Operation Maintenance Repair Parts List

1 Big Lift LLCMANUAL NO. BL-D40-0515 - , PALLET LIFT Patents Nos. D739,112; D770,719; D770,720; 9,586,605 OperationMaintenanceRepair Parts ListNOTE: For the most current Parts information and service updates, please refer to the Big JoeSupport site at not operate this truck unless you have been autho-rized and trained to do so, and have read all warningsand instructions in Operator s Manual and on not operate this truck until you have checked itscondition. Give special attention to wheels, horn, bat-tery, controller, lift system, brakes, steering mecha-nism, guards and safety truck only from designated operating not carry passengers. Keep feet clear of truck andwear foot applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is , stop, travel, steer and brake smoothly.

2 Slowdown for turns and on uneven or slippery surfaces thatcould cause truck to slide or overturn. Use specialcare when traveling without load as the risk of overturnmay be look in direction of travel. Keep a clear view,and when load interferes with visibility, travel with special care when operating on ramps travelslowly, and do not angle or turn. Travel with not handle loads which are higher than the chassisunless load is secured so that no part of it could fallbackward. Before lifting, be sure load is centered,forks are completely under the chassis leaving truck, neutralize travel control, fullylower lifting mechanism and set brake. When leavingtruck unattended, also shut off OF CONTENTSBL-D40-0515 - 08-10-2018iSectionPageSectionPage1 LIST OF LIST OF TABLES.

3 DESCRIPTION.. CONTROL AND STOPPING PROCEDURES.. SWITCH.. ARM GAS SPRING.. AND LOWER .. RAILS.. AND AND QUARTERLY BATTERY CARE.. CARE AND CHARGING .. FREE BATTERIES .. BATTERIES .. TROUBLESHOOTING .. TRUCK AND ARM, CONTROL HEAD AND HEAD .. HEAD HEAD ASSEMBLY REMOVAL.. ASSEMBLY INSTALLATION.. POTENT. REPLACEMENT.. SWITCH SWITCH REPLACEMENT.. / LOWER SWITCH REPLACEMENT .. SPRING REPLACEMENT.. ARM REMOVAL.. ARM INSTALLATION.. 5-76 BRAKE GAP ADJUSTMENT.. DISTANCE ADJUSTMENT.. ASSEMBLY 6-27 TRANSMISSION, DRIVE AND LOAD WHEEL .. WHEEL INSTALLATION .. WHEEL.. 7-38 ELEVATION SYSTEM .. LINKAGE .. 8-29 HYDRAULIC SYSTEM AND AND ELECTR. ASSY. REMOVAL .. PUMP, MOTOR, AND RESERVOIR ASSY .. AND 9-410 ELECTRICAL CONTROL.

4 CONTROLLER REMOVAL.. CONTROLLER INSTALLATION.. CHARGER CHARGER EMERG. DISCONNECT EMERG. DISCONNECT CONTACTOR CONTACTOR FUSE REMOVAL.. 10-2 TABLE OF CONTENTS - ContinuediiBL-D40-0515 - FUSE INSTALLATION.. COOLING FAN REMOVAL.. COOLING FAN INSTALLATION.. BUZZER REMOVAL.. BUZZER INSTALLATION.. KEY SWITCH REMOVAL.. KEY SWITCH INSTALLATION.. BATTERY INDICATOR REMOVAL.. BATTERY INDICATOR INSTALLATION.. LIFT LIMIT SWITCH REMOVAL.. LIFT LIMIT SWITCH INSTALLATION.. MOTOR.. MOTOR.. SWITCH .. 10-711 OPTIONAL EQUIPMENT .. 11-112 ILLUSTRATED Parts BREAKDOWN .. 12-1 LIST OF ILLUSTRATIONSF igurePageFigurePage1-1 NAME PLATE .. 1-11-2D40 LIFT 1-12-1 SAMPLE OF OPERATOR CHECK LIST .. 2-32-2 FORWARD/REVERSE 2-42-3 PUSHBUTTON SWITCHES.

5 2-42-4 BRAKE ACTUATION .. 2-42-5 BELLY-BUTTON 2-53-1 CHARGING BATTERY .. 3-33-2 COVER 3-43-3 CONTROLLER BOARD REMOVAL .. 3-43-4 LUBRICATION DIAGRAM .. 3-64-1 ZAPI CONTROLLER .. 4-44-2 ZAPI HANDSET .. 4-54-3 ZAPI HANDSET .. 4-94-4 THROTTLE 4-104-5 ZAPI HANDSET .. 4-114-6 ZAPI CONTROLLER CONNECTIONS .. 4-135-1 STEERING 5-15-2 CONTROL HEAD .. 5-25-3 EMERGENCY REVERSE SWITCH ASSY.. 5-45-4 CAP ASSEMBLY .. 5-55-5 COMPARTMENT COVER .. 5-66-1 BRAKE ASSEMBLY .. 6-17-1 WHEEL ASSEMBLY .. 7-27-2 TRANSMISSION MOTOR, BRAKE MOUNTING. 7-48-1 FRAME .. 8-18-2 LIFT LINKAGE 8-29-1 HYDRAULIC SYSTEM .. 9-19-2 PUMP & MOTOR 9-39-3 LIFT CYLINDER .. 9-510-1 ELECTRICAL COMPONENTS (SHEET 1) .. 10-310-2 ELECTRICAL COMPONENTS (SHEET 2) .. 10-510-3 ELECTRIC 10-612-1 STEERING ARM .. 12-212-2 CONTROL HEAD.

6 12-412-3 CAP 12-812-4 EMERGENCY REVERSE SWITCH ASSEMBLY .. 12-1012-5 TRANSMISSION MOTOR, BRAKE MOUNTING .. 12-1212-6 TRANSMISSION .. 12-1412-7 COMPARTMENT COVERS .. 12-1812-8 LOAD BACKREST .. 12-2012-9 FRAME .. 12-2412-10 LIFT LINK 12-2612-11 LOAD WHEEL .. 12-2812-12 CASTER .. 12-3012-13 HYDRAULIC SYSTEM .. 12-3212-14 PUMP & MOTOR 12-3412-15 LIFT CYLINDER .. 12-3612-16 ELECTRICAL SYSTEM .. 12-3812-17 MOTOR 12-4012-18 ELECTRICAL COMPONENTS (SHEET 1) .. 12-4212-19 ELECTRICAL COMPONENTS (SHEET 2) .. 12-4412-20 WIRING 12-4812-21 WIRING CABLES .. 12-50 LIST OF TABLEST ablePageTablePage2-1 OPERATOR CHECKS .. 2-23-1 MONTHLY AND QUARTERLY INSPECTION AND SERVICE 3-13-2 RECOMMENDED 3-53-3 LUBRICATION CHART .. 3-64-1 TROUBLESHOOTING CHART .. 4-14-2 SET 4-54-3 ADJUSTMENTS.

7 4-94-4 PARAMETER ADJUSTMENTS .. 4-114-5 ZAPI CONTROLLER CONNECTOR 4-13BL-D40-0515 - 08-10-20181-1 SECTION 1 DESCRIPTION1-1. publication describes the 24 volt D40 lift truck dis-tributed by Big Lift LLC. Included are operating instruc-tions, planned Maintenance instructions, lubricationprocedures, corrective Maintenance procedures and acomplete Parts list with part location shall comply with all requirements indicated inapplicable OSHA standards and current edition Part II. By following these requirementsand the recommendations contained in this manual,you will receive many years of dependable servicefrom your D40 lift truck. 1-2. GENERAL self-propelled D40 truck, Figure 1-2, lifts andtransports payloads up to 4000 pounds on rigid forward and reverse motion is controlled by eitherof two controller levers mounted on the control and turning is controlled by the steering and Lower is controlled by pushbuttons on the con-trol head.

8 The battery powered lift truck is quiet andreliable. The reversible AC motor propels the lift truck in for-ward or reverse direction throughout the availablespeed range. The D40 lift truck can be driven withforks raised or lowered. The lift truck must be pro-tected from the model number will be found on the name plate(Figure 1-1) along with the serial number, lifting capac-ity, and load center. Figure 1-2 shows the locations ofthe truck s main components and 1-1 Name PlateFigure 1-2 . D40 Lift TruckR6209D40-91-2BL-D40-0515 - 08-10-20181-3. SAFETY D40 is designed and engineered to provide maxi-mum safety for operator and payload. Some of thesafety features incorporated into the design are: Dead-man brake to apply the brake and cut off drivepower when the steering arm is released.

9 Belly-button switch to reverse truck should the oper-ator accidentally pin himself against a wall orobstruction when backing up in slow speed. All control functions automatically return to OFF when released. Emergency Disconnect within operator's reach. Readily accessible horn button. Handle to provide a firm hand hold for operator. Flow control valve regulates maximum loweringspeed within prescribed limits. Relief valve maintains hydraulic pressure within pre-scribed limits. High visibility color scheme of truck provides visualalert of truck s presence. Battery Indicator. Adjustable load - 08-10-20182-1 SECTION 2 OPERATION2-1. section gives detailed operating instructions forthe D40 lift truck. The instructions are divided into thevarious phases of operations, such as operating lift,driving, and stopping.

10 Routine precautions areincluded for safe OPERATING :Improper Operation of the lift truck mayresult in operator injury, or load and/or lifttruck damage. Observe the followingprecautions when operating the D40 following safety precautions must be adhered toat all times. Do not operate this truck unless you have beentrained and authorized to do so and have read allwarnings and instructions in this manual and on thetruck. All warnings and instructions must be read andunderstood before using the equipment. Equipment must be inspected by a qualified personon a regular basis. Do not operate this truck until you have checked itscondition. Give special attention to Wheels, Horn,Batteries, Controller, Lift System, Brakes, SteeringMechanism, Guards and Safety Devices Operate truck only from designated operating posi-tion.