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

Big Lift LLC MANUAL NO. BL-D40-0515 - 08-24-2020

www.bigjoeforklifts.com
 WARNING

Do not operate this truck unless you have been autho- care when traveling without load as the risk of overturn
rized and trained to do so, and have read all warnings may be greater.
and instructions in Operator’s Manual and on this
Always look in direction of travel. Keep a clear view,
truck.
and when load interferes with visibility, travel with load
Do not operate this truck until you have checked its trailing.
condition. Give special attention to wheels, horn, bat-
Use special care when operating on ramps travel
tery, controller, lift system, brakes, steering mecha-
slowly, and do not angle or turn. Travel with load
nism, guards and safety devices.
downhill.
Operate truck only from designated operating position.
Do not handle loads which are higher than the chassis
Do not carry passengers. Keep feet clear of truck and
unless load is secured so that no part of it could fall
wear foot protection.
backward. Before lifting, be sure load is centered,
Observe applicable traffic regulations. Yield right of forks are completely under the chassis 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
Start, stop, travel, steer and brake smoothly. Slow truck unattended, also shut off power.
down for turns and on uneven or slippery surfaces that
could cause truck to slide or overturn. Use special
 TABLE OF CONTENTS

Section Page Section Page

1 LIST OF ILLUSTRATIONS..........................................1-II 5-2. COMPARTMENT COVERS......................... 5-6
5-2.1. REMOVAL.................................................... 5-6
1 LIST OF TABLES ........................................................1-II 5-2.2. INSTALLATION............................................ 5-6
1 5-3. STEERING ARM.......................................... 5-7
DESCRIPTION1-1 5-3.1. RETURN SPRING REPLACEMENT. .......... 5-7
1-1. INTRODUCTION. .........................................1-1 5-3.2. STEERING ARM REMOVAL. ...................... 5-7
1-2. GENERAL DESCRIPTION. ..........................1-1 5-3.3. STEERING ARM INSTALLATION. .............. 5-7
1-3. SAFETY FEATURES....................................1-2 6
2 BRAKE SERVICING6-1
OPERATION2-1 6-1. BRAKES....................................................... 6-1
2-1. GENERAL.....................................................2-1 6-1.1. AIR GAP ADJUSTMENT. ............................ 6-1
2-2. OPERATING PRECAUTIONS......................2-1 6-1.2. STOPPING DISTANCE ADJUSTMENT. ..... 6-2
2-3. BEFORE OPERATION.................................2-1 6-1.3. BRAKE ASSEMBLY REPLACEMENT......... 6-2
2-4. GENERAL CONTROL OPERATION............2-4 7
2-5. DRIVE AND STOPPING PROCEDURES. ...2-4 TRANSMISSION, DRIVE AND LOAD WHEEL ................ 7-1
2-6. BELLY-BUTTON SWITCH. ..........................2-4 7-1. LOAD WHEEL.............................................. 7-2
2-7. STEERING ARM GAS SPRING. ..................2-5 7-1.1. REMOVAL.................................................... 7-2
2-8. LIFT AND LOWER CONTROLS...................2-5 7-1.2. REPAIR....................................................... 7-2
2-9. BACKREST. .................................................2-5 7-1.3. LOAD WHEEL INSTALLATION ................... 7-2
2-10. GUIDE RAILS. ..............................................2-5 7-2. DRIVE WHEEL. ........................................... 7-3
2-11. LOADING AND UNLOADING.......................2-5 7-3. TRANSMISSION.......................................... 7-3
2-12. PARKING......................................................2-5
8
3 ELEVATION SYSTEM SERVICING8-1
PLANNED MAINTENANCE3-1 8-1. GENERAL .................................................... 8-1
3-1. GENERAL.....................................................3-1 8-2. LIFT LINKAGE ............................................. 8-1
3-2. MONTHLY AND QUARTERLY CHECKS.....3-1 8-2.1. REMOVAL.................................................... 8-1
3-3. BATTERY CARE. ........................................3-1 8-2.2. REPAIR........................................................ 8-2
3-3.1. GENERAL.....................................................3-1 8-2.3. INSTALLATION............................................ 8-2
3-3.2. SAFETY RULES...........................................3-2
3-3.3. BATTERY CARE AND CHARGING .............3-2 9
3-3.4. BATTERY CLEANING..................................3-2 HYDRAULIC SYSTEM SERVICING9-1
3-3.5. MAINTENANCE FREE BATTERIES ............3-2 9-1. LINES AND FITTINGS................................. 9-1
3-4. CHARGING BATTERIES .............................3-3 9-2. HYDR. AND ELECTR. ASSY. REMOVAL ... 9-2
3-5. BATTERIES REPLACEMENT......................3-4 9-2.1. REMOVAL.................................................... 9-2
3-6. LUBRICATION..............................................3-5 9-2.2. INSTALLATION............................................ 9-2
9-3. HYDR. PUMP, MOTOR, AND
4 RESERVOIR ASSY ..................................... 9-2
TROUBLESHOOTING4-1 9-3.1. REMOVAL.................................................... 9-2
4-1. GENERAL.....................................................4-1 9-3.2. DISASSEMBLY AND REASSEMBLY.......... 9-2
4-2. CONTROLLER TROUBLESHOOTING ........4-4 9-3.3. INSTALLATION............................................ 9-4
4-2.1. ZAPI HANDSET............................................4-4 9-3.4. LIFT CYLINDER........................................... 9-4
4-2.2. FAULT DETECTION.....................................4-4
4-2.3. TESTING TRUCK OPERATION...................4-4 10
4-2.4. SETTINGS AND ADJUSTMENTS................4-5 ELECTRICAL COMPONENTS....................................... 10-1
10-1. ELECTRICAL CONTROL PANEL.............. 10-1
5 10-1.1. MAINTENANCE ......................................... 10-1
STEERING ARM, CONTROL HEAD AND COMPART.....5-1 10-1.2. CLEANING................................................. 10-1
5-1. CONTROL HEAD .........................................5-1 10-1.3. CONTROLLER REMOVAL. ....................... 10-1
5-1.1. CONTROL HEAD REMOVAL.......................5-1 10-1.4. CONTROLLER INSTALLATION. ............... 10-1
5-1.2. CONTROL HEAD INSTALLATION...............5-3 10-1.5. CHARGER REMOVAL............................... 10-1
5-1.3. CAP ASSEMBLY REMOVAL. ......................5-3 10-1.6. CHARGER INSTALLATION....................... 10-1
5-1.4. CAP ASSEMBLY INSTALLATION. ..............5-3 10-1.7. EMERG. DISCONNECT REMOVAL.......... 10-2
5-1.5. SPEED POTENT. REPLACEMENT. ...........5-3 10-1.8. EMERG. DISCONNECT INSTALLATION.. 10-2
5-1.6. BELLY-BUTTON SWITCH REPLACE..........5-3 10-1.9. CONTACTOR REMOVAL.......................... 10-2
5-1.7. HORN SWITCH REPLACEMENT. ...............5-4 10-1.10. CONTACTOR INSTALLATION.................. 10-2
5-1.8. LIFT / LOWER SWITCH REPLACEMENT ...5-5 10-1.11. FUSE REMOVAL. ...................................... 10-2

BL-D40-0515 - 08-24-2020 i
 TABLE OF CONTENTS - Continued

10-1.12. FUSE INSTALLATION. .............................. 10-2 10-2. PUMP MOTOR........................................... 10-7

10-1.13. COOLING FAN REMOVAL........................ 10-4 10-3. DRIVE MOTOR. ......................................... 10-7
10-1.14. COOLING FAN INSTALLATION................ 10-4 10-4. DEADMAN SWITCH .................................. 10-7
10-1.15. BUZZER REMOVAL. ................................. 10-4 10-4.1. REPLACEMENT......................................... 10-7
10-1.16. BUZZER INSTALLATION. ......................... 10-4
10-1.17. KEY SWITCH REMOVAL. ......................... 10-4 11
10-1.18. KEY SWITCH INSTALLATION. ................. 10-4 OPTIONAL EQUIPMENT ............................................... 11-1
10-1.19. BATTERY INDICATOR REMOVAL. .......... 10-4 12
10-1.20. BATTERY INDICATOR INSTALLATION. .. 10-4 ILLUSTRATED PARTS BREAKDOWN .......................... 12-1
10-1.21. LIFT LIMIT SWITCH REMOVAL................ 10-6
10-1.22. LIFT LIMIT SWITCH INSTALLATION........ 10-6

ii BL-D40-0515 - 08-24-2020
 SECTION 1
DESCRIPTION

1-1. INTRODUCTION. forks raised or lowered. The lift truck must be pro-
This publication describes the 24 volt D40 lift truck dis- tected from the elements.
tributed by Big Lift LLC. Included are operating instruc- The model number will be found on the name plate
tions, planned maintenance instructions, lubrication (Figure 1-1) along with the serial number, lifting capac-
procedures, corrective maintenance procedures and a ity, and load center. Figure 1-2 shows the locations of
complete parts list with part location illustrations. the truck’s main components and controls.
Users shall comply with all requirements indicated in
applicable OSHA standards and current edition of
A.N.S.I. B56.1 Part II. By following these requirements
and the recommendations contained in this manual,
you will receive many years of dependable service
from your D40 lift truck.

1-2. GENERAL DESCRIPTION.

The self-propelled 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 the lift truck in for-
ward or reverse direction throughout the available
R6209
speed range. The D40 lift truck can be driven with
Figure 1-1 Name Plate

D40-9

Figure 1-2 . D40 Lift Truck

BL-D40-0515 - 08-24-2020 1-1

1-3. SAFETY FEATURES. • Readily accessible horn button.
The D40 is designed and engineered to provide maxi- • Handle to provide a firm hand hold for operator.
mum safety for operator and payload. Some of the
• Flow control valve regulates maximum lowering
safety features incorporated into the design are:
speed within prescribed limits.
• Dead-man brake to apply the brake and cut off drive
• Relief valve maintains hydraulic pressure within pre-
power when the steering arm is released.
scribed limits.
• Belly-button switch to reverse truck should the oper-
• High visibility color scheme of truck provides visual
ator accidentally pin himself against a wall or
alert of truck’s presence.
obstruction when backing up in slow speed.
• Battery Indicator.
• All control functions automatically return to “OFF”
when released. • Adjustable load backrest.
• Emergency Disconnect within operator's reach.

1-2 BL-D40-0515 - 08-24-2020

 SECTION 2
OPERATION

2-1. GENERAL. • Always look in direction of travel. Keep a clear view,

This section gives detailed operating instructions for and when load interferes with visibility, travel with
the D40 lift truck. The instructions are divided into the load or lifting mechanism trailing.
various phases of operations, such as operating lift, • Do not overload truck. Check nameplate for load
driving, and stopping. Routine precautions are weight and load center information.
included for safe operation.
• Before lifting, be sure load is centered, forks are
completely under load, and load is as far back as
2-2. OPERATING PRECAUTIONS.
possible against the chassis.
WARNING: Improper operation of the lift truck may • Do not handle loads which are higher than the chas-
result in operator injury, or load and/or lift sis unless load is secured so that no part of it could
truck damage. Observe the following fall backward.
precautions when operating the D40 lift
truck. • When leaving truck, neutralize travel control. Fully
lower lifting mechanism and set brake. When leaving
The following safety precautions must be adhered to truck unattended, turn off key switch and disconnect
at all times. switch, and remove key.
• Do not operate this truck unless you have been • The lift truck must be protected from the elements.
trained and authorized to do so and have read all
warnings and instructions in this manual and on the 2-3. BEFORE OPERATION
truck. Table 2-1 covers important inspection points on the
• All warnings and instructions must be read and D40 lift truck which should be checked prior to opera-
understood before using the equipment. tion. Depending on use, some trucks may require
additional checks.
• Equipment must be inspected by a qualified person
on a regular basis. Figure 2-1 shows a sample format for an Operator
Checklist, which can be modified as necessary to fit
• Do not operate this truck until you have checked its
your operation.
condition. Give special attention to Wheels, Horn,
Batteries, Controller, Lift System, Brakes, Steering WARNING: Periodic maintenance of this truck by a
Mechanism, Guards and Safety Devices QUALIFIED TECHNICIAN is required.
• Operate truck only from designated operating posi-
CAUTION: A QUALIFIED SERVICE TECHNICIAN
tion. Do not carry passengers. Keep feet clear of
should check the truck monthly for
truck and wear foot protection.
proper lubrication, proper fluid levels,
• Observe applicable traffic regulations. Yield right of brake operation, motor maintenance and
way to pedestrians. Slow down and sound horn at other areas specified in the SECTION 3.
cross aisles and wherever vision is obstructed.
WARNING: If the truck is found to be unsafe and in
• Start, stop, travel, steer and brake smoothly. Slow need of repair, or contributes to an
down for turns and on uneven or slippery surfaces unsafe condition, report it immediately to
that could cause truck to slide or overturn. Use spe- the designated authority. Do not operate
cial care when traveling without load as the risk of it until it has been restored to a safe
overturn may be greater. operating condition. Do not make any
unauthorized repairs or adjustments. All
service must be performed by a qualified
maintenance technician.

BL-D40-0515 - 08-24-2020 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 Brake Check that brake actuates 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-D40-0515 - 08-24-2020

 R6479

Figure 2-1 Sample of Operator Check List

BL-D40-0515 - 08-24-2020 2-3

2-4. GENERAL CONTROL OPERATION.
The speed control (See Figure 2-2) 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.

D40-10

Figure 2-4 Brake Actuation

2-5. DRIVING AND STOPPING PROCEDURES.

R6617 1. Turn on the emergency disconnect and the key
switch. Grasp the grips of the steering head so
Figure 2-2 Forward/Reverse Control that the speed control can be comfortably oper-
ated by either thumb.
The pushbutton switches (See Figure 2-3), located on
the front of the control head activate the lift-lower con- 2. Lower the steering arm to a comfortable position
trols and the horn. 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 control forward. See Figure 2-2. Press
the forward speed control farther to increase
speed.
4. To slow down or stop, release the speed control
and lower or raise the steering arm to the horizon-
tal or vertical position. See Figure 2-4. In those
positions, the brake engages, slowing or stopping
the truck.
5. Procedures for movement in reverse are the
same as in the forward direction except slowly
press the speed control backward. See Figure 2-
R6618
2.
Figure 2-3 Pushbutton Switches
2-6. BELLY-BUTTON SWITCH.
The brake is fully applied by lowering or raising the
steering arm. (See Figure 2-4) All traction control The belly-button switch (Figure 2-5) minimizes the
power is shut off when the brake is engaged. When possibility of the driver being pinned by the steering
the steering arm is in the upright position, the brake arm while driving the lift truck in slow speed. If the
acts as a parking brake. Deadman braking occurs switch presses against the operator while the lift truck
when the handle is released and spring action raises is being driven toward the operator, the switch
steering arm to the upright position. changes the direction of the lift truck.

2-4 BL-D40-0515 - 08-24-2020

 To lift forks, push in either LIFT button and hold until
forks reach desired height. To lower forks, push in
either LOWER button and hold 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.
R6619 3. Raise forks to lift load.
4. Drive to area where load is to be placed.
Figure 2-5 Belly-Button Switch
5. Move truck to align load with its new position.
2-7. STEERING ARM GAS SPRING. 6. Lower the load until it rests squarely in place and
the forks are free.
The steering arm gas spring automatically raises the
steering arm to the upright position when the steering 7. Slowly move the truck out from under the load.
arm is released. If the steering arm does not return
fully, the steering arm gas spring requires replace- 2-11.PARKING.
ment. Return truck to maintenance for repair. When finished with moving loads, return the truck to its
maintenance or storage area. Turn off the emergency
2-8. LIFT AND LOWER CONTROLS. Disconnect and the key switch. Charge batteries as
Lift/Lower Control buttons are located on the steering necessary. Refer to battery care instructions, SEC-
control head. (Figure 2-3) TION 3.

BL-D40-0515 - 08-24-2020 2-5

 NOTES

2-6 BL-D40-0515 - 08-24-2020

 SECTION 3
PLANNED MAINTENANCE

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

Planned maintenance consists of periodic visual and explosive. Do not smoke, use an open
operational checks, parts inspection, lubrication, and flame, create an arc or sparks in the
scheduled maintenance designed to prevent or dis- vicinity of the battery. Ventilate an
cover malfunctions and defective parts. The operator enclosed area well when charging.
performs the checks in SECTION 2, and refers any CAUTION: Batteries 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 iis 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- handling 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 D40 may be equipped with maintenance free or A voltage check from battery connector terminal to
industrial wet cell batteries. 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 pull rods for proper adjustment.
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-D40-0515 - 08-24-2020 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. Battery terminals should be checked and cleaned
tion of electronic devices on the unit. of corrosion regularly. Good battery terminal con-
3-3.2. Safety Rules tact is essential not only for operation, but also for
proper charging of the battery.
• Wear protective clothing, such as rubber apron,
3. The charging requirements will vary depending on
gloves, boots and goggles when performing any
the use of the truck. The battery should be given
maintenance on batteries. Do not allow electrolyte to
as equalizing charge on a weekly basis. This
come in contact with eyes, skin, clothing or floor. If
charge should normally be an additional three
electrolyte comes in contact with eyes, flush immedi-
hours at the finish rate.
ately and thoroughly with clean water. Obtain medi-
cal attention immediately. Should electrolyte be 4. Make certain battery used meets weight and size
spilled on skin, rinse promptly with clean water and requirements of truck. NEVER operate truck with
wash with soap. A baking soda solution (one pound an undersized battery.
to one gallon of water) will neutralize acid spilled on
clothing, floor or any other surface. Apply solution 3-3.4. Battery Cleaning
until bubbling stops and rinse with clean water. Always keep vent plugs tightly in place when cleaning
battery. When properly watered and charged, the bat-
• If truck is equipped with wet cell batteries, keep vent
tery will remain clean and dry. All that is necessary is
plugs firmly in place at all times except when adding
to brush or blow off any dust or dirt that may accumu-
water or taking hydrometer readings. Do not allow
late on them. However, if electrolyte is spilled or over-
dirt, cleaning solution or other foreign material to
flows from a cell, it should be neutralized with a
enter cells. Impurities in electrolyte has a neutraliz-
solution of baking soda and water, brushing the soda
ing effect reducing available charge.
solution beneath the connectors and removing grime
• Do not bring any type of flame, spark, etc., near the from the covers. Then rinse the battery with cool water
battery. Gas formed while the battery is charging, is from a low pressure supply to remove the soda and
highly explosive. This gas remains in cell long after loosen dirt. If batteries stay wet consistently, they may
charging has stopped. be either overcharged or over filled. This condition
• Do not lay metallic or conductive objects on battery. should be investigated and corrected.
Arcing will result.
3-3.5. MAINTENANCE FREE BATTERIES
• Do not touch non-insulated parts of DC output con-
Some trucks may be equipped with optional mainte-
nector or battery terminals to avoid possible electri-
nance free batteries. These batteries are completely
cal shock.
sealed, will not require any watering and have a full
• De-energize all AC and DC power connections 80% discharge available.
before servicing battery.
Sealed Maintenance Free batteries contain a pressure
• Do not charge a frozen battery. release valve and under normal operating conditions
• Do not use charger if it has been dropped or other- do not require any special ventilation.
wise damaged. CAUTION: Do not try to open this battery or remove
3-3.3. Battery Care and Charging the pressure release valve.

CAUTION: Never smoke or bring open flame near Only under severe overcharging, such as connected
the battery. Gas formed during charging to an improperly sized charger, will any significant
is highly explosive and can cause seri- amount of gasses be released from the battery. Also,
ous injury. being a valve regulated battery, it never requires
watering.

3-2 BL-D40-0515 - 08-24-2020

3-4. CHARGING BATTERIES
Charging requirements will vary depending on depth of
discharge and temperature. Follow safety rules when
placing a battery on charge.
Proceed as follows:
1. Park truck at charging 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.
D40-24

Figure 3-1 Charging Battery

BL-D40-0515 - 08-24-2020 3-3

3-5. BATTERIES REPLACEMENT a. Remove the hose and harness (3, Figure 3-
3) and battery cable (2). Remove four screws
Access to the batteries requires moving the controller
(3) and take out the controller board (4).
board.
Proceed as follows:
1. Remove two screws (1, Figure 3-2) and remove
cover (2).

D40-26

D40-25 Figure 3-3 Controller Board Removal

b. Install in the reverse order of remove. Pay
Figure 3-2 Cover Removal
attention to battery position and cable con-
nection. Position cables to avoid damage.

3-4 BL-D40-0515 - 08-24-2020

3-6. 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 3-4 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

BL-D40-0515 - 08-24-2020 3-5

 D40-27

Figure 3-4 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.
* Raise lift carriage to gain access to grease fittings.

3-6 BL-D40-0515 - 08-24-2020

 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 a. Fuse (12, Figure 12-21) blown. Check fuse and replace if
SYSTEM WILL NOT OPER- necessary.
ATE b. Battery dead or disconnected. Check battery connections and
Truck will not travel nor will lift sys- check battery voltage.
tem operate.
c. Keyswitch (20, Figure 12-22) Bypass keyswitch to determine if it
defective. is malfunctioning.
d. Defective wiring. Check for open circuit. Repair as
required.
TRUCK DOES NOT OPERATE a. Check all wiring. A loose con- Tighten all loose connections
FORWARD OR REVERSE nection may be the cause of before further troubleshooting.
Truck does not travel forward or malfunction.
reverse. All other functions b. Defective deadman switch (16, Check and replace switch if
operate normally. Figure 12-1). defective.
c. Defective controller (18, Figure Check for proper operation and
12-21). replace if necessary.
d. Defective potentiometer (21, Check and replace potentiometer
Figure 12-2). if defective.
Truck travels forward but not in Defective potentiometer (21, Fig- Check and replace potentiometer
reverse. ure 12-2) in control head. if defective.
Truck travels reverse but not in Defective potentiometer (21, Fig- Check and replace potentiometer
forward. ure 12-2) in control head. if defective.
Truck travels forward and in Defective potentiometer (21, Fig- Check and replace potentiometer
reverse at lower speeds; will ure 12-2) in control head. if defective.
not travel at high speed.
TROUBLE WITH BRAKING a. Defective deadman switch (16, Check deadman switch for
Truck does not slow with brake, or Figure 12-1). continuity. If none found when
brake does not engage. the control arm is in the brake
position, replace switch.
b. Defective electric brake (2, Fig- Replace brake.
ure 12-5).
Brake will not release. a. Brake temperature above Allow to cool.
281F (140 C).
b. Open brake circuitry or wiring. Make voltage checks.

BL-D40-0515 - 08-24-2020 4-1

 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH BRAKING -
Continued
Brake drags. Defective electric brake (2, Figure Replace.
12-5).
Brake grabs. Defective electric brake (2, Figure Replace.
12-5).
Abnormal noise and chatter when Defective electric brake (2, Figure Replace.
brake is applied. 12-5).
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 (4, Figure 12-
16) 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-D40-0515 - 08-24-2020

 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 (17,
Figure 12-16). Replace as
required.
Load will not hold a. Oil bypassing internally in con- Replace valve assembly (4, Fig-
trol valve ure 12-16).
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 capac-
ity.
c. Batteries need charging. Change batteries.
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 (7, Figure 12-
16).
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-D40-0515 - 08-24-2020 4-3

4-2. CONTROLLER TROUBLESHOOTING • The number of times that each alarm occurs consec-
utively
4-2.1. Zapi Handset
• The Hour Meter reading (value) when the latest
The Zapi Handset for use with the Zapi controller event of every alarm occurred
serves multiple functions of reading diagnostic data,
testing truck operation, setting options, adjustments • The invert temperature when the latest event of
and parameter changes of the controller. The Zapi every alarm occurred.
Handset is available through your Big Lift LLC dealer. This function permits a deeper diagnosis of problems
If you require dealer location information, contact Big as the recent history can be revisited.
Lift LLC.
4-2.2.2. Logbook Access
Remove the rubber plug from the CNC connector of
the controller and plug in the Zapi Handset connector To view the alarm logbook proceed as follows:
as shown in Figure 4-1. 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
button (1) to find the ALARMS display.
4. Press the ENTER button (3) to view the alarms.
5. Press the OUT button (6) to exit the alarms.

NOTE: Refer to bigjoesupport.com for the Zapi sup-

plement containing detailed information of
alarm codes. There are two versions shown.
The PDS uses the Standard version which
lists the error by: Alarm Name, Repetitions,
Temperature and Hour Meter reading.

4-2.3. Testing Truck Operation.

R6628
The Zapi Handset can be used to test certain truck
Figure 4-1 Zapi Controller operations as follows:

4-2.2. Fault Detection. 1. Connect the Zapi Handset, refer to paragraph 4-

2.1.
4-2.2.1. General 2. Press the ROLL down button (1, Figure 4-2) and
The controller provides diagnostics information to the ENTER button (3) at the same time to enter
assist technicians in troubleshooting problems. When the MAIN MENU.
a fault is detected, an alarm is recorded in the logbook. 3. Press the ROLL down button (2) or the ROLL up
It has a FIFO (First Input First Output) structure that button (1) to find the TESTER display.
means the oldest alarm is lost when the database is
4. Press the ENTER button (3) to view the tests.
full and a new alarm occurs. The logbook is composed
of alarms with the following information: 5. To verify various switch functions, locate the
switch on the display and then operate that func-
• The alarm code
tion to verify operation
6. Press the OUT button (6) to exit the tests.

4-4 BL-D40-0515 - 08-24-2020

4-2.4. Settings and Adjustments

4-2.4.1. Set Options

To set options proceed as follows and refer to Table 4-
2:
1. Connect the Zapi Handset, refer to paragraph
4-2.1.
2. Press the ROLL up button (1, Figure 4-2) and the
SET up button (5) at the same time to enter the
CONFIG MENU.
3. Press the ROLL down button (1) or the ROLL up
button (2) to find the SET OPTIONS display.
4. Press the ENTER button (3) to view the options.
5. Press the ROLL down (2) or the ROLL up button
(1) to find the option to be changed.
6. Press the SET up button (5) or the SET down but-
ton (6) until the desired value setting is reached.
The option is now set at the desired value.
7. Press the OUT button (4) to exit the options.

R6624

Figure 4-2 Zapi Handset

Table 4-2 Set Options
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 be can be set as:
• OPTION #1: CNA is managed as a cutback speed input (SR#1).
• OPTION #2: CNA is managed as a digital handbrake input.
• OPTION #3: CNA is managed as an inching backward.
The input CNA#15 (Table 4-5) can only be used as Aux Lowering
request when the MDIPRC is PRESENT.
This input must be connected to a Keyswitch controlled voltage.
The SR#1 becomes active when CNA#15 (Table 4-5) is open.
The inching backward becomes active when the CNA#15 (Table 4-
5) is closed to a Keyswitch controlled voltage.

BL-D40-0515 - 08-24-2020 4-5

 Table 4-2 Set Options - Continued
Parameter Factory Setting Description
SET INPUT #2 PRESENT It can be can be set as:
• PRESENT: CNA#14 (Table 4-5) is managed as a cutback speed
input (SR#2).
• OPTION #1: CNA#14 (Table 4-5) is managed as an inching back-
ward.
The input CNA#14 (Table 4-5) can only be used as Aux Lifting
request when the MDIPRC is PRESENT.
This input must be connected to a Keyswitch controlled voltage.
The SR#2 becomes active when CNA#14 (Table 4-5) is open.
The inching backward becomes active when the CNA#14 (Table 4-
5) is closed to a Keyswitch controlled voltage.
SET INPUT #4 OPTION #1 This option handles the digital input CNB#7 (Table 4-5). It can be
can be set as:
• BELLY CNB#7 (Table 4-5) is managed as a Belly Switch input.
• BRAKE CNB#7 (Table 4-5) is managed as service brake input.
This information can be used also to recognize when the operator
is driving with a pressed pedal braking.
• EX.HYDRO: CNB#7 (Table 4-5) is managed as Exclusive Hydro.
This input must be connected to a Keyswitch controlled voltage.
The Belly switch active level is specified on the QUICK INV LOGIC
below.
The service 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 battery charge level is ignored.
• Level 1: A BATTERY LOW alarm is raised when the battery level
is calculated being less than 10% of the full charge. A BATTERY
LOW alarm inhibits the Lifting function.
• Level 2: A BATTERY LOW alarm is raised when the battery level
is calculated being less than 10% of the full charge. A BATTERY
LOW alarm reduces the maximum truck speed down to 24% of
the full truck speed then, if the MDI-PRC is absent, inhibits the Lift-
ing function.
• Level 3 Equivalent to Level 1; a BATTERY LOW alarm is raised
when the battery level is calculated being less than 10% of the full
charge. A BATTERY LOW alarm inhibits the Lifting function.
HYDRO KEY ON OFF ON/OFF: If this options is programmed ON the traction Inverter
manages a hydraulic steering function when the keyswitch is
switched ON (only if the AUX OUTPUT #1 option is programmed
as HYDRO CONTACT or as WXCLUSIVE HYDRO).
STOP ON RAMP OFF Not used.

4-6 BL-D40-0515 - 08-24-2020

 Table 4-2 Set Options - Continued
Parameter Factory Setting Description
AUX OUTPUT #1 BRAKE This option handles output CNA#3 (Table 4-5). It can be used as:
• BRAKE: CNA#3 (Table 4-5) drives an electromechanical Brake.
• HYDROCOMNT: CNA#3 (Table 4-5) drives the contractor for a
hydraulic steering function when the direction input or brake pedal
input are active or a movement of the truck is detected.
• EX.HYDRO: CNA#3 (Table 4-5) drives the contractor for a hydrau-
lic steering function when the exclusive hydro input is active.
• FREE: CNA#3 (Table 4-5) is not used.
The current this output can sink is up to 3Adc.
PEDAL BRAKING NONE The analog input CNA#18 (Table 4-5) has one of two functions:
• Pedal Braking input.
• Command input for lifting/lowering proportional valves in MDI-
PRC version.
To turn from the first to the second function is just enough to set
PEDAL BRAKING to HNONE.
This option handles the analog input CNA#18 (Table 4-5) when
used as pedal braking input:
• ANALOG: With this setting it is possible to modulate the strength
of the braking when the accelerator is released. The strength of
the braking is proportional to the brake pedal potentiometer con-
nected to this input. When the pedal potentiometer voltage is
equal/less 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 maximum
(PEDAL BRAKING) intensity. When there is also a switch con-
nected to the pedal braking (i.e. SET INPUT #4 to level BRAKE), it
must be closed, otherwise the release braking is stuck to the mini-
mum strength disregarding the pedal potentiometer position.
• DIGITAL: No pedal potentiometer is expected. Only when both the
SET INPUT #4 is Level BRAKE and the brake switch connected to
CNB#4 (Table 4-5) is closed, the release electrical braking follows
the PEDAL BRAKING setting (maximum strength); in all of the
other conditions the release electrical braking follows the
RELEASE BRAKING setting (minimum strength).
• NONE: The analog input CNA#18 (Table 4-5) is not used for the
release braking modulation.
QUICK INVERSION BELLY This option specifies the quick inversion mode when the SET
INPUT #4 is set BELLY. It can be set as:
• NONE: The quick inversion function is not managed (no effect
when CNB#7 (Table 4-5) switches over).
• TIMED: The quick inversion function is timed.
• BELLY: The quick inversion function is managed but not timed.

Table 4-2 Set Options - Continued

BL-D40-0515 - 08-24-2020 4-7

 Parameter Factory Setting Description
AUX VOLTAGE #1 100% This option specifies the percentage of the keyswitch controlled
voltage to be applied to the loads on CNA#1 (Table 4-5) (main
contactor coil) and CNA#3 (Table 4-5) (electromechanical brake).
The voltage modulation is set with a PWM at 1 kHz frequency.
After an initial delay of about 1 sec in which the entire keyswitch
controlled voltage is applied to the loads, the PWM reduces the
voltage at the loads down to the specified 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 ABSENT This option specifies:
• PRESENT: The MDI-PRC is connected to the ACO via the CAN
Bus: the handling of the Hydraulics is specified on the TRUCK
TYPE setting.
• ABSENT: The MDI-PRC is not connected to the ACO: the TRUCK
TYPE disappears from the SET OPTIONS function list.
MOT SET-UP LOCK OFF Not used.

4-8 BL-D40-0515 - 08-24-2020

4-2.4.2. Adjustments
To change an adjustment proceed as follows and refer
to Table 4-3:
1. Connect the Zapi Handset, refer to paragraph
4-2.1.
2. Press the ROLL up button (1, Figure 4-3) and the
SET up button (5) at the same time to enter the
CONFIG MENU.
3. Press the ROLL down button (1) or the ROLL up
button (2) to find the ADJUSTMENTS display.
4. Press the ENTER button (3) to view the adjust-
ments.
5. Press the ROLL down button (2) or the ROLL up
button (1) to find the adjustment to be changed.
6. Press the SET up button (5) or the SET down but-
ton (6) until the desired value setting is reached.
The adjustment is now set at the desired value.
7. Press the OUT button (4) to exit the adjustments.

R6624

Figure 4-3 Zapi Handset

Table 4-3 Adjustments

Parameter Factory Setting Description
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 the maximum value of braking pedal potenti-
ometer when the braking pedal is fully pressed; 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 BATTERY TYPE 24V Selects the nominal battery voltage.
ADJUST BATTERY XX V Do not modify - Factory adjusted (Fine adjustment of the battery
voltage measured by the controller.)
THROTTLE 0 ZONE 9% Establishes a deadband in the accelerator input curve.

Table 4-3 Adjustments - Continued

BL-D40-0515 - 08-24-2020 4-9

 Parameter Factory Setting Description
THROTTLE X POINT 45% This parameter together with the THROTTLE Y POINT, changes
the characteristic of the accelerator input curve: when the acceler-
ator is de-pressed to X point percent, the corresponding truck
speed is Y point percent of the 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).
THROTTLE Y POINT 68% This parameter together with the THROTTLE X POINT, changes
the characteristic of the accelerator input curve: when the acceler-
ator is de-pressed to X point percent, the corresponding truck
speed is Y point percent of the 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 charge table (Level 0 to 9).
LOAD HM FROM OFF When set On, the Hourmeter of the Controller is transferred and
MDI recorded on the Hourmeter of the Standard MDI (connected on
the Serial Link).
CHECK UP DONE OFF Turn it On when asked Maintenance service has been executed to
cancel the CHECK UP NEEDED warning.
CHECK UP TYPE NONE It specifies the handling of the CHECK UP NEEDED warning:
• NONE: No CHECK UP NEEDED warning.
• OPTION#1: CHECK UP NEEDED warning on the handset and
MDIPRC after 300 hours.
• OPTION#2: Equal to OPTION#1 but Speed reduction after 340
hours.
• OPTION#3: Equal to OPTION#2 but the truck definitively stops
after 380 hours.

R6642

Figure 4-4 Throttle Regulation

4-10 BL-D40-0515 - 08-24-2020

4-2.4.3. Parameter Change
To change a parameter proceed as follows and refer to
Table 4-4:
1. Connect the Zapi Handset, refer to paragraph
4-2.1.
2. Press the ROLL down button (1, Figure 4-5) and
the ENTER button (3) at the same time to enter
the MAIN MENU.
3. Press the ROLL down button (1) or the ROLL up
button (2) to find the PARAMETER CHANGE dis-
play.
4. Press the ENTER button (3) to view the parame-
ters.
5. Press the ROLL down button (2) or the ROLL up
button (1) to find the parameter to be changed.
6. Press the SET up button (5) or the SET down but-
ton (6) until the desired value setting is reached.
The parameter is now set at the desired value.
7. Press the OUT button (4) to exit the parameters.

R6624

Figure 4-5 Zapi Handset

Table 4-4 Parameter Adjustments
Parameter Factory Setting Description
ACCELER. DELAY LEVEL = 8 Level 0 to 9. It determines the acceleration ramp. At Level 9 the
truck takes 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 when the travel
request is released and the brake pedal switch is pressed to its
maximum. At Level 9 the truck brakes abruptly.
SPEED LIMIT BRK LEVEL = 1 Level 0 to 9. It controls the deceleration ramp when the accelerator
has turned down but not completely released. At Level 9 the truck
decelerates abruptly.
BRAKE CUTBACK LEVEL = 5 Level 0 to 9. It controls the deceleration ramp when the a speed
reduction input becomes active and the motor slows down. At
Level 9 the truck decelerates abruptly.
MAX SPEED FORW 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed
in forward direction.
MAX SPEED BACK 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed
in backward direction.

BL-D40-0515 - 08-24-2020 4-11

 Table 4-4 Parameter Adjustments - Continued
Parameter Factory Setting Description
CUTBACK SPEED 100% Typically from 10% to 100%. It determines the percentage of the
max speed applied when the cutback switch 1 (SR#1 on CNA#15
(Table 4-5) is active. When set to 100% the speed reduction is
ineffective.
CUTBACK SPEED 2 37% Typically from 10% to 100%. It determines the percentage of the
max speed applied when the cutback switch 2 (SR#2 on CNA#14
(Table 4-5) is active. When set to 100% the speed reduction is
ineffective.
HS CUTBACK 100% Typically from 10% to 100%. It determine the percentage of the max
speed applied when the Hard & Soft function (H&S switch on
CNB#4 (Table 4-5) is active. When set to 100% the speed reduc-
tion is ineffective.
FREQUENCY 5.00 Hz Hz value. This is the minimum speed applied when the forward or
CREEP 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 96% It specifies the percentage of the absolute current (150A) at which
CURRENT the current will be limited. Normally MAXIMUM CURRENT is
100%. DO NOT CHANGE.
INCHING SPEED 0 Hz Hz value. It determines the speed when the “Inching function” is
active.
INCHING TIME LEVEL = 0 Level 0 to 9. It determines the duration time when the “Inching func-
tion” is active.
AUXILIARY TIME 1 Time units value (seconds). For the encoder version, it determines
the time duration (in seconds) in which the
the frequency was arrived to zero.
ANTIROLLBACK 80% A Percentage of the Maximum Current. This setting increases the
phase current when low frequency during starting operation. It is
used to push up, in feedforward way, the torque when it is not
possible to control the flux, in feedback way, because of the low
frequency.

4-12 BL-D40-0515 - 08-24-2020

 R6628

Figure 4-6 Zapi Controller Connections

Table 4-5 Zapi Controller Connector Pins

CNA Connector
PIN ABBREVATION DESCRIPTION
CNA#1 NMC Negative of main contactor coil.
CNA#2 PMC Positive of main contactor coil.
CNA#3 NEB Output for driving the electromechanical brake coil; drives the load
to -Batt. Maximum 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 hourmeter is active this
output provides a +Batt signal; 3 maximum current.
Table 4-5 Zapi Controller Connector Pins - Continued

BL-D40-0515 - 08-24-2020 4-13

 CNA Connector - Continued
PIN ABBREVATION DESCRIPTION
CNA#12 -BATT -Batt.
CNA#13 MOT TH Motor thermal sensor input. The internal pull-up is a fixed 2mA
(Max 5V) source current.
CNA#14 SR2 Speed reduction 2 input. Active low (switch opened).
CNA#15 SR1 Speed reduction 1 input. Active low (switch opened).
CNA#16 +12V This output provides a +12V signal for the MDI PRC, it present; mA
maximum current.
CNA#17 CAN HIGH High level CAN-BUS voltage I/O.
CNA#18 CPOTB Brake potentiometer wiper.
CNA#19 ENC A Encoder Channel A.
CNA#20 ENC B Encoder Channel B.
CNB Connector
CONNECTOR ABBREVATION DESCRIPTION
PIN
CNB#1 KEY SW Connected to the power supply through a microswitch (KEY) with a
6.3-10 A fuse in series (this could be mounted on the AC-0 cover).
CNB#2 CM Common for FW/BW/SR1/SR2/TILLER/H&S/BELLY/LIFTING/
LOWERING microswitches. This connection supplies a keyswitch
voltage level.
CNB#3 TILLER SW Tiller request input. Must be connected to the tiller microswitch,
active high.
CNB#4 H&S SW Hard & Soft request input. Must be connected to the Hard & Soft
microswitch, active high.
CNB#5 BACKWARD SW Backward direction request input. Must be connected to the back-
ward direction microswitch, active high.
CNB#6 FORWARD SW Forward direction request input. Must be connected to the forward
direction microswitch, active high.

CNB#7 BELLY SW Quick inversion function input; must be connected to the Belly
microswitch; it is active high.
CNB#8 LOWERING SW Lowering request input, active high.
CNB#9 LIFTING SW Lifting request input, active high.
CNB#10 CPOT Lifting request input, active high.
CNB#11 NPOT Negative of accelerator unit, tested for wire disconnection
diagnosis.
CNB#12 PPOT Potentiometer positive: 10V output; keep load >1k

Table 4-5 Zapi Controller Connector Pins - Continued

4-14 BL-D40-0515 - 08-24-2020

 CNC Connector
CONNECTOR ABBREVATION DESCRIPTION
PIN
CNC#1 PCLRXD Positive serial reception.
CNC#2 NCLRXD Negative serial reception.
CNC#3 PCLTXD Positive serial transmission.
CNC#4 NCLTXD Negative serial transmission.
CNC#5 GND Negative console power supply.
CNC#6 +12V Positive console power supply.
CNC#7 FLASH Must be connected to C8 for the Flash memory programming (if
used).
CNC#8 FLASH Must be connected to C7 for the Flash memory programming (If
used).

BL-D40-0515 - 08-24-2020 4-15

 NOTES

4-16 BL-D40-0515 - 08-24-2020

 SECTION 5
STEERING ARM, CONTROL HEAD AND COMPARTMENT

5-1. CONTROL HEAD 2. Remove the cap assembly as described in para-

graph 5-1.3.
5-1.1. Control Head Removal
3. Disconnect wire harness assembly from potenti-
1. Turn off key switch and emergency disconnect. ometer.

DK_0001

Figure 5-1 Steering Arm

BL-D40-0515 - 08-24-2020 5-1

4. Disconnect wire harness assembly from emer- WARNING: When removing the control head in the
gency reverse switch. following steps, be sure to hold it in place
5. Remove two screws, two washers and two flat until the control harness is disconnected.
washers that holds control head to the steering 6. Remove the remaining two screws, two washers
arm. and two flat washers that holds control head to
the steering arm.
7. Remove the control head and handle.

DK_0002

Figure 5-2 Control Head

5-2 BL-D40-0515 - 08-24-2020

5-1.2. Control Head Installation 5. Remove screws, lock washers and flat washers
that secure the potentiometer and switch assem-
1. Secure control head and handle with the screws,
bly to bracket. Remove the potentiometer
washers and flat washers that holds the control
head to the steering arm. 6. Position new potentiometer and switch assembly
in bracket and secure with screws, lock washers
2. Reconnect the wire harness assembly to emer-
and flat washers.
gency reverse switch.
7. Install control knob on potentiometer and secure
3. Reconnect the wire harness assembly to potenti-
with screw and washer.
ometer.
8. Install control knob on the other side of potentiom-
4. Install the cap assembly as described in para-
eter and secure with screw and washer.
graph 5-1.4.
9. Reconnect wire harness assembly to potentiome-
5. Turn on key switch and emergency disconnect.
ter.
5-1.3. Cap Assembly Removal. 10. Install the cap assembly as described in para-
1. Turn off key switch and emergency disconnect. graph 5-1.4.
2. Remove four screws and lift up cap assembly. 5-1.6. Belly-Button Switch Replacement.
3. Disconnect harness from the wire harness assem- 1. Remove the cap assembly as described in para-
bly and remove cap assembly. graph 5-1.3.
5-1.4. Cap Assembly Installation. 2. Disconnect wire harness assembly from emer-
gency disconnect switch.
1. Hold cap assembly in place and connect wire har-
ness assembly to harness. 3. Remove screws, lock washers and flat washers
that secure the potentiometer and switch assem-
2. Position cap assembly on control head and secure bly to bracket. Remove the potentiometer and
with four screws. emergency disconnect switch.
1. Turn on key switch and emergency disconnect.
4. Remove pin, bracket, and spring from button.
5-1.5. Speed Potentiometer Replacement. 5. Remove two pins and switch assembly from
bracket.
1. Remove the cap assembly as described in para-
graph 5-1.3. 6. Position the new switch assembly in bracket and
secure with two pins.
2. Disconnect wire harness assembly from potenti-
ometer. 7. Position bracket and springs in button and install
pin.
3. Remove screw, washer and control knob from
potentiometer. 8. Position potentiometer and switch assembly in
bracket and secure with screws, lock washers
4. Remove screw, washer and control knob from other
and flat washers.
side of potentiometer.
9. Reconnect wire harness assembly to emergency
reverse switch.
10. Install the cap assembly as described in para-
graph 5-1.4.

BL-D40-0515 - 08-24-2020 5-3

 DK_0005

Figure 5-3 Emergency Reverse Switch Assembly

5-1.7. Horn Switch Replacement. 4. Position new switch in bracket of assembly and
secure with the two pins.
1. Remove the cap assembly as described in para-
graph 5-1.3. 5. Position the bracket with two springs in cover and
secure with three screws.
2. Remove three screws, switch bracket and two
springs of assembly. 6. Install the cap assembly as described in para-
graph 5-1.4.
3. Remove the two pins of assembly and remove
switch from the bracket.

5-4 BL-D40-0515 - 08-24-2020

 DK_0003

Figure 5-4 Cap Assembly

5-1.8. Lift and Lower Switch Replacement. 4. Remove two pins, two switches and four springs
from bracket.
1. Remove the cap assembly as described in para-
graph 5-1.3. 5. Position switches and four springs in bracket and
secure with two pins.
2. Remove switch assembly from the cap.
6. Position switch assembly in cover and secure with
3. Remove pin securing buttons to the bracket and
pin.
remove the buttons.
7. Install the cap assembly as described in para-
graph 5-1.4.

BL-D40-0515 - 08-24-2020 5-5

5-2. COMPARTMENT COVERS 6. Remove two screws, two screws and middle cover.
7. Pull lower cover up and out.
5-2.1. Removal.
1. Turn off key switch and emergency disconnect. 5-2.2. Installation.
2. Pull charger cable up and remove cap from the 1. Position lower cover on the frame.
cable. Let charger cable back down into cover. 2. Place middle cover around brake and secure with
3. Remove two screws, two washers and cover. two screws and two screws.
4. Disconnect cable from charger. 3. Install upper cover and secure with four screws
5. Remove four screws, four washers and upper cover. and four washers.
4. Reconnect cable to charger.

DK_0008

Figure 5-5 Compartment Cover

5. Feed the cable through cover and position cover 6. Install cap on cable and position the cap on cover.
on the frame. Secure with two screws and two 7. Turn on key switch and emergency disconnect.
washers.

5-6 BL-D40-0515 - 08-24-2020

5-3. STEERING ARM 5-3.2. Steering Arm Removal.

5-3.1. Return Spring Replacement. 1. Remove steering arm gas return spring as
described in paragraph 5-3.1.
The steering arm gas return spring is replaced while the
2. Disconnect wire harness assembly from harness.
steering arm is in the upright position.
3. Attach a hoist to steering arm.
1. Secure steering arm in the upright position.
4. Remove shaft and the steering arm.
2. Remove screw and free the gas return spring from
bracket. 5-3.3. Steering Arm Installation.
3. Pull downward on gas return spring to free it from 1. Position steering arm over bracket and secure with
its seat inside steering arm. shaft.
4. Position the new gas return spring inside the steer- 2. Reconnect wire harness assembly to harness.
ing arm being sure it fully engages its seat.
3. Install steering arm gas return spring as described
5. Position the opposite end of gas return spring on in paragraph 5-3.1.
bracket and install screw.

BL-D40-0515 - 08-24-2020 5-7

5-8 BL-D40-0515 - 08-24-2020
 SECTION 6
BRAKE SERVICING

6-1. BRAKES. j. Recheck the gap.

The brake system consists of the brake assembly 11. Remove load wheel blocks and check operation.
mounted on top of the drive motor. This brake is elec- 12. Install the compartment covers as described in
trically applied and released. paragraph 5-2.
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 5-2.
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. 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
R6625
screwed clockwise until they bottom.
i. Finally tighten the three mounting screws to Figure 6-1 Brake Assembly
52 in-lb (6 Nm).

BL-D40-0515 - 08-24-2020 6-1

6-1.2. Stopping Distance Adjustment. 4. Remove load wheel blocks and check operation.
The stopping distance of the truck should require mini- 5. Install the compartment covers as described in
mal adjustment. However, this distance should be paragraph 5-2.
checked with each planned maintenance.
6-1.3. Brake Assembly Replacement
Using an unloaded truck, run truck to its top speed on
an even dry concrete surface. Move control handle 1. Block load wheels.
into the lower braking position. Measure length of 2. Remove the compartment covers as described in
braking path from the actuation point of the brakes paragraph 5-2.
until the truck has stopped. The actual length of the 3. Disconnect electric brake from harness.
braking path should be between approximately 1.5 -
2.5 ft (0.5-0.7 m). 4. Remove the three mounting screws and the brake.
5. Place the new brake into position and secure with
To adjust stopping distance, proceed as follows:
the three mounting screws.
1. Block load wheels.
6. Finally tighten the three mounting screws to 52 in-
2. Remove the compartment covers as described in lb (6 Nm).
paragraph 5-2.
7. Reconnect electric brake from harness.
3. Rotate the adjusting nut (Figure 6-1) clockwise to
8. Remove load wheel blocks and check operation.
SHORTEN the stopping distance or counterclock-
wise to LENGTHEN the stopping distance. 9. Install the compartment covers as described in
paragraph 5-2.

6-2 BL-D40-0515 - 08-24-2020

 SECTION 7
TRANSMISSION, DRIVE WHEEL, LOAD WHEEL

7-1. Load Wheel. This ensures level and safe operation of the
lift truck.
7-1.1. Removal
7-1.2. Repair
1. Raise forks.
1. Turn off key switch and emergency disconnect. 1. Remove bearings from wheels.

2. Block the drive wheel to prevent the truck from 2. Inspect bearings and replace if necessary.
rolling. 3. Reassemble bearings in wheels.
3. Jack up the forks to raise the load wheels off the 7-1.3. Load Wheel Installation
floor. Securely block the forks in the raised posi-
tion by positioning supports under both fork tips. 1. Position load wheel assembly in wheel bracket.
2. Install shaft and secure with pin.
NOTE: When shaft is removed, load wheel assembly
will drop free. 3. Remove blocking from under the truck.
4. Lower the forks.
4. Remove pin securing shaft and remove shaft and
load wheel assembly. 5. Turn on key switch and emergency disconnect.

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.

DK_0012

Figure 7-1 Wheel Assembly

BL-D40-0515 - 08-24-2020 7-1

7-2. Drive Wheel. 2. Remove the compartment covers as described in
paragraph 5-2.
1. Turn off key switch and emergency disconnect.
3. Remove the brake as described in paragraph 6-
2. Remove the compartment covers as described in
1.3.
paragraph 5-2.
4. Remove the steering arm as described in para-
3. Loosen but do not remove the five nuts.
graph 5-3.2.
4. Jack up the truck so the drive wheel is off the
5. Disconnect harness from drive motor.
ground; then securely block the truck to prevent
movement. 6. Remove drive motor as described in paragraph
10-3.
5. Remove five nuts, five washers, and drive wheel
from transmission. 7. Remove drive wheel as described in paragraph 7-
2.
6. Install new drive wheel in reverse order of
removal. 8. Support the transmission and remove five screws,
five washers and five flat washers.
7. Install the compartment covers as described in
paragraph 5-2. 9. Slowly lower the transmission out the bottom of
the frame.
8. Turn on key switch and emergency disconnect.
10. Install new transmission by reversing the steps
7-3. Transmission. above.
1. Turn off key switch and emergency disconnect.

7-2 BL-D40-0515 - 08-24-2020

 DK_0006

Figure 7-2 Transmission Motor, Brake Mounting

BL-D40-0515 - 08-24-2020 7-3

7-4 BL-D40-0515 - 08-24-2020
 SECTION 8
ELEVATION SYSTEM SERVICING

8-1. GENERAL under frame (14, Figure 8-1), the rear of frame (4)
The elevation system includes the lift linkage, front and at the tips of the forks.
frame and back frame. 2. Turn off key switch and emergency disconnect.
3. Remove screw and shaft from each side of frame.
8-2. LIFT LINKAGE
4. Remove clips from each side of frame. Support
8-2.1. Removal link assembly and remove shaft.
1. Lift complete truck to height sufficient to permit 5. Lower link assembly to the floor.
access to lift linkage under forks. Provide blocking 6. Remove pins and remove shafts.
7. Lower links to the floor.

DK_0010

Figure 8-1 Frame

BL-D40-0515 - 08-24-2020 8-1

8-2.2. Repair 6. Remove bushings from link if replacement is nec-
essary.
1. Remove pins , shafts and load wheel from wheel
brackets. 7. Install reassemble by reversing the steps above.
2. Remove pins (11) and shafts. Free brackets from 8-2.3. Installation
tension bars.
1. Position link assembly under frame.
3. Remove bushings from brackets if replacement is
necessary, 2. Position wheel brackets in frame and install shafts.
Secure shafts with pins.
4. Remove pins and shafts from connector and free
tension bars from connector. 3. Position link assembly and install shafts. Secure
shafts with screws,
5. Loosen nuts and remove clevises from tension bars.
4. Remove blocking and lower the truck to the ground.
5. Turn on key switch and emergency disconnect.

DK_0011

Figure 8-2 Lift Linkage Assembly

8-2 BL-D40-0515 - 08-24-2020

 SECTION 9
HYDRAULIC SYSTEM SERVICING

9-1. LINES AND FITTINGS NOTE: Leaking hydraulic fittings may be remedied by
simply tightening fittings. If this does not rem-
WARNING: When forks are raised, pressure exists in edy the leak, the fittings or line must be
the hydraulic system lines and fittings. To replaced.
ensure release of pressure, forks must
be fully lowered before performing any 1. Lower forks fully.
maintenance on the hydraulic system. 2. Turn off key switch and emergency disconnect.
3. Remove the compartment covers as described in
paragraph 5-2.

DK_0014

Figure 9-1 Hydraulic System

BL-D40-0515 - 08-24-2020 9-1

CAUTION: Hydraulic oil can damage parts. Wipe off 9-2.2. Installation
any oil immediately. Provide a container 1. Position board on frame and secure with four
under the line or fitting before discon- screws, four lock washers and four flat washers.
necting.
2. Reconnect hose to pump and motor assembly.
4. Refer to Figure 9-1 and remove leaking line or fit-
3. Reconnect all harnesses and cables to electrical
ting and replace it with a new line or fitting. Check
components on board.
level of hydraulic oil. With lift carriage fully low-
ered, fill reservoir with hydraulic oil to 1 inch below 4. Turn on key switch and emergency disconnect.
opening. Use hydraulic oil listed in Table 3-2. 5. Install the compartment covers as described in
5. Turn on key switch and emergency disconnect. paragraph 5-2.
6. Operate the lift and lower buttons to refill the 9-3. HYDRAULIC PUMP, MOTOR, AND RESER-
cylinder and lines with hydraulic oil. VOIR ASSY
7. Check level of hydraulic oil. Hydraulic oil must be
The hydraulic pump/motor assembly can be disas-
1 inch below opening. If required, add hydraulic
sembled and repaired. However, a defective pump,
oil to bring to proper level. Use hydraulic oil listed
valve or motor requires replacement of that compo-
in Table 3-2.
nent.
8. Install the compartment covers as described in
paragraph 5-2. WARNING: When forks are raised, pressure exists in
the hydraulic system lines and fittings. To
9-2. HYDRAULIC AND ELECTRICAL ASSEMBLY ensure release of pressure, forks must
REMOVAL be fully lowered and the batteries discon-
nected before performing any mainte-
The hydraulic system and electrical system can be
nance on the hydraulic system.
removed as an assembly to provide additional clear-
ance for various maintenance procedures. 9-3.1. Removal
WARNING: When forks are raised, pressure exists in 1. Lower forks fully.
the hydraulic system lines and fittings. To 2. Turn off key switch and emergency disconnect.
ensure release of pressure, forks must
3. Remove the hydraulic and electrical assembly as
be fully lowered and the batteries discon-
described in paragraph 9-2.
nected before performing any mainte-
nance on the hydraulic system. NOTE: The reservoir will be filled with hydraulic oil.
Place a container under the pump assembly
9-2.1. Removal
to catch any hydraulic oil.
1. Lower forks fully.
4. Remove two screws, lock washers and flat wash-
2. Turn off key switch and emergency disconnect. ers and remove pump and motor.
3. Remove the compartment covers as described in
paragraph 5-2. 9-3.2. Disassembly and Reassembly
4. Disconnect hose from pump and motor assembly. 1. Remove the hydraulic pump/motor assembly as
described in paragraph 9-3.1.
5. Tag and disconnect all harnesses and cables from
electrical components on board. 2. Refer to Figure 9-2 for disassembly and reassem-
bly.
6. Support board and remove four screws , four lock
washers and four flat washers.
7. Remove board.

9-2 BL-D40-0515 - 08-24-2020

 DK_0015

Figure 9-2 Pump & Motor Assy

BL-D40-0515 - 08-24-2020 9-3

9-3.3. Installation 9-3.4.2.Repair
1. Position pump and motor on board and secure 1. Secure the lift cylinder in a vise, clamping lightly at
with two screws, lock washers and flat washers. the base of the cylinder.
2. Remove the hydraulic and electrical assembly as 2. Unscrew gland nut from body.
described in paragraph 9-2. 3. Remove wiper and O-ring from gland nut.
3. Fill the hydraulic reservoir. Hydraulic oil must be 1 4. Withdraw the cylinder rod from body.
inch below opening. If required, add hydraulic oil
to bring to proper level. Use hydraulic oil listed in 5. Remove bushing, guide ring and seal ring from rod.
Table 3-2. NOTE: If the cylinder body or piston rod are dam-
4. Turn off key switch and emergency disconnect. aged, the entire lift cylinder must be replaced.
5. Operate the lift and lower buttons to refill the 6. Replace guide ring, seal ring, wiper ring and O-
cylinder and lines with hydraulic oil. ring.
6. Check level of hydraulic oil. Hydraulic oil must be 7. Coat all parts with hydraulic oil (Table 3-2).
1 inch below opening. If required, add hydraulic
oil to bring to proper level. Use hydraulic oil listed 8. Install new guide ring, seal ring and bushing (8)
in Table 3-2. on rod.

7. Install the compartment cover as described in 9. Insert piston rod into body.
paragraph 5-2. 10. Install wiper and O-ring in gland nut.
11. Install gland nut in body.
9-3.4. Lift Cylinder
9-3.4.3.Installation
9-3.4.1.Removal
1. Position the cylinder on frame and lower the
1. Lower forks fully.
frame onto the cylinder.
2. Turn off key switch and emergency disconnect.
2. Install pin and retaining rings.
3. Remove the compartment covers as described in
3. Reconnect the hose to cylinder.
paragraph 5-2.
4. Fill the hydraulic reservoir. Hydraulic oil must be 1
4. Ensure that hydraulic pressure has been relieved
inch below opening. If required, add hydraulic oil
from the lift circuit. Disconnect the hydraulic line
to bring to proper level. Use hydraulic oil listed in
from the lift cylinder.
Table 3-2.
5. Disconnect hose from cylinder.
5. Turn on key switch and emergency disconnect.
WARNING: Frame is heavy. Use care while securing 6. Operate the lift and lower buttons to refill the
and lifting in order to prevent injury. cylinder and lines with hydraulic oil.
6. With suitable hoist, carefully raise frame slightly to 7. Check level of hydraulic oil. Hydraulic oil must be
relieve pressure on the cylinder. 1 inch below opening. If required, add hydraulic
oil to bring to proper level. Use hydraulic oil listed
7. Remove retaining rings and pin.
in Table 3-2.
8. Remove cylinder.
8. Install the compartment cover as described in
paragraph 5-2.

9-4 BL-D40-0515 - 08-24-2020

 DK_0016

Figure 9-3 Lift Cylinder

BL-D40-0515 - 08-24-2020 9-5

 NOTES

9-6 BL-D40-0515 - 08-24-2020

 SECTION 10
ELECTRICAL COMPONENTS

10-1.ELECTRICAL CONTROL PANEL 1. Turn off key switch and emergency disconnect.
2. Remove the compartment covers as described in
10-1.1.Maintenance
paragraph 5-2.
NOTE: Erratic operation of the truck may be caused 3. Tag and disconnect master wire harness from
by defective controller components. Before controller.
removing the electrical panel, perform trou-
bleshooting procedures per SECTION 4, to 4. Remove four screws, lock washers and remove
determine corrective action to be taken. controller.

There are no user-serviceable parts inside the control- 10-1.4.Controller Installation.

ler. No attempt should be made to open the controller. 1. Position controller and the board and secure with
Opening the controller may damage it and will void the four screws and lock washers.
warranty.
2. Reconnect master wire harness to controller.
The controller is programmed at the factory specifi- 3. Install compartment covers as described in para-
cally for the truck model on which it is equipped. It is graph 5-2.
important to replace the controller with the correct pre-
programmed unit to assure proper performance set- 1. Turn on key switch and emergency disconnect.
tings intended for that particular truck. See Figure 12- 10-1.5.Charger Removal.
21 for the preprogrammed controller number.
1. Turn off key switch and emergency disconnect.
It is recommended that the controller exterior be
cleaned periodically, and if a Zapi Handset is avail- 2. Remove the compartment covers as described in
able, this periodic cleaning provides a good opportu- paragraph 5-2.
nity to check the controller’s diagnostic history file. It is 3. Tag and disconnect master wire harness from
also recommended that the controller’s fault detection charger.
circuitry be checked whenever the vehicle is serviced. 4. Tag and disconnect remaining two charger leads
10-1.2.Cleaning from the pump motor and the fuse.
5. Remove the screws, lock washers, two straps and
1. Turn off key switch and emergency disconnect.
charger.
2. Remove the compartment covers as described in
paragraph 5-2. 10-1.6.Charger Installation.
3. Remove any dirt or corrosion from the bus bar 1. Position charger on board and secure with the
area. The controller should be wiped clean with a screws, lock washers and two straps.
moist rag. Allow it to dry before reconnecting the 2. Reconnect the two charger leads to the pump
battery. motor and the fuse.
4. Make sure the connections to the buss bars are 3. Reconnect master wire harness to charger.
tight. Use two well insulated wrenches for this
task in order to avoid steering the buss bars. 4. Install compartment covers as described in para-
graph 5-2.
10-1.3.Controller Removal. 5. Turn on key switch and emergency disconnect.

BL-D40-0515 - 08-24-2020 10-1

10-1.7.Emergency Disconnect Removal. 3. Tag and disconnect wires from contactor.
1. Turn off key switch and emergency disconnect. 4. Remove two screws, lock washers, flat washers
and remove contactor.
2. Remove the compartment covers as described in
paragraph 5-2. 10-1.10.Contactor Installation.
3. Tag and disconnect master wire harness from emer- 1. Position contactor on the board and secure with
gency disconnect. two screws, lock washers and flat washers.
4. Remove the knob from the emergency disconnect
2. Reconnect wires to contactor.
5. Remove two screws and remove emergency dis- 3. Install compartment covers as described in para-
connect from bracket. graph 5-2.
10-1.8.Emergency Disconnect Installation. 4. Turn on key switch and emergency disconnect.
1. Position emergency disconnect on bracket and 10-1.11.Fuse Removal.
secure with two screws.
1. Turn off key switch and emergency disconnect.
2. Install the knob on the emergency disconnect.
2. Remove the compartment covers as described in
3. Reconnect master wire harness to emergency paragraph 5-2.
disconnect.
3. Loosen two nuts and rotate and remove fuse.
4. Install compartment covers as described in para-
graph 5-2. 10-1.12.Fuse Installation.
5. Turn on key switch and emergency disconnect. 1. Install fuse on the stand and secure two nuts.
10-1.9.Contactor Removal. 2. Install compartment covers as described in para-
graph 5-2.
1. Turn off key switch and emergency disconnect.
3. Turn on key switch and emergency disconnect.
2. Remove the compartment covers as described in
paragraph 5-2.

10-2 BL-D40-0515 - 08-24-2020

 DK_0019

Figure 10-1 Electrical Components (Sheet 1)

BL-D40-0515 - 08-24-2020 10-3

10-1.13.Cooling Fan Removal.
1. Turn off key switch and emergency disconnect.
2. Remove the compartment covers as described in 10-1.17.Key Switch Removal.
paragraph 5-2.
1. Turn off key switch and emergency disconnect.
3. Tag and disconnect master wire harness from
cooling fan. 2. Remove the compartment covers as described in
paragraph 5-2.
4. Remove four screws, four lock washers and four
flat washers. Remove cooling fan and guard from 3. Tag and disconnect switch wiring harness from
bracket. key switch.
4. Free key switch from bracket.
10-1.14.Cooling Fan Installation.
1. Position cooling fan and guard on bracket and 10-1.18.Key Switch Installation.
secure with four screws, four lock washers and 1. Insert key switch in bracket.
four flat washers.
2. Reconnect switch wiring harness to key switch.
2. Reconnect master wire harness to cooling fan.
3. Install compartment covers as described in para-
3. Install compartment covers as described in para- graph 5-2.
graph 5-2.
4. Turn on key switch and emergency disconnect.
4. Turn on key switch and emergency disconnect.
10-1.19.Battery Indicator Removal.
10-1.15.Buzzer Removal.
1. Turn off key switch and emergency disconnect.
1. Turn off key switch and emergency disconnect.
2. Remove the compartment covers as described in
2. Remove the compartment covers as described in paragraph 5-2.
paragraph 5-2.
3. Tag and disconnect switch wiring harness from
3. Tag and disconnect master wire harness from battery indicator.
buzzer.
4. Remove mounting nuts and bracket and remove
4. Remove two screws and buzzer from bracket. battery indicator from bracket.
10-1.16.Buzzer Installation. 10-1.20.Battery Indicator Installation.
1. Position buzzer on bracket and secure with two 1. Position battery indicator on bracket and secure
screws. with its mounting bracket and nuts.
2. Reconnect master wire harness to buzzer. 2. Reconnect switch wiring harness to battery indi-
3. Install compartment covers as described in para- cator.
graph 5-2. 3. Install compartment covers as described in para-
4. Turn on key switch and emergency disconnect. graph 5-2.
4. Turn on key switch and emergency disconnect.

10-4 BL-D40-0515 - 08-24-2020

 DK_0020

Figure 10-2 Electrical Components (Sheet 2)

BL-D40-0515 - 08-24-2020 10-5

10-1.21.Lift Limit Switch Removal. 10-1.22.Lift Limit Switch Installation.
1. Lower forks fully. 1. Position limit switch on bracket and secure with
2. Turn off key switch and emergency disconnect. two screws, lock washers and nuts.

3. Remove the compartment covers as described in 2. Reconnect master wire harness to limit switch.
paragraph 5-2. 3. Install compartment covers as described in para-
4. Tag and disconnect master wire harness from limit graph 5-2.
switch. 4. Turn on key switch and emergency disconnect.
5. Remove two nuts, screws, lock washers and limit
switch from bracket.

DK_0017

Figure 10-3 Electric System

10-6 BL-D40-0515 - 08-24-2020

10-2.PUMP MOTOR. 1. Turn off key switch and emergency disconnect.
The pump motor is replaceable but not repairable. 2. Remove the compartment covers as described in
Refer to paragraph 9-3. paragraph 5-2.
3. Disconnect wiring from the deadman switch.
10-3.DRIVE MOTOR.
4. Remove the two screws, lock washers and
The drive motor exposed surfaces should be cleaned bracket from bracket.
at least once a month to assure proper cooling of
5. Remove two screws and switch from bracket.
motor. Use an air hose to blow dust off of motor sur-
faces. 6. Position the new switch on bracket and secure
with the two screws.
The drive motor is replaceable but not repairable.
Refer to paragraph 7-3. 7. Position bracket on bracket and secure with two
screws and lock washers.
10-4.DEADMAN SWITCH 8. Install compartment covers as described in para-
graph 5-2.
10-4.1.Replacement
9. Turn on key switch and emergency disconnect.

BL-D40-0515 - 08-24-2020 10-7

 NOTES

10-8 BL-D40-0515 - 08-24-2020

 SECTION 11
OPTIONAL EQUIPMENT

BL-D40-0515 - 08-24-2020 11-1

 NOTES

11-2 BL-D40-0515 - 08-24-2020

 SECTION 12
ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the D40 Lift Truck.

BL-D40-0515 - 08-24-2020 12-1

 DK_0001

Figure 12-1 Steering Arm

12-2 BL-D40-0515 - 08-24-2020

 STEERING ARM
Qty.
Pos. Part Number Description Notes
Reqd.
Used up to Serial Number
1 1120-340000-00-B CONTROL HEAD ASSEMBLY 1
327120792

Used from Serial Number

1a 1115-340000-00-10 CONTROL HEAD ASSEMBLY 1
327120793

2 1146-330000-30 CONTROL ARM ASSEMBLY 1

3 1120-320000-00 GAS SPRING 1

4 0000-000151-00 SCREW, M8 X 25 1

5 1120-300003-00 SHAFT 1

6 0000-000011-00 BUSHING, 2015 2

7 0000-000386-00 SCREW, M6 X 20 1

8 1120-300005-00 BRACKET 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 0000-000122-00 LOCK WASHER, M4 3

21 0000-000377-00 SCREW, M2 X 20 2

22 0000-000378-00 SCREW, M4 X 16 1

23 0000-000702-00 FLAT WASHER, M4 1

24 0000-000491-00 HARNESS CLAMP 1

25 0000-000139-00 NUT, M4 1

26 0000-000109-00 SCREW, M8 X 16 3

27 1220-560001-00 INCHING SWITCH 2

BL-D40-0515 - 08-24-2020 12-3

 DK_0029

Figure 12-2 Steering Arm - Freezer

12-4 BL-D40-0515 - 08-24-2020

 STEERING ARM - FREEZER
Qty.
Pos. Part Number Description Notes
Reqd.
1 1280-360000-20 CONTROL POD ASSEMBLY 1

2 1120-330000-0A CONTROL HANDLE ASSEMBLY 1

3 1120-320000-00 GAS SPRING 1

4 0000-000151-00 SCREW M8×25 1

5 1120-300003-00 SHAFT 1

6 0000-000011-00 BUSHING 2015 2

7 0000-000386-00 SCREW M6×20 1

8 1120-300005-00 BRACKET 1

9 0000-000429-00 SCREW M5×8 1

10 0000-000030-00 SCREW M10×16 1

11 0000-000159-00 LOCK WASHER Ø8 10

12 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 0000-000491-00 HARNESS CLAMP 1

25 0000-000139-00 NUT M4 1

26 0000-000109-00 SCREW M8×16 3

27 2333-320000-10 CONTROL POD BRACKET 1

28 0000-000321-00 SCREW M8×20 3

29 0000-000176-00 FLAT WASHER Ø8 7

30 0000-000322-00 SCREW M8×25 4

31 0000-001329-10 SCREW M3×16 1

BL-D40-0515 - 08-24-2020 12-5

 DK_0002

Figure 12-3 Control Head - Used up to Serial Number 327120792

12-6 BL-D40-0515 - 08-24-2020

 CONTROL HEAD - Used up to Serial Number 327120792
Qty.
Pos. Part Number Description Notes
Reqd.
1 1120-342000-00-B CAP ASSEMBLY 1

2 1120-340005-00 CONTROL KNOB (R) 1

3 0000-000038-00 LOCK WASHER Ø3 2

4 0000-000037-00 SCREW M3×12 2

5 0000-000004-00 SCREW M5×12 2

6 0000-000206-00 LOCK WASHER Ø5 4

7 0000-000390-00 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 1

19 1120-341000-00 GRIPE 1

20 1120-340001-00 POD 1

21 1220-520008-0C ACCELERATOR ASSEMBLY 1

22 0000-000010-00 SCREW M5×6 1

BL-D40-0515 - 08-24-2020 12-7

 DK_0033

Figure 12-4 Control Head - Used from Serial Number 327120793

12-8 BL-D40-0515 - 08-24-2020

 Control Head - Used from Serial Number 327120793

Qty.
Pos. Part Number Description Notes
Reqd.
1 1115-341000-00-10 CAP ASSEMBLY 1

2 1115-340005-00 CONTROL KNOB (R) 1

3 0000-000038-00 LOCK WASHER Ø3 2

4 0000-000037-00 SCREW M3×12 2

5 1115-340006-00 BUSHING 2 Cancelled in 2019

6 1115-340004-00 CONTROL KNOB (L) 1

Used up to serial number

7 1220-520008-0C ACCELERATOR ASSEMBLY 1
3282101427

Used from serial number

7a 1120-340004-00-01 ACCELERATOR ASSEMBLY 1
3282101428

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 0000-000176-00 FLATWASHER Ø8 4

19 1115-340001-00 WASHER 2

20 0000-000035-00 SCREW M5×20 4

BL-D40-0515 - 08-24-2020 12-9

 DK_0027

Figure 12-4 Control Head - Freezer

12-10 BL-D40-0515 - 08-24-2020

 CONTROL HEAD - FREEZER

Qty.
Pos. Part Number Description Notes
Reqd.
1 2333-340001-00 COVER 1

2 2333-340002-00 CAP 1

3 2333-340003-00 CONTROL KNOB RIGHT SIDE 1

4 2333-340004-00 CONTROL KNOB LEFT SIDE 1

5 2333-340005-00 HORN BUTTON 1

6 2333-340006-00 BUTTON REVERSER COVER 1

7 2333-340015-00 LIFT / LOWER 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 LOCK WASHER 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 COVER 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-D40-0515 - 08-24-2020 12-11

 DK_0003

Figure 12-5 Cap Assembly

12-12 BL-D40-0515 - 08-24-2020

 CAP ASSEMBLY
Qty.
Pos. Part Number Description Notes
Reqd.
Used up to Serial Number
1 1120-342001-00 UPPER COVER 1
327120792

Used from Serial Number

1a 1115-341001-00 UPPER COVER 1
327120793

2 1120-342203-00 BUTTON FOR LIFTING (R) 1

3 1120-342202-00 BUTTON FOR LOWERING (R) 1

4 1120-342102-00 SPRING 8

5 1120-342201-00 BUTTON BRACKET (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 1220-560002-00 INCHING SWITCH II 5

17 1120-342002-00 HORN BUTTON 1

18 1120-342005-00 PIN 2

19 1120-342003-00 SPRING 2

20 1120-342004-00 BUTTON BRACKET 1

BL-D40-0515 - 08-24-2020 12-13

 DK_0005

Figure 12-6 Emergency Reverse Switch Assembly - Used up to Serial Number 327120792

12-14 BL-D40-0515 - 08-24-2020

 EMERGENCY REVERSE SWITCH ASSEMBLY - Used up to Serial Number 327120792

Qty.
Pos. Part Number Description Notes
Reqd.
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

BL-D40-0515 - 08-24-2020 12-15

 DK_0008

Figure 12-7 Compartment Covers - Used up to serial number 324180206

12-16 BL-D40-0515 - 08-24-2020

 COMPARTMENT COVERS - USED UP TO SERIAL NUMBER 324180206

Qty.
Pos. Part Number Description Notes
Reqd.
Black - Used up to Serial #
1 1118-100001-00-01 COVER 1
E2316807

Black - Used between

1a 1118-100001-10-01 COVER 1 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

BL-D40-0515 - 08-24-2020 12-17

 DK_0028

Figure 12-8 Compartment Covers - Used from serial number 324180207

12-18 BL-D40-0515 - 08-24-2020

 COMPARTMENT COVERS - USED FROM SERIAL NUMBER 324180207

Qty.
Pos. Part Number Description Notes
Reqd.
1 1118-100001-0A-01 COVER 1 Black

Black, Used on Low Fork Design,

1a 1118-100001-CD-BJ COVER 1
if not sure please contact factory.

Used between serial number

2 1118-100002-10 UPPER COVER 1 324180207-324190035 - Big Joe
Yellow

Used from serial number

2a 1118-100002-1A UPPER COVER 1
324190036 - Big Joe Yellow

Used between serial number

3 1118-100003-10 LOWER COVER 1 324180207-324190035 Big Joe
Yellow

Used from serial number

3a 1118-100003-1A LOWER COVER 1
324190036 - Big Joe Yellow

4 1118-100004-10 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

BL-D40-0515 - 08-24-2020 12-19

 DK_0010

Figure 12-9 Frame

12-20 BL-D40-0515 - 08-24-2020

 FRAME
Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000386-00 SCREW M6×20 1

2 1118-130005-00 SHAFT 1

3 3050-020000-10 SNAP RING FOR HOLE Ø30 2

Used up to E2410519. Fork

4 1118-110000-20-01 FORK FRAME 1
Length 36”, Fork Width 21”

Used between E2410520-

4a 1118-110000-2A-01 FORK FRAME 1 324180206 Fork Length 36”,
Fork Width 21”

Used from 324180207.. Fork

4b 1118-110000-C0-01 FORK FRAME 1
Length 36”, Fork Width 21”

Used up to E2410519. Fork

4c 1118-110000-20-02 FORK FRAME 1
Length 48”, Fork Width 21”

Used between E2410520-

4d 1118-110000-2A-02 FORK FRAME 1 324180206 . Fork Length 48”,
Fork Width 21”

Used from 324180207. Fork

4e 1118-110000-C0-02 FORK FRAME 1
Length 48”, Fork Width 21”

Used up to E2410519. Fork

4f 1118-110000-40-01 FORK FRAME 1
Length 36”, Fork Width 27”

Used between E2410520-

4g 1118-110000-4A-01 FORK FRAME 1 324180206 . Fork Length 36”,
Fork Width 27”

Used from 324180207. Fork

4h 1118-110000-E0-01 FORK FRAME 1
Length 36”, Fork Width 27”

Used up to E2410519. Fork

4i 1118-110000-40-02 FORK FRAME 1
Length 48”, Fork Width 27”

Used between E2410520-

4j 1118-110000-4A-02 FORK FRAME 1 324180206 . Fork Length 48”,
Fork Width 27”

Used from 324180207.. Fork

4k 1118-110000-E0-02 FORK FRAME 1
Length 48”, Fork Width 27”

Used on Low Fork Design, if not

4l 1118-110000-CD-52 FORK FRAME 1 sure please contact factory.
Length 32”, Fork Width 22”

5 1118-130003-00 LINK 1

Used on Low Fork Design, if not

5a 1118-130003-CD LINK 1 sure please contact factory.
Length 32”, Fork Width 22”

6 1115-130004-0A SHAFT 2

7 0000-000708-00 ROUND PIN Ø5×35 2

8 0000-000056-00 LOCK WASHER Ø6 2

BL-D40-0515 - 08-24-2020 12-21

 DK_0010

Figure 12-10 Frame continued

12-22 BL-D40-0515 - 08-24-2020

 FRAME - CONTINUED
Qty.
Pos. Part Number Description Notes
Reqd.
With Grease Fitting. Used for Fork
9 1118-130001-10 LONG SHAFT 1
Width 21”

With Grease Fitting. Fork Width 27”.

9a 1118-130001-20 LONG SHAFT 1 Also used on Low Fork Design with
Fork Width 27”

Used on Low Fork Design, if not sure

9b 1118-130001-2B LONG SHAFT 1 please contact factory.
Fork Width 22”

10 0000-000677-00 BUSHING 1610F 4

11 1118-130004-00 SHAFT 1

12 0000-000438-00 FLAT WASHER Ø12 1

13 0000-000057-00 NUT M12 1

14 1118-120000-10 BACK FRAME 1 Used up to serial number E2410519

Used between serial numbers

14a 1118-120000-70 BACK FRAME 1
E2410520-324180206

14b 1118-120000-A0-00 BACK FRAME 1 Used from serial number 324180207

Used on Low Fork Design, if not sure

14c 1118-120000-CD BACK FRAME 1 please contact factory.
Length 32”, Fork Width 22”

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 FLAT WASHER Ø8 10

23 0000-000109-00 SCREW M8×16 4

24 0000-000055-00 SCREW M6×16 2

25 0000-001130-00 BUSHING 1612 2 Used from 07-04-2013-

26 1118-101000-10 PLATE 1

27 0000-000008-00 SCREW M10×20 4 Used between serial numbers

E2316808-E2410519
28 0000-000063-00 LOCK WASHER Ø10 4

29 0000-000007-00 FLAT WASHER Ø10 4

30 1118-600005-00-01 SHIM A.R. As Required, 1mm

30a 1118-600005-00-02 SHIM A.R. As Required, 3mm

BL-D40-0515 - 08-24-2020 12-23

 DK_0038

Figure 12-11 Frame - Fork 16”x45”

12-24 BL-D40-0515 - 08-24-2020

 FRAME - FORK 16”X45”
Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000386-00 SCREW M6×20 1

2 1118-130005-00 SHAFT 1

3 3050-020000-10 SNAP RING FOR HOLE Ø30 2

4 1118-110000-70 FORK FRAME 1 Used up to serial number 324180206

4a 1118-110000-H0 FORK FRAME 1 Used from serial number 324180207

5 1118-130003-00 LINK 1

6 1118-130004-70 SHAFT 2

7 0000-000708-00 ROUND PIN Ø5×35 2

8 0000-000056-00 LOCK WASHER Ø6 10

9 1118-130001-70 LONG SHAFT 1 With Grease Fitting

10 0000-000677-00 BUSHING 4

11 1118-130004-00 SHAFT 1

12 0000-000438-00 FLAT WASHER Ø12 1

13 0000-000057-00 NUT M12 1

14 1118-120000-70 BACK FRAME 1 Used up to serial number 324180206

14a 1118-120000-A0-01 BACK FRAME 1 Used from serial number 324180207

15 1118-133000-00 SHAFT 2 Used up to 07-03-2013

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 FLAT WASHER Ø8 10

23 0000-000109-00 SCREW M8×16 4

24 0000-000055-00 SCREW M6×16 2

25 0000-001130-00 BUSHING 2

26 1118-100001-70 RUBBER PLATE 1 Used from serial number 324190322

27 1118-100002-70 PLATE 1

28 0000-000371-00 SCREW M6×16 8

29 0000-000123-00 FLATWASHER Ø6 8

30 1118-600005-00-01 SHIM A.R. As Required, 1mm

30a 1118-600005-00-02 SHIM A.R. As Required, 1mm

BL-D40-0515 - 08-24-2020 12-25

 DK_0013

Figure 12-12 Caster

12-26 BL-D40-0515 - 08-24-2020

 CASTER

Qty.
Pos. Part Number Description Notes
Reqd.
— 1118-140000-00 CASTER ASSEMBLY 2

1 0000-000985-00 SCREW, M10 X 20 1

2 1118-140003-00 PLATE 1

3 1118-140001-00 CASTER SUPPORT 1

4 0000-000986-00 BEARING, 6307 1

5 1118-140002-00 CASTER SUPPORT 1

6 0000-000168-00 BOLT, M10 X 90 1

7 1120-140003-00 PU BLOCK 1

8 1120-142000-00 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 Used up to 02-25-2014

18 0000-000007-00 FLAT WASHER, M10 1 Used up to 02-25-2014

19 0000-000435-00 FLAT WASHER M20 2

20 0000-000060-00 LOCK WASHER, M12 1 Used up to 02-25-2014

21 0000-000373-00 FLAT WASHER, M12 1 Used up to 02-25-2014

22 0000-000004-00 SCREW, M5 X 12 1

BL-D40-0515 - 08-24-2020 12-27

 DK_0011

Figure 12-13 Lift Link Assembly

12-28 BL-D40-0515 - 08-24-2020

 LIFT LINK ASSEMBLY

Qty.
Pos. Part Number Description Notes
Reqd.
1 1219-141000-00 DOWN LINK 1 Fork width 21” (540mm)

1a 1219-141000-30 DOWN LINK 1 Fork width 27” (685mm)

2 0000-001034-00 BUSHING 2

3 1219-140001-00 SHAFT 2

4 0000-000101-00 NUT, M22 X 1.5 2

5 1219-142200-00 CONNECTOR 2

6 1118-132000-70 LONG LINK 2 Fork 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 0000-000435-00 FLAT WASHER, M20 4

15 1118-132100-70 LONG ROD 2 Fork length 36”

15a 1118-132100-20 LONG ROD 2 Fork length 48”

16 1115-130008-00 WASHER 4

BL-D40-0515 - 08-24-2020 12-29

 DK_0036

Figure 12-14 Low Profile Lift Link Assembly

12-30 BL-D40-0515 - 08-24-2020

 LOW PROFILE LIFT LINK ASSEMBLY

Qty.
Pos. Part Number Description Notes
Reqd.
Used on Low Fork Design, if not
1 1118-134000-CD-R0 DOWN LINK 1 sure please contact factory.
Fork width 21” (540mm)

Used on Low Fork Design, if not

1a 1118-134000-CD-01 DOWN LINK 1 sure please contact factory.
Fork width 27” (685mm)

2 0000-001034-00 BUSHING 2

3 1219-140001-00 SHAFT 2

4 0000-000101-00 NUT, M22 X 1.5 2

5 1118-142200-CD CONNECTOR 2

Used on Low Fork Design, if not

6 1118-132000-CD-R0 LONG LINK 2 sure please contact factory.
Fork length 32”

Used on Low Fork Design, if not

6a 1118-132000-CD-52 LONG LINK 2 sure please contact factory.
Fork length 45”

7 0000-000907-00 BUSHING 4

8 1118-130005-CD WHEEL BRACKET 2

9 0000-000908-00 BUSHING 4

10 1115-130003-C0 LOAD WHEEL BRACKET PIVOT SHAFT 2

11 0000-000708-00 PIN, M5 X 35 8

12 1118-130007-CD LOAD WHEEL SHAFT 2

13 1118-133000-CD LOAD WHEEL 2

14 0000-000435-00 FLAT WASHER, M20 4

15 1118-132100-CD-R0 LONG ROD 2 Fork length 32”

15a 1118-132100-CD-52 LONG ROD 2 Fork length 45”

16 1115-130007-C0 WASHER 4

BL-D40-0515 - 08-24-2020 12-31

 DK_0039

Figure 12-15 Lift Link Assembly - Fork 16”x45”

12-32 BL-D40-0515 - 08-24-2020

 LIFT LINK ASSEMBLY - FORK 16”X45”

Qty.
Pos. Part Number Description Notes
Reqd.
1 1118-141000-70 DOWN LINK 1 Used up to serial number 326210270

1a 1118-141000-7A DOWN LINK 1 Used from serial number 326210271

2 0000-001034-00 BUSHING 2

3 1219-140001-00 SHAFT 2

4 0000-000101-00 NUT, M22 X 1.5 2

5 1219-142200-00 CONNECTOR 2

6 1118-132000-A0 LONG LINK 2

7 0000-000907-00 BUSHING 4

8 1118-130005-70 WHEEL BRACKET 2 Used up to serial number 326210270

8a 1118-130005-7A WHEEL BRACKET 2 Used from serial number 326210271

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 1115-130008-00 WASHER 4

15 1118-132100-A0 LONG ROD 2

BL-D40-0515 - 08-24-2020 12-33

 DK_0012

Figure 12-16 Load Wheel

12-34 BL-D40-0515 - 08-24-2020

 LOAD WHEEL

Qty.
Pos. Part Number Description Notes
Reqd.
— 1115-133000-40 LOAD WHEEL ASSEMBLY 2 Including bearings

Including bearings -
Used on Low Fork Design,
— 1118-133000-CD LOW PROFILE LOAD WHEEL ASSEMBLY 2
if not sure please contact
factory.

1 0000-000020-00 BEARING 2

Used on Low Fork Design,

1a 3090-000000-29 BEARING 2 if not sure please contact
factory.

2 1115-133002-40 LOAD WHEEL 1

Used on Low Fork Design,

2a 1118-133002-CD LOAD WHEEL 1 if not sure please contact
factory.

BL-D40-0515 - 08-24-2020 12-35

 DK_0009

Figure 12-17 Load Backrest

12-36 BL-D40-0515 - 08-24-2020

 LOAD BACKREST

Qty.
Pos. Part Number Description Notes
Reqd.
1 1118-151000-00 LOAD BACKREST 1 Height 48” (1220mm)

1a 1118-152000-00 LOAD BACKREST 1 Height 60” (1524mm)

2 0000-000153-00 BOLT 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 0000-000054-00 NUT 1

BL-D40-0515 - 08-24-2020 12-37

 DK_0040

Figure 12-18 Load Backrest - Fork 16”x45” - Used up to Serial Number E2410289

12-38 BL-D40-0515 - 08-24-2020

 LOAD BACKREST - FORK 16”X45” - USED UP TO SERIAL NUMBER E2410289

Qty.
Pos. Part Number Description Notes
Reqd.
1 1118-151000-70 LOAD BACKREST 1 Height 48” (1220mm)

2 0000-000153-00 BOLT M12×20 4

3 0000-000060-00 LOCK WASHER 4

4 0000-000373-00 FLAT WASHER 4

5 1115-680000-K0 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 1115-680000-K0 FLATWASHER Ø8 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 0000-000054-00 NUT 1

BL-D40-0515 - 08-24-2020 12-39

 DK_0041

Figure 12-19 Load Backrest - Fork 16”x45” - Used up to Serial Number E2410290

12-40 BL-D40-0515 - 08-24-2020

 LOAD BACKREST - FORK 16”X45” - USED FROM SERIAL NUMBER E2410290

Qty.
Pos. Part Number Description Notes
Reqd.
1 1118-151000-7A LOAD BACKREST 1 Height 48” (1220mm)

2 0000-000153-00 BOLT 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 0000-000712-00 SCREW M8 X 20 4

11 901803 LOAD RESTRAINT KIT 1 Includes Items 11,12,13, 14, 15

12 -- Included in Item 12

13 0000-000070-00 SCREW 1

14 0000-000054-00 NUT 1

BL-D40-0515 - 08-24-2020 12-41

 DK_0006

Figure 12-20 Transmission Motor, Brake Mounting

12-42 BL-D40-0515 - 08-24-2020

 TRANSMISSION MOTOR, BRAKE MOUNTING

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000027-00 SCREW, M6 X 55 3

Used up to serial number

2 1120-210000-00 BRAKE ASSEMBLY 1
325130008

Used from serial number

2a 1120-210000-10 BRAKE ASSEMBLY 1
325130009

3 1120-220000-00 MOTOR ASSEMBLY 1

4 0000-000154-00 SCREW, M8 X 35 8

5 0000-000159-00 LOCK WASHER, M8 8

6 0000-000176-00 FLAT WASHER, M8 8

7 0000-000155-00 SCREW, M10 X 40 5

8 0000-000063-00 LOCK WASHER, M10 5

9 0000-000007-00 FLAT WASHER, 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

Used between Serial #

12a 1120-240000-30 TRANSMISSION ASSEMBLY 1
E2219365 - 327120197

12b ZK12-240000-00 TRANSMISSION ASSEMBLY 1 Used from Serial # 327120198

13 1120-200001-00 DRIVE WHEEL ASSEMBLY 1 Poly (Standard)

Non Marking Rubber Flat

13a 506161-10 DRIVE WHEEL ASSEMBLY 1
Face

Non Marking Rubber Dia-

13b 506161-11 DRIVE WHEEL ASSEMBLY 1
mond-X Cut

13c 1120-200001-20 DRIVE WHEEL ASSEMBLY 1 Poly Diamond-X Cut

14 0000-000025-00 LOCK WASHER, M12 5 Used up to Serial # 327120197

14a ZK12-240018-00 LOCK WASHER, M12 5 Used from Serial # 327120198

15 0000-000157-00 NUT, M12 X 1.25 5 Used up to Serial # 327120197

15a 0000-001131-10 NUT, M12 X 1.25 5 Used from Serial # 327120198

16 0000-000070-00 SCREW, M10 X 25 2

17 1120-210002-00 BRAKE PLATE 1

18 1120-240014-30 STUDS 5 Used up to Serial # 327120197

18a ZK12-240003-00 STUDS 5 Used from Serial # 327120198

19 1120-211101-10 DUST BAND 1 Used from Serial # 3281500170

BL-D40-0515 - 08-24-2020 12-43

 DK_0007

Figure 12-21 Transmission Transmission Used up to Serial # E2219364

12-44 BL-D40-0515 - 08-24-2020

 TRANSMISSION USED UP TO SERIAL # E2219364
Qty.
Pos. Part Number Description Notes
Reqd.
— 4230-210000-10 TRANSMISSION ASSEMBLY 1

1 1120-240001-30 GEAR CASE 1

2 1120-240002-30 PLUG 1

3 0000-000214-00 O-RING 135 X 3.1 1

4 1120-240003-30 COVER 1

5 0000-000056-00 LOCK WASHER, M6 12

6 0000-000259-00 BOLT, M6 X 16 8

7 1120-240019-30 WASHER A.R. As Required

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 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 X 3.1 1

20 1120-240010-30 COVER 1

21 1120-240011-30 VENT PLUG 1

22 0000-000055-00 SCREW M6 X16 4

23 1120-240017-30 SEAL WASHER, TC80 X 65 X 8 1

24 1120-240013-30 OUTPUT SHAFT 1

BL-D40-0515 - 08-24-2020 12-45

 DK_0024

Figure 12-22 Transmission Used between Serial # E2219365 - 327120197

12-46 BL-D40-0515 - 08-24-2020

 TRANSMISSION USED BETWEEN SERIAL # E2219365 - 327120197
Qty.
Pos. Part Number Description Notes
Reqd.
-- 1120-240000-30 TRANSMISSION ASSEMBLY 1

1 1120-240001-30 GEAR CASE 1

2 1120-240002-30 PLUG 1

3 0000-000214-00 O-RING 135×3.1 1

4 1120-240003-30 COVER 1

5 0000-000056-00 LOCK WASHER Ø6 12

6 0000-000259-00 BOLT M6×16 8

7 1120-240019-30 WASHER A.R. As required

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-RING 150×3.1 1

20 1120-240010-30 COVER 1

21 1120-240011-30 GAS PLUG 1

22 0000-000055-00 SCREW M6×16 4

23 1120-240017-30 SEAL WASHER TC80×65×8 1

24 1120-240013-30 OUTPUT SHAFT 1

BL-D40-0515 - 08-24-2020 12-47

 DK_0034

Figure 12-23 Transmission Used from serial number 327120198

12-48 BL-D40-0515 - 08-24-2020

 TRANSMISSION
Used from serial number 327120198

Qty.
Pos. Part Number Description Notes
Reqd.
-- ZK12-240000-00 GEARBOX ASSEMBLY 1 Ratio 22.07
1 ZK12-240004-00 GEAR CASE 1
2 ZK12-240016-00 PLUG 1
3 0000-000214-00 O-RING 135×3.1 1
4 ZK12-240006-00 COVER 1
5 0000-000056-00 LOCKWASHER Ø6 12
6 0000-000259-00 BOLT M6×16 8
7 ZK12-240010-00 PROTECTIVE SLEEVE 1
8 0000-000961-00 BEARING 2
9 ZK12-240017-00 PLUG 1
Used between Serial #
10 ZK12-GB30-10 SPIRAL BEVEL GEAR SET 1 327120198-327150591
Includes 2 gears
Used from Serial # 327150592
10a ZK12-GB30-1A 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-RING 150×3.1 1
20 ZK12-240005-00 COVER 1
21 ZK12-241000-00 PLUG 1
22 0000-000055-00 SCREW M6×16 4
23 3060-030000-17 SEAL WASHER TC80×65×8 1
Used between Serial #
24 ZK12-240007-00 OUTPUT SHAFT 1
327120198-327150591
24a ZK12-240007-0A OUTPUT SHAFT 1 Used from Serial # 327150592

BL-D40-0515 - 08-24-2020 12-49

 DK_0018

Figure 12-24 Drive Motor Assembly

12-50 BL-D40-0515 - 08-24-2020

 DRIVE MOTOR ASSEMBLY

Qty.
Pos. Part Number Description Notes
Reqd.
-- 1120-220000-00 MOTOR ASSEMBLY 1

1 0000-000293-00 RETAINING 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

BL-D40-0515 - 08-24-2020 12-51

 DK_0014

Figure 12-25 Hydraulic System

12-52 BL-D40-0515 - 08-24-2020

 HYDRAULIC SYSTEM

Qty.
Pos. Part Number Description Notes
Reqd.
1 2706-141400-00 CONNECTOR, M14 X 1.5 1 Used up to 01/14/2014

1a 2401-143500-00 BOLT M14 X 35 1 Used from 01/15/2014

2 0000-000044-00 WASHER, M14 2

Used up to Serial #
3 1118-430000-0A HOSE ASSY 1
E2316807

Used from Serial #

3a 1118-430000-10 HOSE ASSY 1
E2316808 to E2410519

Used from Serial #

3b 1118-430000-0A HOSE ASSY 1
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

Used on Low Fork Design,

8a 1118-410000-CD CYLINDER 1 if not sure please contact
factory.

9 0000-000293-00 RETAINING RING, M20 2

10 1118-400001-00 SHAFT 1

11 0000-000210-00 FLAT WASHER, M8 2

12 0000-000705-00 BUSHING 2

BL-D40-0515 - 08-24-2020 12-53

 DK_0015

Figure 12-26 Pump & Motor Assy

12-54 BL-D40-0515 - 08-24-2020

 PUMP & MOTOR ASSY

Qty.
Pos. Part Number Description Notes
Reqd.
— 1118-420000-00 PUMP & MOTOR ASSY 1

1 1115-560001-00 CLAMP 2

2 1118-420002-00 WIRE HARNESS 1

3 1115-560003-00 DC MOTOR, 0.8KW/24V 1

4 1115-560002-00 RELAY, 24V/150A 1

5 1115-560008-00 SCREW, M8 X 8 2

6 1115-560007-00 BALL, 6G20B 4

7 1118-420007-00 VALVE PLATE 1

8 1115-560006-00 SAFETY 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

21 1120-430021-00 O-RING, 69 X 3.5 1

22 1118-420022-00 OIL TANK 1

23 1115-560023-00 O-RING, 11.2 X 2.65 1

24 1115-560024-00 AIR FILTER 1

25 1115-561001-00 CARBON BRUSH 1

BL-D40-0515 - 08-24-2020 12-55

 DK_0016

Figure 12-27 Lift Cylinder

12-56 BL-D40-0515 - 08-24-2020

 LIFT CYLINDER

Qty.
Pos. Part Number Description Notes
Reqd.
— 1118-410000-00 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

BL-D40-0515 - 08-24-2020 12-57

 DK_0037

Figure 12-28 Low Profile Forks - Lift Cylinder

12-58 BL-D40-0515 - 08-24-2020

 LOW PROFILE FORKS - LIFT CYLINDER

Qty.
Pos. Part Number Description Notes
Reqd.
— 1118-410000-CD LIFT CYLINDER 1

— 1118-QSY-0A SEAL KIT 1 Includes Items 1, 2, 3

1 -- WIPER RING, M40 X 48 X 5-6.5 1

2 -- O-RING, M45 X 3.1 1

3 -- ROD PACKING Ø40×50×6 1

BL-D40-0515 - 08-24-2020 12-59

 DK_0017

Figure 12-29 Electrical System

12-60 BL-D40-0515 - 08-24-2020

 ELECTRICAL SYSTEM

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000030-00 SCREW, M10 X 16 4

2 0000-000063-00 LOCK WASHER, M10 4

3 0000-000007-00 FLAT WASHER, M10 4

4 1118-511000-00 ELECTRICAL MOUNTING PLATE 1 Up to Serial # E2410289

4a 1118-511000-70 ELECTRICAL MOUNTING PLATE 1 From Serial # E2410290

5 0000-000368-00 SCREW, M8 X 12 2

6 2214-150002-00 WASHER 2

7 0000-000108-00 NUT, M6 4 Used up to 04/23/2014

8 1118-540000-00 BOARD 1 Up to Serial # 324170264

8a 1118-540000-70 BOARD 1 From Serial # 324170265

9 0000-000117-00 SCREW, M5 X 10 3

10 0000-000206-00 LOCK WASHER, M5 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 1

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 0000-001031-00 SCREW, M4 X 30 2

20 0000-000122-00 LOCK WASHER, M4 2

21 0000-000139-00 NUT, M4 2

22 003231 BATTERY 2 85Ah Battery

22a 1118-560007-00 BATTERY 2 100Ah Battery

23 1118-100011-00 SPACER A.R. As required

24 1118-100010-00 PLATE 2 Used up to 04/23/2014

25 0000-000055-00 SCREW, M6 X 16 4 Used up to 04/23/2014

26 1115-100002-00 SPACER A.R. As required

27 1280-100005-00 FLAT PLUG 1 Up to Serial # 324170264

BL-D40-0515 - 08-24-2020 12-61

 DK_0019

Figure 12-30 Electrical Components (Sheet 1)

12-62 BL-D40-0515 - 08-24-2020

 ELECTRICAL COMPONENTS (SHEET 1)

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000119-00 SCREW, M5 X 12 2

2 1115-510008-00 EMERGENCY STOP SWITCH 1

3 1118-510002-00 MOUNTING PLATE 1

Used on Low Fork Design,

3a 1118-510002-CD MOUNTING PLATE 1 if not sure please contact
factory.

4 0000-000700-00 SCREW, M8 X 16 4

5 0000-000159-00 LOCK WASHER, M8 4

6 0000-000176-00 FLAT WASHER, M8 4

Used up to Serial #
7 1118-510005-00 UPPER MOUNTING PLATE 1
E2316807

Used from Serial #

7a 1118-510005-0A UPPER MOUNTING PLATE 1
E2316808

Used on Low Fork Design,

7b 1118-510005-CD UPPER MOUNTING PLATE 1 if not sure please contact
factory.

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

Used up to Serial #
12 1120-540002-00 FUSE, 200A 1
3291400129

Used from Serial #

12a 3218-630002-01 FUSE, 200A 1
3291400130

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 5

17 0000-000206-00 LOCK WASHER, M5 4

18 1120-500004-00-30 CONTROLLER AC0 1

19 1120-500005-10 CONTACTOR 1

20 1118-560006-00-01 CHARGER ASSEMBLY 15A 1

20a 1118-560006-00-02 CHARGER ASSEMBLY 20A 1

BL-D40-0515 - 08-24-2020 12-63

 DK_0019

Figure 12-30Electrical Components (Sheet 1) - Continued

12-64 BL-D40-0515 - 08-24-2020

 ELECTRICAL COMPONENTS (SHEET 1) - CONTINUED

Qty.
Pos. Part Number Description Notes
Reqd.
21 1115-500006-10 CHARGER CABLE 1

22 1115-500009-00 CHARGER HOOP 2

23 0000-000031-00 SCREW, M5 X 8 1

24 0000-000390-00 FLAT WASHER, M5 4

25 0000-000546-00 NUT, M5 3

Only used from Serial #

26 1118-510005-10 PLATE II 1
E2316808 to E2410289

Only used from Serial #

27 0000-000035-00 SCREW M5×20 2
E2316808 to E2410289

Used from Serial #

27a 0000-000004-00 SCREW M5×12 2
E2410290

Used from Serial #

28 1220-150005-00 NUT M8 2
E2316808

29 1115-510008-10 SWITCH BUTTON 1

BL-D40-0515 - 08-24-2020 12-65

 DK_0020

Figure 12-31 Electrical Components (Sheet 2)

12-66 BL-D40-0515 - 08-24-2020

 ELECTRICAL COMPONENTS (SHEET 2)
Qty.
Part Number Description Notes
Reqd.
1 1118-560001-00 TIMING RELAY 1

2 1118-560002-00 TIMING RELAY SET 1 Optional up to serial number

324170264. Standard from
3 1118-510001-00 RELAY BRACKET 1 serial number 324170265

4 0000-000009-00 SCREW, M4 X 12 2

5 0000-000031-00 SCREW, M5 X 8 4

6 0000-000206-00 LOCK WASHER, M5 6

7 0000-000390-00 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 WASHER, M4 4

19 0000-000702-00 FLAT WASHER, M4 4

20 1115-520019-0A 2-WAY SWITCH 1

21 1115-500016-00 2-WAY SWITCH KEY 2

22 1115-520013-00 LED WIRE HARNESS 1

23 1115-510009-00 LAMP HOLDER 1

Optional up to serial number

24 1118-522000-00 BRAKE RELEASE BUTTON 1 324170264. Standard from
serial number 324170265

25 1115-520005-0A BDI WIRE HARNESS 1 Without Hourmeter

25a 1115-520005-20 BDI WIRE HARNESS 1 With Hourmeter

Used from serial number

26 0000-000498-00 SCREW M6 X 30 2
324170265

BL-D40-0515 - 08-24-2020 12-67

 DK_0020

Figure 12-31 Electrical Components (Sheet 2) - Continued

12-68 BL-D40-0515 - 08-24-2020

 ELECTRICAL COMPONENTS (SHEET 2) - CONTINUED

Qty.
Part Number Description Notes
Reqd.
Used from serial number
27 1118-540002-70 PLATE 1
324170265

Without Hourmeter. Set

the BDI dial to the follow-
28 1115-510006-00 BDI (BATTERY INDICATOR) 1
ing: M = Industrial Battery,
Q = Maint.Free Battery

With Hourmeter. Set the

BDI dial to the following: M
28a 1115-510006-20 BDI (BATTERY INDICATOR) 1
= Industrial Battery, Q =
Maint.Free Battery

Only used from Serial #

29 1118-510004-10 PLATE I 1
E2316808 to E2410289

Used from serial number

30 0000-000108-00 NUT M6 4
324170265

BL-D40-0515 - 08-24-2020 12-69

 DK_0030

Figure 12-31 Electrical Components - Freezer

12-70 BL-D40-0515 - 08-24-2020

 ELECTRICAL COMPONENTS - FREEZER

Qty.
Part Number Description Notes
Reqd.
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

BL-D40-0515 - 08-24-2020 12-71

 DK_0021

Figure 12-32 Wiring Harness

12-72 BL-D40-0515 - 08-24-2020

 WIRING HARNESS

Qty.
Pos. Part Number Description Notes
Reqd.
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

Only used up to serial num-

5 1118-520008-10 SHORT CIRCUIT SWITCH 1
ber 324170264 (Optional)

BL-D40-0515 - 08-24-2020 12-73

 DK_0031

Figure 12-33 Wiring Harness - Freezer

12-74 BL-D40-0515 - 08-24-2020

 WIRING HARNESS - FREEZER

Qty.
Pos. Part Number Description Notes
Reqd.
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

BL-D40-0515 - 08-24-2020 12-75

 DK_0022

Figure 12-34 Wiring Cables

12-76 BL-D40-0515 - 08-24-2020

 WIRING CABLES

Qty.
Pos. Part Number Description Notes
Reqd.
1 1118-531003-00 CABLE, BATTERY CONNECTOR 1

2 1118-531002-00 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

BL-D40-0515 - 08-24-2020 12-77

Big Lift LLC