. 3. Loosen screws to provide clearance between
dashboard cover and compartment cover.
8. Remove the steering arm assembly.
4. Remove two screws and pry cover away from the
5-2.3. Steering Arm Installation. frame.
1. Position steering arm assembly on the transmis-
5-3.2. Installation.
sion and secure with eight screws , lock washers
and flat washers. 1. Position compartment cover on the frame and tap
it forward. Secure with two screws. Do not over
2. Secure the steering arm assembly to the frame
tighten the screws.
with four screws, lock washers, flat washers and
nuts. 2. Reinstall mat.
3. Reconnect handle harness to main harness. 3. Reconnect the battery and turn on the key switch.

5-4 BL-WRT-0816 - 10-19-2018

 R6776A

Figure 5-3 Steering System

BL-WRT-0816 - 10-19-2018 5-5

 NOTES

5-6 BL-WRT-0816 - 10-19-2018

 SECTION 6
BRAKE SERVICING

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.

6-1.1. Air Gap Adjustment.

The “air gap” is the distance between the magnet body
and the rotor plate with the brake applied. As the brake
pads and rotor wear normally, the air gap will increase
and should be readjusted when it measures more than
0.25 mm.

NOTE: If the air gap measures more than 0.25 mm,

the brake may not release properly. Air gap
adjustment can be performed as long as the
brake pads and rotor function properly or until
the adjustable spacer threads are fully
engaged (adjustment limit reached).

1. Block load wheels.

2. Remove the compartment covers as described in
paragraph 5-3.
3. Using low pressure air, remove any dirt between
armatures and magnet body.
4. Using standard feeler gauges, check the gap
between the magnet body and the rotor plate. The
gap should be 0.25 mm.
5. If necessary, refer to Figure 6-1 and adjust the
gap as follows:
a. Loosen the three mounting screws by half a
turn.
f. The threaded air gap adjusting nuts can then
be screwed into Magnet Body by turning
counterclockwise.
g. Turn the three mounting screws clockwise
until the gap measures 0.012” (0.25 mm).
h. The threaded air gap adjusting nuts are then
screwed clockwise until they bottom.
R6625
i. Finally tighten the three mounting screws to
52 in-lb (6 Nm). Figure 6-1 Brake Assembly - Up to s/n 324200414
j. Recheck the gap.

BL-WRT-0816 - 10-19-2018 6-1

6-1.2. Stopping Distance Adjustment. 8. Remove load wheel blocks and check operation.
The stopping distance of the truck should require mini- 9. Install the compartment covers as described in
mal adjustment. However, this distance should be paragraph 5-3.
checked with each maintenance.
6-2. BRAKE - Used from S/N 324200415.
Using an unloaded truck, run truck to its top speed on
an even dry concrete surface. Move control handle The brake system consists of a drive motor mounted
into the lower braking position. Measure length of brake. This brake is spring applied and electrically
braking path from the actuation point of the brakes released.
until the truck has stopped. The actual length of the 1. 1.Engage the emergency power disconnect
braking path should be between approximately 1.5 - switch and turn off key switch.
2.5 ft (0.5-0.7 m).
2. Block load wheels.
To adjust stopping distance, proceed as follows:
3. Remove the compartment cover as described in
1. Block load wheels. paragraph 5-3.1.
2. Remove the compartment covers as described in 4. Disconnect electric brake from harness.
paragraph 5-3.
5. Remove the mounting screws and brake.
3. Rotate the adjusting nut (Figure 6-1) clockwise to
6. Place the new brake into position and secure with
SHORTEN the stopping distance or counterclock-
the mounting screws.
wise to LENGTHEN the stopping distance.
7. Reconnect electric brake to harness.
4. Remove load wheel blocks and check operation.
8. Remove load wheel blocks and check operation.
5. Install the compartment covers as described in
paragraph 5-3. 9. Disengage the emergency power disconnect
switch and turn on key switch.
6-1.3. Brake Assembly Replacement
1. Block load wheels.
2. Remove the compartment covers as described in
paragraph 5-3.
3. Disconnect electric brake from main harness.
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).
Figure 6-2 Brake Assembly - From s/n 324200415
7. Reconnect electric brake to main harness.

6-2 BL-WRT-0816 - 10-19-2018

 SECTION 7
TRANSMISSION, DRIVE WHEEL, LOAD WHEEL

7-1. Drive Wheel.

1. Turn off the key switch and disconnect the battery.
2. Remove the compartment covers as described in
paragraph 5-3.
3. Loosen but do not remove the six screws.
4. Jack up the truck so the drive wheel is off the
ground; then securely block the truck to prevent
movement.
5. Remove the six screws and drive wheel from the
transmission.
6. Install new drive wheel in reverse order of
removal.
7. Install the compartment covers as described in
paragraph 5-3.
8. Reconnect the battery and turn on the keyswitch.

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 cleanance for removal of the
transmission/motot/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

Figure 7-1 Transmission, Motor, Brake Assembly

BL-WRT-0816 - 10-19-2018 7-1

 R6781

Figure 7-2 Drive System

7-2 BL-WRT-0816 - 10-19-2018

7-3. Load Wheel. 7-3.2. Repair

7-3.1. Removal 6. Remove washers, bearings and washers from

wheels.
1. Raise forks.
7. Inspect bearings and replace if necessary.
2. Turn off the key switch and disconnect the battery.
8. Reassemble washers, bearings and washers in
3. Block the drive wheel to prevent the truck from wheels.
rolling.
4. Jack up the forks to raise the load wheels off the 7-3.3. Load Wheel Installation
floor. Securely block the forks in the raised posi- 1. Position load wheel assembly in wheel bracket.
tion by positioning supports under both fork tips.
2. Install shaft and secure with pin.
NOTE: When shaft is removed, load wheel assembly 3. Remove blocking from under the truck.
will drop free. 4. Lower the forks.
5. Remove pin securing shaft and remove shaft and 5. Reconnect the battery and turn on the keyswitch.
load wheel assembly.
7-4. CASTERS
NOTE: Inspect the load wheel assembly. If the load
wheel is worn within 1/8" of the metal sleeve, Casters provide for additional stability. Installation of
or is cracked or damaged, replace the entire the casters is shown in Figure 12-15 and repair parts
load wheel and bearing assembly. Big Lift as shown in Figure 12-19.
LLC recommends that both load wheel
assemblies be replaced at the same time.
This ensures level and safe operation of the
lift truck.

BL-WRT-0816 - 10-19-2018 7-3

 NOTES

7-4 BL-WRT-0816 - 10-19-2018

 SECTION 8
ELEVATION SYSTEM SERVICING

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.

BL-WRT-0816 - 10-19-2018 8-1

 R6786A

Figure 8-1 Frame

8-2 BL-WRT-0816 - 10-19-2018

 R6787A

Figure 8-2 Lift Linkage

BL-WRT-0816 - 10-19-2018 8-3

 NOTES

8-4 BL-WRT-0816 - 10-19-2018

 SECTION 9
HYDRAULIC SYSTEM SERVICING

9-1. LINES AND FITTINGS 9. Install the compartment covers as described in

paragraph 5-3.
WARNING: When forks are raised, pressure exists in
the hydraulic system lines and fittings. To 9-2. HYDRAULIC PUMP, MOTOR, AND RESER-
ensure release of pressure, forks must VOIR ASSY
be fully lowered and the battery discon-
nected before performing any mainte- The hydraulic pump/motor assembly can be disas-
nance on the hydraulic system. sembled and repaired. However, a defective pump,
valve or motor requires replacement of that compo-
NOTE: Leaking hydraulic fittings may be remedied by nent.
simply tightening fittings. If this does not rem-
edy the leak, the fittings or line must be WARNING: When forks are raised, pressure exists in
replaced. the hydraulic system lines and fittings. To
ensure release of pressure, forks must
1. Lower forks fully. be fully lowered and the battery discon-
2. Turn off the key switch and disconnect the battery. nected before performing any mainte-
nance on the hydraulic system.
3. Remove the compartment covers as described in
paragraph 5-3. 9-2.1. Removal
CAUTION: Hydraulic oil can damage parts. Wipe off 1. Lower forks fully.
any oil immediately. Provide a container 2. Turn off the key switch and disconnect the battery.
under the line or fitting before discon-
3. Remove the compartment covers as described in
necting.
paragraph 5-3.
4. Refer to Figure 9-1 and remove leaking line or fit- 4. Tag and disconnect electrical leads from pump/
ting and replace it with a new line or fitting. motor assembly (Figure 9-2) and solenoid.
5. Check level of hydraulic oil. If required, add
NOTE: The reservoir and hose will be filled with
hydraulic oil to bring to 1 inch below opening. Use
hydraulic oil. Place a container under the
hydraulic oil listed in Table 3-2.
pump assembly to catch any hydraulic oil.
6. Reconnect the battery and turn on the keyswitch.
5. Disconnect hose (Figure 9-1) from pump/motor
7. Operate the lift and lower buttons to refill the
assembly.
cylinder and lines with hydraulic oil.
6. While supporting the pump/motor assembly,
8. Check level of hydraulic oil. If required, add
remove two screws, two lock washers and two flat
hydraulic oil to bring to 1 inch below opening. Use
washers.
hydraulic oil listed in Table 3-2.
7. Remove the pump/motor assembly.

BL-WRT-0816 - 10-19-2018 9-1

 R6789

Figure 9-1 Hydraulic System

9-2 BL-WRT-0816 - 10-19-2018

9-2.2. Disassembly and Reassembly 9-2.4. Lift Cylinder
1. Remove the hydraulic pump/motor assembly as 9-2.4.1.Removal
described in paragraph 9-2.1.
1. Lower forks fully.
2. Refer to Figure 9-2 for disassembly and reassem-
bly. 2. Turn off the key switch and disconnect the battery.
3. Remove the compartment covers as described in
9-2.3. Installation paragraph 5-3.
1. While supporting the pump/motor assembly (Fig- 4. Ensure that hydraulic pressure has been relieved
ure 9-1), install two screws, two lock washers and from the lift circuit.
two flat washers.
5. Disconnect hose from cylinder.
2. Reconnect hose to pump/motor assembly.
6. Remove connector and seal from cylinder.
3. Connect electrical leads to motor and solenoid.
7. Remove screw (Figure 9-1), lock washer and
4. Fill the hydraulic reservoir to 1 inch below open- shaft securing the top of cylinder.
ing. Use hydraulic oil listed in Table 3-2.
WARNING: Frame is heavy. Use care while securing
5. Reconnect the battery and turn on the keyswitch.
and lifting in order to prevent injury.
6. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil. 8. With suitable hoist, carefully raise frame (Figure
12-15) slightly to relieve pressure from the cylin-
7. Check level of hydraulic oil. If required, add
der mounts.
hydraulic oil to bring to 1 inch below opening. Use
hydraulic oil listed in Table 3-2. 9. Remove screw (Figure 9-1), lock washer and
shaft securing the bottom of cylinder and remove
8. Install the compartment covers as described in
the cylinder.
paragraph 5-3.

BL-WRT-0816 - 10-19-2018 9-3

 R6790

Figure 9-2 Pump & Motor Assy

9-4 BL-WRT-0816 - 10-19-2018

9-2.4.2.Repair 9. Install the compartment covers as described in
paragraph 5-3.
1. Secure the lift cylinder in a vise, clamping lightly
at the base of the cylinder.
2. Remove gland nut from cylinder tube.
3. Remove wiper ring and O-ring from gland nut.
4. Withdraw the cylinder rod from the cylinder.

NOTE: If the cylinder tube or piston rod are dam-

aged, the entire lift cylinder must be replaced.

5. Replace seal ring and guide ring from piston rod.

6. Coat all parts with hydraulic oil (Table 3-2).
7. Install guide ring and new seal ring on piston rod.
8. Insert piston rod, with attached parts, into cylinder
tube.
9. Install new wiper ring and new O-ring on gland nut
.
10. Install gland nut on cylinder tube.

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.
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.

BL-WRT-0816 - 10-19-2018 9-5

 NOTES

9-6 BL-WRT-0816 - 10-19-2018

 SECTION 10
ELECTRICAL COMPONENTS

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.
24 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 Smart Console kit
and laptop computer are available, this periodic clean- 10-1.5.Panel Installation.
ing provides a good opportunity to check the control- 1. Install the control panel and secure with four
ler’s diagnostic history file. It is also recommended screws, four lock washers, four flat washers.
that the controller’s fault detection circuitry be checked
2. Refer to Figure 12-25 thru Figure 12-26 and con-
whenever 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
moist rag. Allow it to dry before reconnecting the
battery.

BL-WRT-0816 - 10-19-2018 10-1

 R6478

R6792A

Figure 10-1 Electrical System

10-2 BL-WRT-0816 - 10-19-2018

 R6478

R6794A

Figure 10-2 Electrical Panel

BL-WRT-0816 - 10-19-2018 10-3

10-2. HORN REPLACEMENT
1. Turn off the key switch and disconnect the battery.
2. Remove the compartment covers as described in
paragraph 5-3.
3. Tag and disconnect all electrical connections from
horn.
4. Remove screw, lock washer, flat washer, and
horn.
5. Install horn and secure with, lock washer, flat
washer.
6. Install the compartment covers as described in
paragraph 5-3.
7. Reconnect the battery and turn on the keyswitch . R6802

Figure 10-3 Brake Actuation

10-4 BL-WRT-0816 - 10-19-2018

10-3.PUMP MOTOR.
The pump motor is replaceable but not repairable.
Refer to paragraph 9-2.

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.LIFT LIMIT SWITCH

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

4. Position the new switch on mounting plate and

Figure 10-4 Transmission, Motor, Brake Assembly
secure with two screws, two lock washers, flat
washers and two nuts. 10-5.2.Adjustment
5. Position bracket on the frame and secure with two 1. Raise the forks until switch is aligned with the
screws, two lock washers and two flat washers . detent on the frame.
6. Adjust the switch as described in paragraph 2. The detent should trigger the lift limit switch and
10-5.2. stop the hydraulic pump and motor.
3. If necessary, loosen screws and adjust mounting
plate.
4. Tighten screws and recheck.

BL-WRT-0816 - 10-19-2018 10-5

10-6.DEADMAN SWITCH 3. Position the new switch on bracket and secure
with two screws, two lock washers, two flat wash-
10-6.1.Replacement ers.
1. Disconnect harness from the deadman switch . 4. Reconnect harness to the deadman switch.
2. Remove the two screws, two lock washers, two
flat washers and switch rom bracket.

10-6 BL-WRT-0816 - 10-19-2018

 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.

BL-WRT-0816 - 10-19-2018 11-1

 NOTES

11-2 BL-WRT-0816 - 10-19-2018

 SECTION 12
ILLUSTRATED PARTS BREAKDOWN

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

BL-WRT-0816 - 10-19-2018 12-1

 R6776A

Figure 12-1 Steering System

12-2 BL-WRT-0816 - 10-19-2018

 Steering System
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
Used up to serial number
1 1280-000002-00 COVER 1
326110884
Used from serial number
1a 1280-000002-0A COVER 1
326110885

2 0000-000368-00 SCREW M8×12 2

3 0000-000553-00 NUT M10 4

4 0000-000274-00 BOLT M6×25 8

5 0000-000056-00 LOCKWASHER Ø6 8
6 0000-000380-00 FLATWASHER Ø6 8

7 0000-000155-00 SCREW M10×40 4

8 0000-000063-00 LOCKWASHER Ø10 4

9 0000-000007-00 FLATWASHER Ø10 4
10 2214-150002-00 WASHER 2
11 1146-151002-30 MANUAL HOLDER 1
Used from serial number
12 0000-000119-00 SCREW M5×12 4
326110885
13 0000-000546-00 NUT M5 4

BL-WRT-0816 - 10-19-2018 12-3

 R6778B

Figure 12-2 Steering Arm - Used up to serial number E2318057 (Except E2315544 & E2315546)

12-4 BL-WRT-0816 - 10-19-2018

 Steering Arm - Used up to serial number E2318057 (Except E2315544 & E2315546)
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 0000-000322-00 SCREW M8×25 10
2 0000-000159-00 LOCKWASHER Ø8 17
3 0000-000176-00 FLATWASHER Ø8 17
4 1280-300002-00 PANEL 1
5 1280-300001-00 BRAKE BRACKET 1
6 1280-330000-00 TURNING PANEL 1
7 0000-000142-00 BEARING 2
8 1280-310000-00 HANDLE BRACKET 1
9 0000-000011-00 BEARING 2
10 1120-300003-00 SHAFT 1
11 1280-320000-0A CONTROL HANDLE 1
12 1280-340000-00 GAS SPRING 1
13 1280-360000-00 CONTROL POD ASSEMBLY 1
14 0000-000028-00 SCREW M4×10 2
15 1120-300006-00 SPACER 1
16 0000-000030-00 SCREW M10×16 1
17 2130-300001-00 TURNING BRACKET 1
18 0000-000681-00 KEY C8×7×14 1
19 0000-000143-00 LOCKWASHER Ø52 1
20 0000-000114-00 NUT M52×1.5 1
21 1280-300005-00 REVOLVING COVER 1
22 0000-000683-00 RETAINING RING Ø12 2 Optional
23 1280-300003-00 SHAFT 1 Optional
24 1280-300004-00 SUPPORT BLOCK 1 Optional
25 1280-350000-00 SUPPORT ASSEMBLY 1 Optional
26 0000-000550-00 NUT M8 3
27 1280-520002-00 WIRE HARNESS 1
28 0000-000429-00 SCREW M5×8 1
29 0000-000122-00 LOCKWASHER Ø4 2
30 0000-000702-00 FLATWASHER Ø4 2
31 1280-520005-00-B SWITCH WIRE HARNESS 1 Used up to 07-19-2012
31a 1280-520005-00 SWITCH WIRE HARNESS 1 Used from 07-20-2012
32 0000-000377-00 SCREW M2×20 2
33 0000-000004-00 SCREW M5×12 1
34 0000-000491-00 CLAMP 1
35 0000-000278-00 SCREW M8×30 3
36 0000-000321-00 SCREW M8×20 3
37 1220-560001-00 INCHING SWITCH I 2
38 1280-510005-00 BRACKET 1 Used from 06-20-2013
39 0000-000109-00 SCREW M8×16 2 Used from 06-20-2013

BL-WRT-0816 - 10-19-2018 12-5

 R8225

Figure 12-3 Steering Arm - Used from serial number E2318058 (And E2315544 & E2315546)

12-6 BL-WRT-0816 - 10-19-2018

 Steering Arm - Used from serial number E2318058 (And E2315544 & E2315546)
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 0000-000322-00 SCREW M8×25 10
2 0000-000159-00 LOCKWASHER Ø8 20
3 0000-000176-00 FLATWASHER Ø8 20
4 1280-300002-00 PANEL 1
5 1280-300001-00 BRAKE BRACKET 1
6 1280-330000-00 TURNING PANEL 1
7 0000-000142-00 BEARING 2
8 1280-310000-00 HANDLE BRACKET 1
9 0000-000011-00 BEARING 2
10 1120-300003-00 SHAFT 1
Used for serial number E2315544,
11 1280-321000-00 CONTROL HANDLE 1 E2315546 and between serial number
E2318058 and 324160664
11a 1280-321000-0A CONTROL HANDLE 1 Used from serial number 324160665
12 1280-340000-00 GAS SPRING 1
13 1280-360000-20 CONTROL POD ASSEMBLY 1
14 0000-000028-00 SCREW M4×10 2
15 1120-300006-00 SPACER 1
16 0000-000030-00 SCREW M10×16 1
17 2130-300001-00 TURNING BRACKET 1
18 0000-000681-00 KEY C8×7×14 1
19 0000-000143-00 LOCKWASHER Ø52 1
20 0000-000114-00 NUT M52×1.5 1
21 1280-300005-00 REVOLVING COVER 1
22 0000-000683-00 RETAINING RING Ø12 2 Optional
23 1280-300003-00 SHAFT 1 Optional
24 1280-300004-00 SUPPORT BLOC 1 Optional
25 1280-350000-00 SUPPORT ASSEMBLY 1 Optional
26 0000-000550-00 NUT M8 3
27 1280-520002-00 WIRE HARNESS 1
28 0000-000429-00 SCREW M5×8 1
29 0000-000122-00 LOCKWASHER Ø4 2
30 0000-000702-00 FLATWASHER Ø4 2
31 1280-520005-00-B SWITCH WIRE HARNESS 1 Used up to 07-19-2012
31a 1280-520005-00 SWITCH WIRE HARNESS 1 Used from 07-20-2012
32 0000-000377-00 SCREW M2×20 2
33 0000-000004-00 SCREW M5×12 1
34 0000-000491-00 CLAMP 1
35 0000-000278-00 SCREW M8×30 3
36 0000-000321-00 SCREW M8×20 6
37 1220-560001-00 INCHING SWITCH I 2
38 1280-510005-00 BRACKET 1 Used from 06-20-2013
39 0000-000109-00 SCREW M8×16 2 Used from 06-20-2013
40 2333-320000-10 CONTROL POD BRACKET 1

BL-WRT-0816 - 10-19-2018 12-7

 R6780A

Figure 12-4 Control Head - Used up to serial number E2318057 (Except E2315544 & E2315546)

12-8 BL-WRT-0816 - 10-19-2018

 Control Head - Used up to serial number E2318057 (Except E2315544 & E2315546)
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-360001-00 BRACKET 1
2 1280-360002-00 HANDLE R 1
3 1280-360004-00 COVER 1
4 1280-360003-00 COVER 1
5 0000-000320-00 SCREW M6×35 2
6 0000-000032-00 SCREW M6×25 2
7 0000-000498-00 SCREW M6×30 4
8 1280-360013-00 BUTTON BRACKET 6
9 1280-360006-00 CONTROL KNOB-L 1
10 1220-520008-0C WIRE HARNESS-ACCELERATOR 1
11 1120-343003-00 SPRING 2
12 1280-360005-00 CONTROL KNOB-R 1
13 1220-520005-0C WIRE HARNESS-REVERSING SWITCH( 1
14 1280-360012-00 BUTTON REVERSER 1
15 1280-360009-00 LOWER BUTTON-L 1
16 1280-360007-00 LIFTING BUTTON-L 1
17 1280-360011-00 HORN BUTTON 1
18 1280-360008-00 LIFTING BUTTON-R 1
19 1280-360010-00 LOWER BUTTON-R 1
20 1280-360014-00 SPRING 2
21 1220-520006-0C WIRE HARNESS-BUTTONS 1
22 0000-000037-00 SCREW M3×12 2
23 0000-000038-00 LOCKWASHER Ø3 2
24 1280-360017-00 HANDLE L 1
25 1280-360015-00 SPRING II 2
26 1280-360016-00 SPRING I 6
27 1220-560002-00 INCHING SWITCH II 5

BL-WRT-0816 - 10-19-2018 12-9

 R8226

Figure 12-5 Control Head - Used from serial number E2318058 (And E2315544 & E2315546)

12-10 BL-WRT-0816 - 10-19-2018

 Control Head - Used from serial number E2318058 (And E2315544 & E2315546)
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 2333-340001-00 COVER 1
2 2333-340002-00 CAP 1
3 2333-340003-00 TRAVELING KNOB R 1
4 2333-340004-00 TRAVELING KNOB L 1
5 2333-340005-00 HORN BUTTON 1
6 2333-340006-00 BUTTON REVERSER COVER 1
7 2333-340015-00 DIRECTION BUTTON 2
8 2333-340013-00 SCREW M5×30 2
9 2333-340014-00 SCREW M5×55 2
10 2333-520004-10 REVERSING SWITCH WIRE 1
11 2333-520003-10 ACCELERATOR ASSEMBLY 1
12 1280-360001-20 BUTTONS ASSEMBLY 1
13 2333-340017-00 CLAMP 4
14 2333-340009-00 MOUNTING SEAT 2
15 2333-340012-00 SCREW ST2.9×9.5 2
16 2333-340010-00 SPRING 1
17 0000-000037-00 SCREW M3×12 2
18 0000-000038-00 LOCKWASHER Ø3 2
19 2333-340018-00 BRACKET 1
20 2333-340019-00 SCREW M3×10 1
21 2333-340020-00 COVER 4
22 2333-340022-00 SEALING PLATE 1
23 2333-340023-00 BUTTON 1
24 2333-340024-00 SCREW M5×12 2
25 2333-340025-00 SCREW ST2.9×20 2
26 2333-340026-00 BUSHING 2
27 2333-340027-00 BUSHING 2

BL-WRT-0816 - 10-19-2018 12-11

 R6785A

Figure 12-6 Grab Bar Assembly

12-12 BL-WRT-0816 - 10-19-2018

 Grab Bar Assembly
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-140000-00 GRAB BAR ASSEMBLY 1
2 0000-000077-00 SCREW M6×12 4
3 1280-141002-00 COVER 1
4 1280-141001-00 COVER 1
5 1280-141005-00 RABBIT BUTTON-L 1
6 1280-141006-00 RABBIT BUTTON-R 1
7 1280-141003-00 LIFTING BUTTON 1
8 1280-141009-00 SPRING 8
9 1280-141007-00 HORN BUTTON-L 1
10 1280-141008-00 HORN BUTTON-R 1
11 1280-141004-00 LOWER BUTTON 1
12 1280-520004-00 SWITCH WIRE HARNESS 1
13 1280-520003-00 WIRE HARNESS 1
14 0000-000032-00 SCREW M6×25 2
15 0000-000056-00 LOCKWASHER Ø6 2
16 0000-000380-00 FLATWASHER Ø6 2
17 1220-560002-00 INCHING SWITCH II 6

BL-WRT-0816 - 10-19-2018 12-13

 R6781

Figure 12-7 Drive System

12-14 BL-WRT-0816 - 10-19-2018

 Drive System
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 0000-000432-00 SCREW M16×80 4
2 0000-000191-00 LOCKWASHER Ø16 4
3 0000-000220-00 FLATWASHER Ø16 4
4 0000-000187-00 NUT M16 4
5 1280-200002-00 BUSHING 4
6 1280-200001-00 DRIVING BLOCK 1
7 0000-000516-00 SCREW M12×40 6
8 0000-000060-00 LOCKWASHER Ø12 6
9 0000-000373-00 FLATWASHER Ø12 6
Used up to serial number
10 1280-200000-00 DRIVE UNIT 1
324200414
Used between serial number
10a 1280-200000-0A DRIVE UNIT 1
324200415 and 325150487
Used between serial number
10b 1280-200000-0B DRIVE UNIT 1
325150488 and 326140212
Used from serial number
10c 1280-200000-0C DRIVE UNIT 1
326140213

BL-WRT-0816 - 10-19-2018 12-15

 R8228

Figure 12-8 Drive Assembly - Used up to serial number 324200414

12-16 BL-WRT-0816 - 10-19-2018

 Drive Assembly - Used up to serial number 324200414
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-210048-00 MOTOR 1
2 1280-210034-00 SCREW M8×75 4
3 1280-210011-00 SNAP RING 8.4×17 1
4 1280-210047-00 DRIVE WHEEL PU 1 Used up to 10-09-2012
Used from 01-09-2012 to serial
4a 1280-220000-00 PRESS ON TIRE ASSEMBLY 1
number 324200414
5 1280-210035-00 BOLT M10×30 6
6 1280-210001-00 SNAP RING 10.5×16×1.5 6

BL-WRT-0816 - 10-19-2018 12-17

 R8229

Figure 12-9 Drive Assembly - Used between serial number 324200415 and 325150487

12-18 BL-WRT-0816 - 10-19-2018

 Drive Assembly - Used between serial number 324200415 and 325150487
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 0000-001287-10 SCREW M6×70 3
2 1280-210000-00 BRAKE ASSEMBLY 1
3 2333-210004-00 BRAKE LINING 1
4 1280-210048-00 MOTOR,4KW 1
5 0000-000516-00 SCREW M12×40 4
6 0000-000060-00 LOCKWASHER Ø12 4
7 0000-000373-00 FLATWASHER Ø12 4
8 1280-230000-00 GEAR CASE ASSEMBLY 1
9 2415-230000-10 DRIVE WHEEL 1
10 0000-000283-00 BOLT M10×30 6
11 0000-000063-00 LOCKWASHER Ø10 6

BL-WRT-0816 - 10-19-2018 12-19

 R8230

Figure 12-10 Drive Assembly - Used from serial number 325150488

12-20 BL-WRT-0816 - 10-19-2018

 Drive Assembly - Used from serial number 325150488
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 0000-001287-10 SCREW M6×70 3
2 1280-210000-00 BRAKE ASSEMBLY 1
3 2333-210004-00 BRAKE LINING 1
4 1280-210048-00 MOTOR,4KW 1
5 0000-000516-00 SCREW M12×40 4
6 0000-000060-00 LOCKWASHER Ø12 4
7 0000-000373-00 FLATWASHER Ø12 4
Used between serial numbers
8 1280-230000-0A GEAR CASE ASSEMBLY 1
325150488 and 326140212
Used from serial number
8a ZK18-240000-00-01 GEAR CASE ASSEMBLY 1
326140213
9 1280-220000-0A DRIVE WHEEL 1
10 0000-001131-10 NUT M12×1.5 6
11 0000-000025-00 LOCKWASHER Ø12 6
12 1120-240014-3A STUDS 6

BL-WRT-0816 - 10-19-2018 12-21

 R8231

Figure 12-11 Drive Wheel Assembly - Used up to serial number 324200414

12-22 BL-WRT-0816 - 10-19-2018

 Drive Wheel Assembly - Used up to serial number 324200414
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-220002-00 POLY DRIVE TIRE - PRESS ON 1
2 1280-220001-00 HUB 1

BL-WRT-0816 - 10-19-2018 12-23

 R8231

Figure 12-12 Drive Wheel Assembly - Used from serial number 325150488

12-24 BL-WRT-0816 - 10-19-2018

 Drive Wheel Assembly - Used from serial number 325150488
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-220002-00 POLY DRIVE TIRE - PRESS ON 1
2 1280-220001-0A HUB 1

BL-WRT-0816 - 10-19-2018 12-25

 R6783

Figure 12-13 Transmission, Motor and Brake Assembly - Used up to serial number 324200414

12-26 BL-WRT-0816 - 10-19-2018

 Transmission, Motor and Brake Assembly - Used up to serial number 324200414
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-210001-00 SNAP RING 10.5×16×1.5 18
2 1280-210002-00 SNAP RING 30.3×44.0 1
3 1280-210003-00 SNAP RING 55.3×61.7 1
4 1280-210004-00 SNAP RING 95.2×109.8 1
5 1280-210005-00 SNAP RING 95.3×109.5×2.5 1
6 1280-210006-00 SUPPORT CENTRAL 30.2×38×20 1
7 1280-210007-00 ELASTIC COLLAR 100.5×114.5 1
8 1280-210008-00 ELASTIC COLLAR 135.5×149.5 1
9 1280-210009-00 ELASTIC COLLAR 40.3×46.7 1
10 1280-210010-00 BEARING 1
11 1280-210011-00 SNAP RING 8.4×17 1
12 1280-210012-00 BEARING 1
13 1280-210013-00 BEARING 1
14 1280-210014-00 BEARING 1
15 1280-210015-00 BOLT M8×20 8
16 1280-210016-00 SCREW M10×25 6
17 1280-210017-00 SNAP RING Ø30 1
18 1280-210018-00 ELASTIC COLLAR Ø100 1
19 1280-210019-00 ELASTIC COLLAR Ø62 1
20 1280-210020-00 ELASTIC COLLAR Ø150 1
21 1280-210021-00 BEARING SEAL 30×62×7 1
22 1280-210022-00 BEARING SEAL 100×150×13 1
23 1280-210023-00 BEARING 1
24 1280-210024-00 ELASTIC COLLAR 2075 (1.78×18.77) 1
25 1280-210025-00 V-SEAL V160L 1
26 1280-210026-00 KEY 6×6×20 2
27 1280-210027-00 KEY 8×7×15 1
28 1280-210028-00 BEARING 2
29 1280-210029-00 BEARING 2
30 1280-210030-00 SNAP RING 8×14×1.5 1
31 1280-210031-00 Pin ø8×20 5
32 1280-210032-00 Nut M8×1.25 1
33 1280-210033-00 Screw M14×1.5 2
34 1280-210034-00 Screw M8×75 4
35 1280-210035-00 Bolt M10×30 6
36 1280-210036-00 Screw M10×50 6
37 1280-210037-00 Nut M20×1.5 1
38 1280-210038-00 GEAR SHAFT 1
39 1280-210039-00 GEAR Z=37Z 1
40 1280-210040-00 SNAP RING 133.4×149.7 1

BL-WRT-0816 - 10-19-2018 12-27

 R6783

Figure 12-13Transmission, Motor and Brake Assembly - Used up to serial number 324200414 - Continued

12-28 BL-WRT-0816 - 10-19-2018

Transmission, Motor and Brake Assy. - Used up to serial number 324200414 - Continued
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
41 1280-210041-00 GEAR CASE 1
42 1280-210042-00 BEARING BLOCK 1
43 1280-210043-00 SNAP RING 1
44 1280-210044-00 BEARING BLOCK 1
45 1280-210045-00 GEAR 1
46 1280-210046-00 GEAR 1
47 1280-210047-00 DRIVE WHEEL PU 1 Used up to 01-09-2012
Used from 010912 to serial
47a 1280-220000-00 PRESS ON TIRE ASSEMBLY 1
number 324200414
48 1280-210048-00 MOTOR 1
49 1280-210000-00 BRAKE 1

BL-WRT-0816 - 10-19-2018 12-29

 R8233

Figure 12-14 Transmission, Motor and Brake Assembly - Used between

serial number 324200415 and 326140212

12-30 BL-WRT-0816 - 10-19-2018

 Transmission, Motor and Brake Assy. - Used between serial number 324200415 and 326140212
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
Used between serial number
-- 1280-230000-00 GEAR BOX ASSEMBLY 1
324200415 and 325150487
Used between serial number
-- 1280-230000-0A GEAR BOX ASSEMBLY 1
325150488 and 326140212
1 2415-220001-10 GEAR CASE 1
2 2415-220002-10 COVER 1
3 2415-220008-10 O-RING 1
4 0000-000056-00 LOCKWASHER Ø6 8
5 0000-000055-00 SCREW M6×16 8
6 2415-GB10-00 GEAR KIT 1 This kit includes 2 gears.
7 1120-240007-30 WASHER 1
8 1120-240008-30 LOCKING PLATE 1
9 0000-000277-00 BOLT M8×25 3
10 0000-001054-00 BEARING 2
11 2415-220009-10 COVER 2
12 0000-000077-00 SCREW M6×12 14
13 3315-GB00-00 GEAR KIT (z1/z2=25/62) 1
14 0000-000379-00 FLATWASHER Ø14 1
15 0000-001055-00 WASHER Ø14 1
16 0000-001056-00 NUT M14×1.5 1
17 2415-220014-10 SEAL WASHER TC100×150×13 1
Used between serial number
18 2415-220003-10 OUTPUT SHAFT 1
324200415 and 325150487
Used between serial number
18a 2415-220003-1A OUTPUT SHAFT 1
325150488 and 326140212
19 2415-220018-10 COVER PLATE 1
20 2415-220010-10 SEAT 1
21 0000-001285-10 BEARING 2
22 2415-220012-10 PLATE 1
23 0000-000255-00 BOLT M8×20 6
24 0000-001699-00 SNAP RING Ø55 1
25 2415-220015-10 SEAL WASHER TC35×62×7 1
26 0000-000762-00 ELASTIC COLLAR Ø62 1
27 0000-000183-00 RETAINER RING Ø35 1
28 0000-001282-10 BEARING 2
29 2415-220011-10 SLEEVE 1
30 0000-001286-10 BEARING 1
31 0000-001283-10 BEARING 1
32 2415-220016-10 RING WIPER VL-160 1
33 2415-220017-10 DUST COVER 1

BL-WRT-0816 - 10-19-2018 12-31

 DB_0030

Figure 12-15 Transmission, Motor and Brake Assembly - Used from serial number 326140213

12-32 BL-WRT-0816 - 10-19-2018

 Transmission, Motor and Brake Assy. - Used from serial number 326140213
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
-- ZK18-240000-00-01 GEAR BOX ASSEMBLY 1
1 0000-000911-00 BOLT M8×20 6
2 ZK18-240011-00 PLATE 1
3 ZK18-240017-00 WASHER A.R. As Required
4 ZK18-240009-00 DUST COVER 1
5 0000-001285-10 BEARING 2
6 ZK18-240004-00 SEAT 1
7 ZK18-240012-00 PLATE 1
8 0000-001786-00 SEAL WASHER TC35*62*7 1
9 0000-001445-00 BEARING 2
10 ZK18-240010-00 SLEEVE 1
11 ZK18-GB00-00 GEAR KIT (z1/z2=25/62) 1 This kit includes 2 gears.
12 ZK18-240006-00 COVER PLATE 1
13 0000-000762-00 SNAP RING Ø62 1
14 0000-001056-00 NUT M14×1.5 2
15 0000-000070-00 SCREW M10×25 6
16 0000-000379-00 FLAT WASHER Ø14 1
17 0000-001055-00 WASHER Ø14 1
18 ZK18-240008-00 COVER 1
19 0000-000056-00 LOCKWASHER Ø6 22
20 0000-000077-00 SCREW M6×12 14
21 0000-000055-00 SCREW M6×16 8
22 0000-001054-00 BEARING 2
23 ZK18-240005-00 COVER 1
24 0000-001789-00 O-RING 155×4 1
25 ZK18-240003-00 GEAR CASE 1
26 ZK18-GB00-10 GEAR KIT (z1/z2=6/43) 1 This kit includes 2 gears.
27 ZK18-240007-00 OUTPUT SHAFT 1
28 0000-001790-00 BEARING 2
29 0000-001791-00 SNAP RING Ø140 1
30 0000-001792-00 RETAINER RING Ø100 1
31 0000-001787-00 SEAL WASHERTC140*100*12 1
32 ZK12-240011-00 WASHER A.R. As Required
33 ZK12-240017-00 PLUG M14*1.5 1
34 ZK12-240016-00 PLUG M14*1.5 1

BL-WRT-0816 - 10-19-2018 12-33

 R6786A

Figure 12-16 Frame

12-34 BL-WRT-0816 - 10-19-2018

 Frame
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-100003-00 RUBBER CUSHION 1
2 2140-140000-00 CASTER ASSEMBLY 2
3 1280-120000-00 FRAME 1
4 0000-000109-00 SCREW M8×16 8
5 0000-000159-00 LOCKWASHER Ø8 16
6 0000-000176-00 FLATWASHER Ø8 16
7 0000-000154-00 SCREW M8×35 10
8 0000-000056-00 LOCKWASHER Ø6 4
9 0000-000055-00 SCREW M6×16 4
10 1280-131000-00 SHAFT 2
11 1280-132000-00 SHAFT 2
12 0000-000694-00 BUSHING CSB-20 2220 4
13 0000-000692-00 FLATWASHER Ø22 6
14 1280-130001-00 LINK 2
15 1280-110000-00 FORK FRAME 1 W=28”,L=96”
15a 1260-110000-00 FORK FRAME 1 W=27”,L=48”
15b 1260-110000-20 FORK FRAME 1 W=27”,L=36”
15c 1260-110000-10 FORK FRAME 1 W=27”,L=60”
15d 1260-110000-50 FORK FRAME 1 W=27”,L=65”
16 0000-000630-00 NUT M12 2
17 0000-000286-00 BOLT M12×60 2 Used up to 03-20-2013
17 0000-001142-00 BOLT M16×80 2 Used from 03-21-2013
18 0000-000630-00 NUT M12 2 Used up to 03-20-2013
18 0000-000187-00 NUT M16 2 Used from 03-21-2013
19 0000-000380-00 FLATWASHER Ø6 4
20 0000-000411-00 LUBRICATION FITTING M6 4
21 2140-140005-00 WASHER 16
22 0000-000285-00 SCREW M12×35 2
23 0000-000060-00 LOCKWASHER Ø12 2
24 0000-000373-00 FLATWASHER Ø12 2
25 1260-100001-00 BOLT 6
26 1260-100002-00 WHEEL 6 Used up to 03-14-2013
26 1260-100003-00 WHEEL 6 Used from 03-15-2013
27 0000-000057-00 NUT 12 6
28 0000-000191-00 LOCKWASHER Ø16 2 Used from 03-21-2013
29 0000-000220-00 FLATWASHER Ø16 2 Used from 03-21-2013

BL-WRT-0816 - 10-19-2018 12-35

 R8234

Figure 12-17 Battery Roller Bed

12-36 BL-WRT-0816 - 10-19-2018

 Battery Roller Bed
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 0000-000109-00 SCREW M8×16 2
2 0000-000159-00 LOCKWASHER Ø8 9
3 0000-000176-00 FLATWASHER Ø8 9
4 0000-000322-00 SCREW M8×25 6
5 1280-160001-00 ROLLER(??) 4
6 1280-161000-00 SLIPPERY COURSE FRAMEWORK 1
7 1280-180002-00 BAFFLE 1 Used from 08-30-2012
9 1280-190000-00 FIXING HOLDER 1
10 1120-100003-00 BATTERY CLAMP 1
11 0000-000242-00 BOLT M8×16 1
14 0000-000077-00 SCREW M6×12 8
15 1120-100004-00 RUBBER BLOCK 4

BL-WRT-0816 - 10-19-2018 12-37

 R8235

Figure 12-18 Load Backrest

12-38 BL-WRT-0816 - 10-19-2018

 Load Backrest
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-171000-00 LOAD BACKREST 1 Optional, Height=48in
1a 1280-171000-10 LOAD BACKREST 1 Optional, Height=60in
2 0000-000880-00 SCREW M8×16 5

BL-WRT-0816 - 10-19-2018 12-39

 DB_0008

Figure 12-19 Lift Linkage

12-40 BL-WRT-0816 - 10-19-2018

 Lift Linkage
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 0000-000587-00 LUBRICATION FITTING M6 16
2 1280-130002-00 SHAFT 2
3 0000-000410-00 PIN Ø6×40 10
4 0000-000693-00 BUSHING CSB-20 2225 20
5 1280-130003-00 SHAFT 2
6 0000-000414-00 PIN Ø6×50 6
7 1280-130005-00 SHAFT 2
8 1280-130004-00 LINK 2
Used up to Serial number 324190051
9 1280-133000-00 TENSION BAR 2
Fork Width=28”, Fork Length=96”
Used from Serial number 324190052
9a 1280-133000-0A TENSION BAR 2
Fork Width=28”, Fork Length=96”
Used up to Serial number 324190051
9b 1260-133000-00 TENSION BAR 2
Fork Width=27”, Fork Length=48”
Used from Serial number 324190052
9c 1260-133000-0A TENSION BAR 2
Fork Width=27”, Fork Length=48”
Used up to Serial number 324190051
9d 1260-133000-20 TENSION BAR 2
Fork Width=27”, Fork Length=36”
Used from Serial number 324190052
9e 1260-133000-2A TENSION BAR 2
Fork Width=27”, Fork Length=36”
Used up to Serial number 324190051
9f 1280-133000-10 TENSION BAR 2
Fork Width=27”, Fork Length=60”
Used from Serial number 324190052
9g 1280-133000-1A TENSION BAR 2
Fork Width=27”, Fork Length=60”
Used up to Serial number 324190051
9h 1280-133000-50 TENSION BAR 2
Fork Width=27”, Fork Length=65”
Used from Serial number 324190052
9i 1280-133000-5A TENSION BAR 2
Fork Width=27”, Fork Length=65”
10 0000-000691-00 NUT M22×1.5 10 Used up to Serial number 324190051
10a 3030-190000-05 NUT M24 10 Used from Serial number 324190052
11 1280-130009-00 TENSION KIT 2 Used up to Serial number 324190051
11a 1280-130009-0A TENSION KIT 2 Used from Serial number 324190052
12 1280-130007-00 END TORSION BAR 2 Used up to Serial number 324190051
12a 1280-130007-0A END TORSION BAR 2 Used from Serial number 324190052
13 1280-130008-00 SHAFT 2
14 1280-130012-00 SHAFT 2
15 0000-000695-00 BUSHING 4
16 1280-130013-00 ROLLER 2
17 1280-130010-00 WHEEL BRACKET 2
18 1260-130006-00 SHAFT 2
19 1280-130011-00 LOADING WHEEL 2
20 1280-134001-00 SHAFT 2
21 0000-000100-00 BEARING 8
22 1280-134002-00 WASHER 4
23 0000-000249-00 FLATWASHER Ø24 4
24 1280-134100-00 LOAD WHEEL ASSEMBLY 2 Includes Pos. # 19, 21, 22

BL-WRT-0816 - 10-19-2018 12-41

 R6788

12-42 BL-WRT-0816 - 10-19-2018

 Figure 12-20 Caster Wheel
Caster Wheel
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
-- 2140-140000-00 CASTER ASSEMBLY 2
1 0000-000093-00 NUT M27×1.5 1
2 0000-000094-00 WASHER Ø27 1
3 1220-140001-00 SNAP RING 1
4 0000-000420-00 BEARING 1
5 2140-140002-00 BEARING BLOCK 1
6 0000-000421-00 BEARING 1
7 2140-140004-00 SPRING 2
8 2140-141000-00 YOKE 1
9 0000-000242-00 BOLT M8×16 2
10 0000-000159-00 LOCKWASHER Ø8 2
11 2140-142000-00 HINGE PIN 1
12 2140-145000-00 SHAFT 1
13 2140-140003-00 SHAFT 2
14 2140-143000-00 YOKE 1
15 2140-144002-00 POLY WHEEL 1
16 0000-000424-00 BEARING 2
17 0000-000249-00 FLATWASHER Ø24 2

BL-WRT-0816 - 10-19-2018 12-43

 R6789

Figure 12-21 Hydraulic System

12-44 BL-WRT-0816 - 10-19-2018

 Hydraulic System
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 2402-384000-00 BOLT G3/8×40 1
2 0000-000634-00 WASHER Ø18 2
3 1280-440000-00 HOSE 1
4 1220-440000-10 PUMP - MOTOR ASSEMBLY 1
5 0000-000251-00 SCREW M10×25 2
6 0000-000063-00 LOCKWASHER Ø10 2
7 0000-000007-00 FLATWASHER Ø10 2
8 0000-000055-00 SCREW M6×16 2
9 0000-000056-00 LOCKWASHER Ø6 2
10 1280-420000-00 SHAFT 1
11 2701-141600-10 UNION 1
12 0000-000044-00 WASHER Ø14 1
13 1280-410000-00 SHAFT 1
14 1280-430000-00 CYLINDER 1
15 0000-000109-00 SCREW M8×16 1
16 0000-000159-00 LOCKWASHER Ø8 1
17 0000-000176-00 FLATWASHER Ø8 1
18 2112-400002-00 VITTA NIP 1

BL-WRT-0816 - 10-19-2018 12-45

 R6790

Figure 12-22 Pump & Motor Assy

12-46 BL-WRT-0816 - 10-19-2018

 Pump & Motor Assy
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1220-430020-00 SCREW 2
2 1220-430002-00 CABLE 1
3 2125-430021-00 WIRE 1
4 1220-430021-00 SCREW 2
5 1120-420017-00 CONTACTOR 1
6 1220-430003-00 MOTOR 1
7 1120-420011-00 VALVE SOLENOID 1
8 1120-420010-00 CARTRIDGE 1
9 1220-440001-10 VALVE 1
10 1220-430022-00 PLUG 1
11 1220-430008-00 ADAPTER 1
12 1220-430011-00 PUMP 1
13 1220-430012-00 SCREW 4
14 1220-420015-00 TUBE 1
15 1220-430016-00 TUBE 1
16 1120-420008-00 FILTER 1
17 1220-430018-00 PLUG 1
18 1220-420014-00 CLAMP 1
19 1220-430023-00 PIPE( 1
20 1220-430019-00 RESERVOIR 1
21 1220-430024-00 BRUSH 1

BL-WRT-0816 - 10-19-2018 12-47

 R6791A

Figure 12-23 Lift Cylinder

12-48 BL-WRT-0816 - 10-19-2018

 Lift Cylinder
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
-- 1280-430000-00 LIFT CYLINDER 1
-- 1280-SK SEAL KIT FOR LIFT CYLINDER 1 Include item1,3,6
1 0000-000045-00 RING WIPER 55×63×5-6.5 1
2 1280-430002-00 CAP 1
3 0000-000690-00 O-RING 60×3.1 1
4 1280-430001-00 PISTON ROD 1
5 1280-430003-00 RING BACK UP 20×2.5 1
6 0000-000689-00 ROD PACKING 60×70×6 1
7 1280-431000-00 CYLINDER BLOCK 1
8 0000-000411-00 LUBRICATION FITTING M6 2

BL-WRT-0816 - 10-19-2018 12-49

 R6792A

Figure 12-24 Electrical System

12-50 BL-WRT-0816 - 10-19-2018

 Electrical System
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 0000-000433-00 SCREW M8×12 4
2 0000-000159-00 LOCKWASHER Ø8 6
3 0000-000194-00 FLATWASHER Ø8 4
4 1120-500003-00 HORN 1
5 0000-000499-00 SCREW M4×45 4 Used up to 10-14-2012
5 0000-001033-00 SCREW M4×55 4 Used from 10-15-2012
6 0000-000122-00 LOCKWASHER Ø4 6
7 0000-000702-00 FLATWASHER Ø4( 6
8 1220-500003-00 FAN 1
9 0000-000209-00 NUT M4 6
10 1280-520006-00 DRIVING SWITCH ASSEMBLY 2
11 1280-100001-00 COVER 1
12 1220-520002-0C 2 WAY KEY SWITCH ASSEMBLY 1 Used up to 09-27-2012
12a 1220-520002-1C 2 WAY KEY SWITCH ASSEMBLY 1 Used from 09-28-2012
12b 1115-500010-00 BLACK PLASTIC MOLDED KEY - SET OF 2 Used up to 09-27-2012
12c 1120-500016-10 2 WAY SWITCH KEYS, SET OF 2 Used from 09-28-2012
13 1115-510006-20 METER 803 1
14 1220-520007-0C METER WIRING HARNESS 1 Used up to 04-14-2012
14 1220-520007-0D METER WIRING HARNESS 1 Used from 04-15-2012
15 -- CONTROLLER BOARD ASSEMBLY 1 See Electrical Panel Section
16 0000-000109-00 SCREW M8×16 2
17 0000-000015-00 SCREW M6×10 2
18 0000-000056-00 LOCKWASHER Ø6 2
19 0000-000380-00 FLATWASHER Ø6 2
20 1280-510003-00 BRACKET 1
21 1220-500004-00 VEIL MATS 1
22 0000-000208-00 SCREW M4×25 2
23 1120-500006-00 LIFTING LIMIT SWITCH ASSEMBLY 1
24 1220-500009-00 PLASTIC CASING 4
25 1280-560004-00 BUTTON 2

BL-WRT-0816 - 10-19-2018 12-51

 R6794A

Figure 12-25 Electrical Panel

12-52 BL-WRT-0816 - 10-19-2018

 Electrical Panel
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-560001-00-20 CONTROLLER 1
2 0000-000074-00 SCREW M6×20 4
3 0000-000056-00 LOCKWASHER Ø6 6
4 0000-000380-00 FLATWASHER Ø6 6
5 0000-000196-00 NUT M8 8
6 0000-000210-00 FLATWASHER Ø8 4
7 1120-540002-00 FUSE 200A 2
8 0000-000126-00 SCREW M6×16 4
9 0000-000206-00 LOCKWASHER Ø5 4
10 1120-540001-00-B FUSE BLOCK 2
11 1280-510002-00 BAR COPPER 1
12 1280-510001-00 BAR COPPER 1
13 0000-000015-00 SCREW M6×10 2
14 1120-530006-00 COPPER CONDUCTOR 1
15 1280-560003-00 CONTACTOR 1
16 0000-000159-00 LOCKWASHER Ø8 4
17 0000-000176-00 FLATWASHER Ø8 2
18 1280-510000-00 PLATE 1
19 1280-510004-00 HEAT SINK PLATE 1
20 0000-000004-00 SCREW M5×12 4

BL-WRT-0816 - 10-19-2018 12-53

 R6796A

Figure 12-26 Wiring Harness

12-54 BL-WRT-0816 - 10-19-2018

 Wiring Harness
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-520001-00 MAIN WIRE HARNESS 1 Used up to 06-14-2013
1a 1280-520001-0A MAIN WIRE HARNESS 1 Used from 06-15-2013
2 1120-500010-00 FUSE 10A 1

BL-WRT-0816 - 10-19-2018 12-55

 R6798A

Figure 12-27 Wiring Cables

12-56 BL-WRT-0816 - 10-19-2018

 Wiring Cables
QTY.
POS. PART NUMBER DESCRIPTION NOTES
REQD.
1 1280-531003-00 TRACTION ELECTRIC MACHINE CABLE W 1
2 1280-531002-00 TRACTION ELECTRIC MACHINE CABLE V 1
3 1280-531001-00 TRACTION ELECTRIC MACHINE CABLE U 1
4 1280-531004-00 PUMP CABLE (+) 1
5 1280-531005-00 PUMP CABLE (-) 1
6 1280-531100-00 TRUCK CONNECTOR ASSEMBLY 1
7 0000-000498-00 SCREW M6×30 2
8 0000-000056-00 LOCKWASHER Ø6 2
9 1120-112008-00 PLATE 1

BL-WRT-0816 - 10-19-2018 12-57

Big Lift LLC