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Big Lift D40, Operation, Maintenance, Repair Parts

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Big Lift D40 Operation, Maintenance, Repair Parts Download Page 52

9-2

BL-D40-0515 - 01-27-2019

CAUTION:

Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container
under the line or fitting before discon-
necting.

4.

Refer to 

Figure 9-1

 and remove leaking line or fit-

ting and replace it with a new line or fitting. Check
level of hydraulic oil. With lift carriage fully low-
ered, fill reservoir with hydraulic oil to 1 inch below
opening. Use hydraulic oil listed in 

Table 3-2

.

5.

Turn on key switch and emergency disconnect.

6.

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

7.

Check level of hydraulic oil. Hydraulic oil must be
1 inch below opening. If required, add hydraulic
oil to bring to proper level. Use hydraulic oil listed
in 

Table 3-2

.

8.

Install the compartment covers as described in
paragraph 

5-2.

9-2. HYDRAULIC AND ELECTRICAL ASSEMBLY
REMOVAL

The hydraulic system and electrical system can be
removed as an assembly to provide additional clear-
ance for various maintenance procedures. 

WARNING:

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

9-2.1. Removal

1.

Lower forks fully.

2.

Turn off key switch and emergency disconnect.

3.

Remove the compartment covers as described in
paragraph 

5-2.

4.

Disconnect hose from pump and motor assembly.

5.

Tag and disconnect all harnesses and cables from
electrical components on board.

6.

Support board and remove four screws , four lock
washers and four flat washers.

7.

Remove board.

9-2.2. Installation

1.

Position board on frame and secure with four
screws, four lock washers and four flat washers.

2.

Reconnect hose to pump and motor assembly.

3.

Reconnect all harnesses and cables to electrical
components on board.

4.

Turn on key switch and emergency disconnect.

5.

Install the compartment covers as described in
paragraph 

5-2.

9-3. HYDRAULIC PUMP, MOTOR, AND RESER-
VOIR ASSY

The hydraulic pump/motor assembly can be disas-
sembled and repaired. However, a defective pump,
valve or motor requires replacement of that compo-
nent. 

WARNING:

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

9-3.1. Removal

1.

Lower forks fully.

2.

Turn off key switch and emergency disconnect.

3.

Remove the hydraulic and electrical assembly as
described in paragraph 

9-2.

NOTE:

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

4.

Remove two screws, lock washers and flat wash-
ers and remove pump and motor.

9-3.2. Disassembly and Reassembly

1.

Remove the hydraulic pump/motor assembly as
described in paragraph 

9-3.1.

2.

Refer to 

Figure 9-2

 for disassembly and reassem-

bly.

Summary of Contents for D40

Page 1: ...s com D40 SELF PROPELLED PALLET LIFT TRUCK U S Patents Nos D739 112 D770 719 D770 720 9 586 605 Operation Maintenance Repair Parts List NOTE For the most current parts information and service updates please refer to the Big Joe Support site at www bigjoesupport com ...

Page 2: ...sion is obstructed Start stop travel steer and brake smoothly Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or overturn Use special care when traveling without load as the risk of overturn may be greater Always look in direction of travel Keep a clear view and when load interferes with visibility travel with load trailing Use special care when operating on ...

Page 3: ...SPEED POTENT REPLACEMENT 5 3 5 1 6 BELLY BUTTON SWITCH REPLACE 5 3 5 1 7 HORN SWITCH REPLACEMENT 5 4 5 1 8 LIFT LOWER SWITCH REPLACEMENT 5 5 5 2 COMPARTMENT COVERS 5 6 5 2 1 REMOVAL 5 6 5 2 2 INSTALLATION 5 6 5 3 STEERING ARM 5 7 5 3 1 RETURN SPRING REPLACEMENT 5 7 5 3 2 STEERING ARM REMOVAL 5 7 5 3 3 STEERING ARM INSTALLATION 5 7 6 BRAKE SERVICING6 1 6 1 BRAKES 6 1 6 1 1 AIR GAP ADJUSTMENT 6 1 6 ...

Page 4: ...CONTROL HEAD 5 2 5 3 EMERGENCY REVERSE SWITCH ASSY 5 4 5 4 CAP ASSEMBLY 5 5 5 5 COMPARTMENT COVER 5 6 6 1 BRAKE ASSEMBLY 6 1 7 1 WHEEL ASSEMBLY 7 2 7 2 TRANSMISSION MOTOR BRAKE MOUNTING 7 4 8 1 FRAME 8 1 8 2 LIFT LINKAGE ASSEMBLY 8 2 9 1 HYDRAULIC SYSTEM 9 1 9 2 PUMP MOTOR ASSY 9 3 9 3 LIFT CYLINDER 9 5 10 1 ELECTRICAL COMPONENTS SHEET 1 10 3 10 2 ELECTRICAL COMPONENTS SHEET 2 10 5 10 3 ELECTRIC S...

Page 5: ...led D40 truck Figure 1 2 lifts and transports payloads up to 4000 pounds on rigid forks The forward and reverse motion is controlled by either of two controller levers mounted on the control head Stopping and turning is controlled by the steering arm Lift and Lower is controlled by pushbuttons on the con trol head The battery powered lift truck is quiet and reliable The reversible AC motor propels...

Page 6: ...or accidentally pin himself against a wall or obstruction 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 lowering speed within prescribed limits Relief valve maintains hydraulic pressure withi...

Page 7: ...re when traveling without load as the risk of overturn may be greater Always look in direction of travel Keep a clear view and when load interferes with visibility travel with load or lifting mechanism trailing Do not overload truck Check nameplate for load weight and load center information Before lifting be sure load is centered forks are completely under load and load is as far back as possible...

Page 8: ... all speed ranges in forward and reverse and that belly button switch functions Wheels Check drive wheel for cracks or damage Move truck to check load for freedom of rotation Hydraulic controls Check operation of lift and lower to their maximum positions Brake Check that brake actuates when steering arm is raised to upright position and when lowered to horizontal position Deadman Parking brake Che...

Page 9: ...BL D40 0515 01 27 2019 2 3 Figure 2 1 Sample of Operator Check List R6479 ...

Page 10: ...ch Grasp the grips of the steering head so that the speed control can be comfortably oper ated by either thumb 2 Lower the steering arm to a comfortable position above horizontal to disengage the brake and to energize the electrical circuits If the truck is not moved the electrical circuits will time out and will deenergize See Figure 2 4 3 To move forward with load in front slowly press the speed...

Page 11: ...ld until forks descend to desired height 2 9 BACKREST A load backrest Figure 12 9 is optional 2 10 LOADING AND UNLOADING 1 Move truck to location where load is to be picked up 2 Move the truck into position so forks are within pallet or skid and the load is centered over the forks and as far back as possible 3 Raise forks to lift load 4 Drive to area where load is to be placed 5 Move truck to alig...

Page 12: ...2 6 BL D40 0515 01 27 2019 NOTES ...

Page 13: ...ater Obtain medical attention when eyes are affected A baking soda solution one pound to one gallon of water applied to spilled acid until bub bling stops neutralizes the acid for safe handling and disposal Leakage voltage from battery terminals to battery case can cause misleading trouble symptoms with the truck electrical system Since components of the truck elec trical system are insulated from...

Page 14: ...ng charging is highly explosive and can cause seri ous injury 1 Charge the battery only in areas designated for that use 2 Battery terminals should be checked and cleaned of corrosion regularly Good battery terminal con tact is essential not only for operation but also for proper charging of the battery 3 The charging requirements will vary depending on the use of the truck The battery should be g...

Page 15: ...ging station with forks lowered and turn the key switch off 2 Check the condition of the AC cord and battery cables If there are any cuts in the cable any exposed wires loose plugs or connectors DO NOT attempt to charge the batteries Contact appropriate personnel for repairs to be made 3 Pull the charger cord 1 Figure 3 1 out of the top cover and connect to the appropriate power sup ply Figure 3 1...

Page 16: ...1 Figure 3 2 and remove cover 2 Figure 3 2 Cover Removal a Remove the hose and harness 3 Figure 3 3 and battery cable 2 Remove four screws 3 and take out the controller board 4 Figure 3 3 Controller Board Removal b Install in the reverse order of remove Pay attention to battery position and cable con nection Position cables to avoid damage D40 25 D40 26 ...

Page 17: ... for Application No 1 Transmission oil EP SAE 80W 90 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...

Page 18: ... 3 APPLICATION OF LUBRICANT 1 Transmission Capacity 2 pints Can No 1 Fill to level plug opening 2 Hydraulic Reservoir Capacity 1 quarts Can No 3 With lift carriage fully lowered fill reservoir with hydraulic oil to 1 inch below opening 3 Lift Linkage Fittings Gun No 2 Pressure lubricate Raise lift carriage to gain access to grease fittings D40 27 ...

Page 19: ...function Tighten all loose connections before further troubleshooting b Defective deadman switch 16 Figure 12 1 Check and replace switch if defective c Defective controller 18 Figure 12 21 Check for proper operation and replace if necessary d Defective potentiometer 21 Figure 12 2 Check and replace potentiometer if defective Truck travels forward but not in reverse Defective potentiometer 21 Fig u...

Page 20: ... low Add oil to reservoir Weak slow or uneven action of hydraulic system a Defective pump or relief valve Check pressure Adjust as 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 4 Figure 12 16 on electrical panel e Battery charge low Charge battery Forks do not lift pump motor does not run...

Page 21: ...need charging Change batteries Forks creep downward under load when in a raised position Leak in hydraulic system lift cylin der or lowering valve Check for leaking fitting in hydrau lic line and repair as required Repack lift cylinder or replace valve assembly 7 Figure 12 16 MISCELLANEOUS Steering arm does not return to the upright position a Week return spring Replace spring b Binding Check and ...

Page 22: ...test event of every alarm occurred This function permits a deeper diagnosis of problems as the recent history can be revisited 4 2 2 2 Logbook Access To view the alarm logbook proceed as follows 1 Connect the Zapi Handset refer to paragraph 4 2 1 2 Press the ROLL down button 1 Figure 4 2 and the ENTER button 3 at the same time to enter the MAIN MENU 3 Press the ROLL down button 2 or the ROLL up bu...

Page 23: ...ptions Figure 4 2 Zapi Handset Table 4 2 Set Options R6624 Parameter Factory Setting Description TILLER switch HANDLE This option handles the input CNB 3 Table 4 5 This input opens when the operator leaves the truck released It is connected to a Keyswitch controlled voltage when the operator is present SET INPUT 1 OPTION 1 Standard Version only This option handles the digital input CNA 15 It can b...

Page 24: ...rvice brake of the exclusive hydro becomes active when CNB 7 is opened HOUR COUNTER RUNNING This option specifies the hour counter mode It can be set as RUNNING The counter registers travel time only key on The counter registers when the keyswitch is closed BATTERY CHECK Level 1 This option specifies the handling of the low battery charge detec tion It can be set as Level 0 Nothing happens the bat...

Page 25: ...s than the SET POT BRK MIN the minimum release braking strength is applied following the RELEASE BRAKING setting When the pedal potentiometer voltage is equal higher than the SET POT BRK MAX the maximum release braking strength is applied following the PEDAL BRAKING setting In the intermedi ate position the electrical braking strength is a linear function between the minimum RELEASED BRAKING and m...

Page 26: ...cified percentage PERFORMANCE OPTION 1 This option can be set OPTION 1 OPTION 2 QUICK INV LOGIC OPTION 1 This option specifies the active level for the Belly switch input CNB 7 OPTION 1 The quick inversion is executed when CNB 7 Table 4 5 is closed to a Keyswitch controlled voltage OPTION 2 The quick inversion is executed when CNB 7 Table 4 5 is opened from a Keyswitch controlled voltage MDI PRC A...

Page 27: ...SET POT BRK MIN 0 5 V This setting records the minimum value of braking pedal potentiom eter when the braking pedal switch is closed the procedure is similar to the PROGRAM VACC function This procedure must be carried out only if the PEDAL BRAKING option is programmed as ANALOG No adjustment is necessary when PEDAL BRAKING options is programmed as NONE SET POT BRK MAX 4 5 V This setting records th...

Page 28: ... Maximum truck speed The rela tionship between the accelerator position and the truck speed is linear between the THROTTLE 0 ZONE and the X point and also between the X point and the maximum accelerator position but with two different slopes Figure 4 4 ADJUSTMENT 01 LEVEL 5 Adjust the upper level of the battery charge table Level 0 to 9 ADJUSTMENT 02 LEVEL 5 Adjust the lower level of the battery c...

Page 29: ... a long time to accelerate RELEASE BRAKING LEVEL 5 Level 0 to 9 It controls the deceleration ramp when the travel request is released At Level 9 the truck brakes abruptly INVERS BRAKING LEVEL 4 Level 0 to 9 It controls the deceleration ramp when the direction switch is inverted during travel At Level 9 the truck brakes abruptly PEDAL BRAKING LEVEL 9 Level 0 to 9 It controls the deceleration ramp w...

Page 30: ...peed applied when the forward or reverse switch is closed but the accelerator at its minimum In the ACO sense Coils this setting is higher equal than 5 Hz RPM CREEP 100 A Percentage value Set to 100 and not Used MAXIMUM CURRENT 96 It specifies the percentage of the absolute current 150A at which the current will be limited Normally MAXIMUM CURRENT is 100 DO NOT CHANGE INCHING SPEED 0 Hz Hz value I...

Page 31: ...m current 3 A CNA 4 NPC Negative of pump contactor soil CNA 5 PPC PEV Positive of pump contactor coil and lowering electrovalve coil CNA 6 NEV Negative of the lowering electrovalve coil CNA 7 CAN LOW Low level CAN BUS voltage I O CNA 8 BAT Bat CNA 9 ENC Encoder Positive Supply 5 or 12 Vdc CNA 10 ENC Encoder Negative Supply GND to minus battery CNA 11 HM B Output for driving an hourmeter when the h...

Page 32: ...1 SR2 TILLER H S BELLY LIFTING LOWERING microswitches This connection supplies a keyswitch voltage level CNB 3 TILLER SW Tiller request input Must be connected to the tiller microswitch active high CNB 4 H S SW Hard Soft request input Must be connected to the Hard Soft microswitch active high CNB 5 BACKWARD SW Backward direction request input Must be connected to the back ward direction microswitc...

Page 33: ...ive serial reception CNC 3 PCLTXD Positive serial transmission CNC 4 NCLTXD Negative serial transmission CNC 5 GND Negative console power supply CNC 6 12V Positive console power supply CNC 7 FLASH Must be connected to C8 for the Flash memory programming if used CNC 8 FLASH Must be connected to C7 for the Flash memory programming If used ...

Page 34: ...4 16 BL D40 0515 01 27 2019 NOTES ...

Page 35: ... HEAD AND COMPARTMENT 5 1 CONTROL HEAD 5 1 1 Control Head Removal 1 Turn off key switch and emergency disconnect 2 Remove the cap assembly as described in para graph 5 1 3 3 Disconnect wire harness assembly from potenti ometer Figure 5 1 Steering Arm DK_0001 ...

Page 36: ... holds control head to the steering arm WARNING When removing the control head in the following steps be sure to hold it in place until the control harness is disconnected 6 Remove the remaining two screws two washers and two flat washers that holds control head to the steering arm 7 Remove the control head and handle Figure 5 2 Control Head DK_0002 ...

Page 37: ... 5 Remove screws lock washers and flat washers that secure the potentiometer and switch assem bly to bracket Remove the potentiometer 6 Position new potentiometer and switch assembly in bracket and secure with screws lock washers and flat washers 7 Install control knob on potentiometer and secure with screw and washer 8 Install control knob on the other side of potentiom eter and secure with screw...

Page 38: ... 1 3 2 Remove three screws switch bracket and two springs of assembly 3 Remove the two pins of assembly and remove switch from the bracket 4 Position new switch in bracket of assembly and secure with the two pins 5 Position the bracket with two springs in cover and secure with three screws 6 Install the cap assembly as described in para graph 5 1 4 DK_0005 ...

Page 39: ...ve switch assembly from the cap 3 Remove pin securing buttons to the bracket and remove the buttons 4 Remove two pins two switches and four springs from bracket 5 Position switches and four springs in bracket and secure with two pins 6 Position switch assembly in cover and secure with pin 7 Install the cap assembly as described in para graph 5 1 4 DK_0003 ...

Page 40: ...two screws two screws and middle cover 7 Pull lower cover up and out 5 2 2 Installation 1 Position lower cover on the frame 2 Place middle cover around brake and secure with two screws and two screws 3 Install upper cover and secure with four screws and four washers 4 Reconnect cable to charger Figure 5 5 Compartment Cover 5 Feed the cable through cover and position cover on the frame Secure with ...

Page 41: ...as return spring inside the steer ing arm being sure it fully engages its seat 5 Position the opposite end of gas return spring on bracket and install screw 5 3 2 Steering Arm Removal 1 Remove steering arm gas return spring as described in paragraph 5 3 1 2 Disconnect wire harness assembly from harness 3 Attach a hoist to steering arm 4 Remove shaft and the steering arm 5 3 3 Steering Arm Installa...

Page 42: ...5 8 BL D40 0515 01 27 2019 ...

Page 43: ...mit reached 1 Block load wheels 2 Remove the compartment covers as described in paragraph 5 2 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...

Page 44: ...emove the compartment covers as described in paragraph 5 2 3 Rotate the adjusting nut Figure 6 1 clockwise to SHORTEN the stopping distance or counterclock wise to LENGTHEN the stopping distance 4 Remove load wheel blocks and check operation 5 Install the compartment covers as described in paragraph 5 2 6 1 3 Brake Assembly Replacement 1 Block load wheels 2 Remove the compartment covers as describ...

Page 45: ...eel assembly NOTE Inspect the load wheel assembly If the load wheel is worn within 1 8 of the metal sleeve or is cracked or damaged replace the entire load wheel and bearing assembly Big Lift LLC recommends that both load wheel assemblies be replaced at the same time This ensures level and safe operation of the lift truck 7 1 2 Repair 1 Remove bearings from wheels 2 Inspect bearings and replace if...

Page 46: ...as described in paragraph 5 2 8 Turn on key switch and emergency disconnect 7 3 Transmission 1 Turn off key switch and emergency disconnect 2 Remove the compartment covers as described in paragraph 5 2 3 Remove the brake as described in paragraph 6 1 3 4 Remove the steering arm as described in para graph 5 3 2 5 Disconnect harness from drive motor 6 Remove drive motor as described in paragraph 10 ...

Page 47: ...BL D40 0515 01 27 2019 7 3 Figure 7 2 Transmission Motor Brake Mounting DK_0006 ...

Page 48: ...7 4 BL D40 0515 01 27 2019 ...

Page 49: ... permit access to lift linkage under forks Provide blocking under frame 14 Figure 8 1 the rear of frame 4 and at the tips of the forks 2 Turn off key switch and emergency disconnect 3 Remove screw and shaft from each side of frame 4 Remove clips from each side of frame Support link assembly and remove shaft 5 Lower link assembly to the floor 6 Remove pins and remove shafts 7 Lower links to the flo...

Page 50: ...5 Loosennutsandremoveclevisesfromtensionbars 6 Remove bushings from link if replacement is nec essary 7 Install reassemble by reversing the steps above 8 2 3 Installation 1 Position link assembly under frame 2 Position wheel brackets in frame and install shafts Secure shafts with pins 3 Position link assembly and install shafts Secure shafts with screws 4 Remove blocking and lower the truck to the...

Page 51: ...ure forks must be fully lowered before performing any maintenance on the hydraulic system NOTE Leaking hydraulic fittings may be remedied by simply tightening fittings If this does not rem edy the leak the fittings or line must be replaced 1 Lower forks fully 2 Turn off key switch and emergency disconnect 3 Remove the compartment covers as described in paragraph 5 2 Figure 9 1 Hydraulic System DK_...

Page 52: ...cribed in paragraph 5 2 4 Disconnect hose from pump and motor assembly 5 Tag and disconnect all harnesses and cables from electrical components on board 6 Support board and remove four screws four lock washers and four flat washers 7 Remove board 9 2 2 Installation 1 Position board on frame and secure with four screws four lock washers and four flat washers 2 Reconnect hose to pump and motor assem...

Page 53: ...BL D40 0515 01 27 2019 9 3 Figure 9 2 Pump Motor Assy DK_0015 ...

Page 54: ...rame slightly to relieve pressure on the cylinder 7 Remove retaining rings and pin 8 Remove cylinder 9 3 4 2 Repair 1 Secure the lift cylinder in a vise clamping lightly at the base of the cylinder 2 Unscrew gland nut from body 3 Remove wiper and O ring from gland nut 4 Withdraw the cylinder rod from body 5 Remove bushing guide ring and seal ring from rod NOTE If the cylinder body or piston rod ar...

Page 55: ...BL D40 0515 01 27 2019 9 5 Figure 9 3 Lift Cylinder DK_0016 ...

Page 56: ...9 6 BL D40 0515 01 27 2019 NOTES ...

Page 57: ... 3 Remove any dirt or corrosion from the bus bar area The controller should be wiped clean with a moist rag Allow it to dry before reconnecting the battery 4 Make sure the connections to the buss bars are tight Use two well insulated wrenches for this task in order to avoid steering the buss bars 10 1 3 Controller Removal 1 Turn off key switch and emergency disconnect 2 Remove the compartment cove...

Page 58: ...onnect 10 1 9 Contactor Removal 1 Turn off key switch and emergency disconnect 2 Remove the compartment covers as described in paragraph 5 2 3 Tag and disconnect wires from contactor 4 Remove two screws lock washers flat washers and remove contactor 10 1 10 Contactor Installation 1 Position contactor on the board and secure with two screws lock washers and flat washers 2 Reconnect wires to contact...

Page 59: ...BL D40 0515 01 27 2019 10 3 Figure 10 1 Electrical Components Sheet 1 DK_0019 ...

Page 60: ...master wire harness to buzzer 3 Install compartment covers as described in para graph 5 2 4 Turn on key switch and emergency disconnect 10 1 17 Key Switch Removal 1 Turn off key switch and emergency disconnect 2 Remove the compartment covers as described in paragraph 5 2 3 Tag and disconnect switch wiring harness from key switch 4 Free key switch from bracket 10 1 18 Key Switch Installation 1 Inse...

Page 61: ...BL D40 0515 01 27 2019 10 5 Figure 10 2 Electrical Components Sheet 2 DK_0020 ...

Page 62: ...ster wire harness from limit switch 5 Remove two nuts screws lock washers and limit switch from bracket 10 1 22 Lift Limit Switch Installation 1 Position limit switch on bracket and secure with two screws lock washers and nuts 2 Reconnect master wire harness to limit switch 3 Install compartment covers as described in para graph 5 2 4 Turn on key switch and emergency disconnect Figure 10 3 Electri...

Page 63: ...agraph 7 3 10 4 DEADMAN SWITCH 10 4 1 Replacement 1 Turn off key switch and emergency disconnect 2 Remove the compartment covers as described in paragraph 5 2 3 Disconnect wiring from the deadman switch 4 Remove the two screws lock washers and bracket from bracket 5 Remove two screws and switch from bracket 6 Position the new switch on bracket and secure with the two screws 7 Position bracket on b...

Page 64: ...10 8 BL D40 0515 01 27 2019 NOTES ...

Page 65: ...BL D40 0515 01 27 2019 11 1 SECTION 11 OPTIONAL EQUIPMENT ...

Page 66: ...11 2 BL D40 0515 01 27 2019 NOTES ...

Page 67: ...BL D40 0515 01 27 2019 12 1 SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the D40 Lift Truck ...

Page 68: ...12 2 BL D40 0515 01 27 2019 Figure 12 1 Steering Arm DK_0001 ...

Page 69: ...RACKET 1 9 0000 000429 00 SCREW M5 X 8 1 10 0000 000030 00 SCREW M10 X 16 1 11 0000 000159 00 LOCK WASHER M8 3 12 0000 000063 00 LOCK WASHER M10 1 13 0000 000490 00 HARNESS CLAMP 1 14 0000 000031 00 SCREW M5 X 8 1 15 1118 520003 00 WIRE HARNESS 1 16 1118 520005 10 DEADMAN SWITCH ASSEMBLY 1 17 1120 300001 0A BRAKE BRACKET 1 18 1120 300006 00 SPACER 1 19 0000 000009 00 SCREW M4 X 12 2 20 0000 000122...

Page 70: ...12 4 BL D40 0515 01 27 2019 Figure 12 2 Steering Arm Freezer DK_0029 ...

Page 71: ...0000 000063 00 LOCK WASHER Ø10 1 13 0000 000490 00 HARNESS CLAMP 1 14 0000 000031 00 SCREW M5 8 1 15 1118 520003 X0 WIRE HARNESS 1 16 1118 520005 X0 INCHING SWITCH 1 17 1120 300001 0A BRAKE BRACKET 1 18 1120 500002 LK PLATE 1 19 0000 000378 00 SCREW M4 16 2 20 0000 000122 00 LOCK WASHER Ø4 1 21 1120 520005 LK HEATER BAND 1 22 0000 000378 00 SCREW M4 16 1 23 0000 000702 00 FLAT WASHER Ø4 1 24 0000 ...

Page 72: ...12 6 BL D40 0515 01 27 2019 Figure 12 3 Control Head Used up to Serial Number 327120792 DK_0002 ...

Page 73: ...0 000390 00 FLAT WASHER Ø5 4 8 0000 000088 00 SCREW M4 8 2 9 0000 000122 00 LOCK WASHER Ø4 2 10 0000 000702 00 FLAT WASHER Ø4 2 11 0000 000322 00 SCREW M8 25 2 12 0000 000159 00 LOCK WASHER Ø8 2 13 0000 000176 00 FLAT WASHER Ø8 2 14 1120 340003 00 CONTROL KNOB L 1 15 1120 343000 00 B REVERSING SWITCH ASSEMBLY 1 16 0000 000004 00 SCREW M5 12 2 17 0000 000035 00 SCREW M5 20 4 18 1120 340002 00 COVER...

Page 74: ...12 8 BL D40 0515 01 27 2019 Figure 12 4 Control Head Used from Serial Number 327120793 DK_0033 ...

Page 75: ...15 340004 00 CONTROL KNOB L 1 7 1220 520008 0C ACCELERATOR ASSEMBLY 1 8 0000 000323 00 SCREW M5 16 1 9 0000 000390 00 FLATWASHER Ø5 1 10 1115 340007 00 WIRE HARNESS COVER 1 11 1120 520009 00 REVERSING SWITCH WIRE 1 12 0000 000989 00 SCREW M2 12 2 13 1115 340003 00 COVER 1 14 1121 310004 00 SPRING 2 15 1115 340002 00 COVER 1 16 0000 000322 00 SCREW M8 25 4 17 0000 000159 00 LOCKWASHER Ø8 4 18 0000 ...

Page 76: ...12 10 BL D40 0515 01 27 2019 Figure 12 5 Cap Assembly DK_0003 ...

Page 77: ...CKET R 1 6 1120 342105 00 PIN 6 7 1120 342104 00 BUTTON FOR LIFTING L 1 8 1120 342103 00 BUTTON FOR LOWERING L 1 9 1120 342101 00 BUTTON BRACKET L 1 10 1120 342300 00 HORN BUTTON ASSEMBLY 1 11 0000 000039 00 SCREW ST3 5 9 5 6 12 0000 000490 00 HARNESS CLAMP 3 13 1120 342200 00 LIFT AND LOWER BOX R ASSEMBLY 1 14 1120 342100 00 LIFT AND LOWER BOX L ASSEMBLY 1 15 1220 520006 0C BUTTONS ASSEMBLY 1 16 ...

Page 78: ...12 12 BL D40 0515 01 27 2019 Figure 12 5 Control Head Freezer DK_0027 ...

Page 79: ...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 LOCK WASHER Ø3 2 19 2333 340018 00 BRACKET 1 20 2333 340019 00 SCREW M3 10 1 21 2333 340020 0...

Page 80: ...12 14 BL D40 0515 01 27 2019 Figure 12 6 Emergency Reverse Switch Assembly Used up to Serial Number 327120792 DK_0005 ...

Page 81: ...al Number 327120792 Pos Part Number Description Qty Reqd Notes 1 1120 343002 00 EMERGENCY REVERSE BUTTON 1 2 1120 343003 00 SPRING 2 3 1120 342005 00 PIN 2 4 1120 343001 0A BRACKET 1 5 1120 343004 00 PIN 1 6 1220 520005 0C WIRE HARNESS REVERSING SWITCH 1 7 1220 560002 00 SWITCH 1 ...

Page 82: ...12 16 BL D40 0515 01 27 2019 Figure 12 7 Transmission Motor Brake Mounting DK_0006 ...

Page 83: ... M10 5 10 1120 230000 00 BEARING 1 11 0000 000013 00 GREASE FITTING M8 1 12 4230 210000 10 TRANSMISSION ASSEMBLY 1 Used up to Serial E2219364 12a 1120 240000 30 TRANSMISSION ASSEMBLY 1 Used between Serial E2219365 327120197 12b ZK12 240000 00 TRANSMISSION ASSEMBLY 1 Used from Serial 327120198 13 1120 200001 00 DRIVE WHEEL ASSEMBLY 1 Poly Standard 13a 506161 10 DRIVE WHEEL ASSEMBLY 1 Non Marking Ru...

Page 84: ...12 18 BL D40 0515 01 27 2019 Figure 12 8 Transmission Transmission Used up to Serial E2219364 DK_0007 ...

Page 85: ...000 000961 00 BEARING 2 9 1120 240005 30 PLUG 1 10 1120 GB30 10 SPIRAL BEVEL GEAR KIT 1 Includes 2 gears 11 1120 240007 30 WASHER 1 12 1120 240008 30 LOCKING PLATE 1 13 0000 000277 00 BOLT M8 X 25 3 14 0000 001054 00 BEARING 2 15 4230 GB10 00 GEAR KIT 1 Includes 2 gears 16 0000 000379 00 FLAT WASHER M14 1 17 0000 001055 00 WASHER M14 1 18 0000 001056 00 NUT M14 X 1 5 1 19 0000 000211 00 O RING 150...

Page 86: ...12 20 BL D40 0515 01 27 2019 Figure 12 9 Transmission Used between Serial E2219365 327120197 DK_0024 ...

Page 87: ...quired 8 0000 000961 00 BEARING 2 9 1120 240005 30 PLUG 1 10 1120 GB30 10 SPIRAL BEVEL GEAR KIT 1 Includes 2 gears 11 1120 240007 30 WASHER 1 12 1120 240008 30 LOCKING PLATE 1 13 0000 000277 00 BOLT M8 25 3 14 0000 001054 00 BEARING 2 15 1120 GB30 00 GEAR KIT 1 Includes 2 gears 16 0000 000379 00 FLAT WASHER Ø14 1 17 0000 001055 00 WASHER Ø14 1 18 0000 001056 00 NUT M14 1 5 1 19 0000 000211 00 O RI...

Page 88: ...12 22 BL D40 0515 01 27 2019 Figure 12 10 Transmission Used from serial number 327120198 DK_0034 ...

Page 89: ...E SLEEVE 1 8 0000 000961 00 BEARING 2 9 ZK12 240017 00 PLUG 1 10 ZK12 GB30 10 SPIRAL BEVEL GEAR SET 1 Includes 2 gears 11 ZK12 240015 00 WASHER 65x36 5x3 1 12 ZK12 240021 00 WASHER Ø36 1 13 3030 110000 06 NUT M36 3 14 0000 001054 00 BEARING 2 15 ZK12 GB30 00 GEAR 1 Includes 2 gears 16 0000 000379 00 FLATWASHER Ø14 1 17 ZK12 240020 00 WASHER Ø14 1 18 3030 070000 04 NUT M14 1 19 0000 000211 00 O RIN...

Page 90: ...12 24 BL D40 0515 01 27 2019 Figure 12 11 Compartment Covers Used up to serial number 324180206 DK_0008 ...

Page 91: ...ial E2316807 1a 1118 100001 10 01 COVER 1 Black Used between Serial E2316808 324180206 2 1118 100002 00 UPPER COVER 1 Big Joe Yellow 3 1118 100003 00 LOWER COVER 1 Big Joe Yellow 4 0000 000649 00 SCREW M8 X 20 6 5 2214 150002 00 WASHER 6 6 1118 100005 00 CHARGER CAP 1 7 0000 000126 00 SCREW M6 X 16 2 8 0000 000119 00 SCREW M5 X 12 2 9 1118 100004 00 01 MIDDLE COVER 1 Black ...

Page 92: ...12 26 BL D40 0515 01 27 2019 Figure 12 12 Compartment Covers Used from serial number 324180207 DK_0028 ...

Page 93: ... 2a 1118 100002 1A UPPER COVER 1 Used from serial number 324190036 Big Joe Yellow 3 1118 100003 10 LOWER COVER 1 Used between serial number 324180207 324190035 Big Joe Yellow 3a 1118 100003 1A LOWER COVER 1 Used from serial number 324190036 Big Joe Yellow 4 0000 000649 00 SCREW M8 X 20 6 5 2214 150002 00 WASHER 6 6 1118 100005 00 CHARGER CAP 1 7 0000 000126 00 SCREW M6 X 16 2 8 0000 000119 00 SCRE...

Page 94: ...12 28 BL D40 0515 01 27 2019 Figure 12 13 Load Backrest DK_0009 ...

Page 95: ...M12 20 4 3 0000 000060 00 LOCK WASHER 4 4 0000 000373 00 FLAT WASHER 4 5 1118 682000 00 BASKET 1 Basket Only 6 1115 681000 K0 BRACKET 1 7 0000 000740 00 NUT 2 8 0000 000321 00 SCREW 2 9 0000 000159 00 LOCK WASHER Ø8 6 10 0000 000700 00 SCREW M8 X 16 4 11 0000 000030 00 SCREW 1 12 901803 LOAD RESTRAINT KIT 1 Includes Items 11 12 13 14 15 13 Included in Item 12 14 0000 000070 00 SCREW 1 15 0000 0000...

Page 96: ...12 30 BL D40 0515 01 27 2019 Figure 12 14 Frame DK_0010 ...

Page 97: ...2410520 324180206 Fork Length 48 Fork Width 21 4e 1118 110000 C0 02 FORK FRAME 1 Used from 324180207 Fork Length 48 Fork Width 21 4f 1118 110000 40 01 FORK FRAME 1 Used up to E2410519 Fork Length 36 Fork Width 27 4g 1118 110000 4A 01 FORK FRAME 1 Used between E2410520 324180206 Fork Length 36 Fork Width 27 4h 1118 110000 E0 01 FORK FRAME 1 Used from 324180207 Fork Length 36 Fork Width 27 4i 1118 1...

Page 98: ...12 32 BL D40 0515 01 27 2019 Figure 12 15 Frame continued DK_0010 ...

Page 99: ...120000 A0 00 BACK FRAME 1 Used from serial number 324180207 15 1220 132000 0A SHAFT 2 Used up to 07 03 2013 15a 1118 133000 00 SHAFT 2 Used from 07 04 2013 16 0000 000013 00 GREASE FITTING M8 2 17 1118 100006 00 ANTI COLLISION BLOCK L 1 18 1118 100007 00 ANTI COLLISION BLOCK R 1 19 1118 140000 00 CASTER ASSEMBLY 2 20 0000 000151 00 SCREW M8 25 6 21 0000 000159 00 LOCK WASHER Ø8 6 22 0000 000176 00...

Page 100: ...12 34 BL D40 0515 01 27 2019 Figure 12 16 Lift Link Assembly DK_0011 ...

Page 101: ...ork length 36 6a 1118 132000 20 LONG LINK 2 Fork length 48 7 0000 000907 00 BUSHING 4 8 1115 130005 0B WHEEL BRACKET 2 Used up to Serial E2219364 8a 1115 130005 4A WHEEL BRACKET 2 Used from Serial E2219365 9 0000 000908 00 BUSHING 4 10 1115 130003 00 LOAD WHEEL BRACKET PIVOT SHAFT 2 11 0000 000708 00 PIN M5 X 35 8 12 1115 130007 40 LOAD WHEEL SHAFT 2 13 1115 133000 40 LOAD WHEEL 2 14 0000 000435 0...

Page 102: ...12 36 BL D40 0515 01 27 2019 Figure 12 17 Load Wheel DK_0012 ...

Page 103: ...BL D40 0515 01 27 2019 12 37 LOAD WHEEL Pos Part Number Description Qty Reqd Notes 1115 133000 40 LOAD WHEEL ASSEMBLY 2 Including bearings 1 0000 000020 00 BEARING 2 2 1115 133002 40 LOAD WHEEL 1 ...

Page 104: ...12 38 BL D40 0515 01 27 2019 Figure 12 18 Caster DK_0013 ...

Page 105: ...2000 00 WHEEL BRACKET 1 9 0000 000495 00 BOLT M12 X 85 1 10 1120 143001 00 SHAFT 1 11 0000 000020 00 BEARING 6204 2 12 1120 143003 00 PU WHEEL 1 13 0000 000426 00 NUT M10 1 14 1120 140004 00 SPRING 1 15 0000 000987 00 SNAP RING 1 16 0000 000165 00 NUT M12 1 Used up to 02 25 2014 16a 0000 000057 00 NUT M12 1 Used from 02 26 2014 17 0000 000063 00 LOCK WASHER M10 1 18 0000 000007 00 FLAT WASHER M10 ...

Page 106: ...12 40 BL D40 0515 01 27 2019 Figure 12 19 Hydraulic System DK_0014 ...

Page 107: ...HOSE ASSY 1 Used up to Serial E2316807 3a 1118 430000 10 HOSE ASSY 1 Used from Serial E2316808 to E2410519 3b 1118 430000 0A HOSE ASSY 1 Used from Serial E2410520 4 1118 420000 00 PUMP MOTOR ASSY 1 5 0000 000321 00 SCREW M8 X 20 2 6 0000 000159 00 LOCK WASHER M8 2 7 0000 000176 00 FLAT WASHER M8 2 8 1118 410000 00 CYLINDER 1 9 0000 000293 00 RETAINING RING M20 2 10 1118 400001 00 SHAFT 1 11 0000 0...

Page 108: ...12 42 BL D40 0515 01 27 2019 Figure 12 20 Pump Motor Assy DK_0015 ...

Page 109: ...TY VALVE 1 9 1115 560005 00 THROTTLE 1 10 1115 560025 00 O RING 16 36 X 2 21 1 11 1115 560026 00 SCREW 1 12 1115 560016 00 CHECK VALVE 1 13 1115 560017 00 SOLENOID VALVE 1 14 1118 420014 00 RETURN PIPE 1 15 1115 560010 00 CONNECTING SHAFT 1 16 1115 560011 00 GEAR PUMP 1 17 1115 560012 00 WASHER M5 2 18 1115 560013 00 SCREW M5 X 70 2 19 1115 560015 00 OIL FILTER 1 20 1118 420020 00 SUCTION PIPE 1 2...

Page 110: ...12 44 BL D40 0515 01 27 2019 DK_0016 ...

Page 111: ...00 00 LIFT CYLINDER 1 1118 QSY 0A SEAL KIT 1 Includes Items 2 3 7 1 1118 410001 00 PISTON ROD 1 2 0000 000672 00 WIPER RING M40 X 50 X 5 6 5 1 3 0000 000673 00 O RING M45 X 3 1 1 4 1115 410002 0B GLAND NUT 1 5 1118 411000 00 CYLINDER BODY 1 6 1115 410003 0B GUIDE RING 1 7 0000 000512 00 VX SEAL 1 8 1115 410004 00 BUSHING 1 ...

Page 112: ...12 46 BL D40 0515 01 27 2019 Figure 12 22 Electrical System DK_0017 ...

Page 113: ... 5 11 0000 000390 00 FLAT WASHER M5 5 12 0000 001103 00 R HARNESS CLAMP UC 1 5 2 13 0000 001086 00 R HARNESS CLAMP UC 5 2 14 2112 410005 00 RUBBER CUSHION 2 Used up to 10 27 2013 14a 1115 100005 00 RUBBER CUSHION 2 Used from 10 28 2013 15 1118 500002 00 BRACKET 1 16 0000 000004 00 SCREW M5 X 12 2 17 1120 500006 00 LIFTING LIMIT SWITCH 1 18 1118 520007 10 WIRE HARNESS OF LIMIT SWITCH 1 19 0000 0010...

Page 114: ...12 48 BL D40 0515 01 27 2019 Figure 12 23 Drive Motor Assembly DK_0018 ...

Page 115: ... RING M20 2 2 0000 000226 00 KEY 1 3 1120 220001 00 TERMINAL BLOCK 1 4 0000 000206 00 LOCK WASHER M5 17 5 0000 000117 00 SCREW M5 X 10 2 6 0000 000166 00 NUT M6 6 7 0000 000056 00 LOCK WASHER M6 6 8 1120 220002 00 BEARING 1 9 0000 000204 00 KEY 1 10 0000 000409 00 O RING M63 X 3 55 1 11 0000 000436 00 NUT M12 X 1 5 1 12 0000 000323 00 SCREW M5 X 16 14 ...

Page 116: ...12 50 BL D40 0515 01 27 2019 Figure 12 24 Electrical Components Sheet 1 DK_0019 ...

Page 117: ... PLATE 1 Used up to Serial E2316807 7a 1118 510005 0A UPPER MOUNTING PLATE 1 Used from Serial E2316808 8 0000 000077 00 SCREW M6 X 12 2 9 0000 000056 00 LOCK WASHER M6 2 10 0000 000380 00 FLAT WASHER M6 2 11 1120 540001 00 B FUSE STAND 1 12 1120 540002 00 FUSE 200A 1 13 0000 000074 00 SCREW M6 X 20 2 14 0000 000550 00 NUT M8 2 15 0000 000210 00 FLAT WASHER M8 2 16 0000 000004 00 SCREW M5 X 12 7 17...

Page 118: ...12 52 BL D40 0515 01 27 2019 Figure 12 24Electrical Components Sheet 1 Continued DK_0019 ...

Page 119: ...0000 000031 00 SCREW M5 X 8 1 24 0000 000390 00 FLAT WASHER M5 4 25 0000 000546 00 NUT M5 3 26 1118 510005 10 PLATE II 1 Only used from Serial E2316808 to E2410289 27 0000 000035 00 SCREW M5 20 2 Only used from Serial E2316808 to E2410289 27a 0000 000004 00 SCREW M5 12 2 Used from Serial E2410290 28 1220 150005 00 NUT M8 2 Used from Serial E2316808 29 1115 510008 10 SWITCH BUTTON 1 ...

Page 120: ...12 54 BL D40 0515 01 27 2019 Figure 12 25 Electrical Components Sheet 2 DK_0020 ...

Page 121: ...00 000390 00 FLAT WASHER M5 6 8 1118 520006 10 RELAY WIRE HARNESS 1 See note for pos 1 4 9 1118 510004 00 TIE PLATE 1 10 0000 000004 00 SCREW M5 X 12 2 11 1118 510003 00 PLATE 1 12 1115 520015 00 BUZZER ASSEMBLY 1 13 0000 000037 00 SCREW M3 X 12 2 14 0000 000139 00 NUT M4 2 15 1115 520007 00 FAN ASSEMBLY 1 16 1115 500007 00 FAN GUARD 1 17 0000 000121 00 SCREW M4 X 35 4 18 0000 000122 00 LOCK WASHE...

Page 122: ...12 56 BL D40 0515 01 27 2019 Figure 12 25 Electrical Components Sheet 2 Continued DK_0020 ...

Page 123: ...er 26 0000 000498 00 SCREW M6 X 30 2 Used from serial number 324170265 27 1118 540002 70 PLATE 1 Used from serial number 324170265 28 1115 510006 00 BDI BATTERY INDICATOR 1 Without Hourmeter Set the BDI dial to the follow ing M Industrial Battery Q Maint Free Battery 28a 1115 510006 20 BDI BATTERY INDICATOR 1 With Hourmeter Set the BDI dial to the following M Industrial Battery Q Maint Free Batter...

Page 124: ...12 58 BL D40 0515 01 27 2019 Figure 12 25 Electrical Components Freezer DK_0030 ...

Page 125: ...r Description Qty Reqd Notes 1 1220 520014 X0 HEATER BAND VALVE 1 2 1120 520004 X0 HEATER BAND BRAKE 1 3 1221 500002 X0 CLAMP 1 4 2108 520003 LK TEMPERATURE DETECT SWITCH 1 5 0000 000009 00 SCREW M4 12 2 6 0000 000122 00 LOCK WASHER Ø4 2 7 0000 000702 00 FLAT WASHER Ø4 2 ...

Page 126: ...12 60 BL D40 0515 01 27 2019 Figure 12 26 Wiring Harness DK_0021 ...

Page 127: ...scription Qty Reqd Notes 1 1118 520001 00 MASTER WIRE HARNESS 1 2 1120 500010 00 FUSE 10A 1 3 1118 520002 00 SWITCHING WIRE HARNESS 1 4 1118 520004 00 WIRE HARNESS OF PUMP 1 5 1118 520008 10 SHORT CIRCUIT SWITCH 1 Only used up to serial num ber 324170264 Optional ...

Page 128: ...12 62 BL D40 0515 01 27 2019 Figure 12 27 Wiring Harness Freezer DK_0031 ...

Page 129: ...9 12 63 WIRING HARNESS FREEZER Pos Part Number Description Qty Reqd Notes 1 1118 520001 X0 MASTER WIRE HARNESS 1 2 1120 500010 00 FUSE 10A 1 3 1118 520002 X0 SWITCHING WIRE HARNESS 1 4 1118 520004 X0 WIRE HARNESS OF PUMP 1 ...

Page 130: ...12 64 BL D40 0515 01 27 2019 Figure 12 28 Wiring Cables DK_0022 ...

Page 131: ... 531002 00 CABLE BATTERY 1 3 1118 531001 00 CABLE BATTERY 1 4 1118 531004 00 F CABLE 1 5 1118 531006 00 M CABLE 1 6 1118 531008 00 B CABLE 1 7 1118 531007 00 PUMP POWER CABLE 1 8 1118 531005 00 PUMP POWER CABLE 1 9 1118 532001 00 DRIVING MOTOR CABLE U 1 10 1118 532002 00 DRIVING MOTOR CABLE V 1 11 1118 532003 00 DRIVING MOTOR CABLE W 1 ...

Page 132: ...Big Lift LLC ...

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