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Big Lift D40 User Manual

Big Lift D40
132 pages
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Big Lift LLC MANUAL NO. BL-D40-0515 - 01-27-2019
www.bigjoeforklifts.com
D40
SELF-PROPELLED,
PALLET LIFT TRUCK
U.S. Patents Nos. D739,112; D770,719; D770,720; 9,586,605
Operation
Maintenance
Repair Parts List
NOTE: For the most current parts information and service updates, please refer to the Big Joe
Support site at www.bigjoesupport.com

Table of Contents

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Big Lift D40 Specifications

General IconGeneral
BrandBig Lift
ModelD40
CategoryForklifts
LanguageEnglish

Summary

SECTION 1 DESCRIPTION

1-3. SAFETY FEATURES

Lists the safety features incorporated into the D40 truck design for operator and payload.

SECTION 2 OPERATION

2-2. OPERATING PRECAUTIONS

Provides critical safety precautions for operating the lift truck to prevent injury.

2-5. DRIVING AND STOPPING PROCEDURES

Details the steps for starting, driving, stopping, and braking the truck.

SECTION 3 PLANNED MAINTENANCE

3-3. BATTERY CARE

Covers general battery care, safety rules, charging, and cleaning procedures.

3-3.2. Safety Rules

Lists safety precautions for handling batteries and electrolyte.

3-3.3. Battery Care and Charging

Details procedures for charging batteries safely and properly.

3-4. CHARGING BATTERIES

Provides step-by-step instructions for safely charging the truck's batteries.

SECTION 4 TROUBLESHOOTING

4-2. CONTROLLER TROUBLESHOOTING

Focuses on troubleshooting issues related to the Zapi controller and handset.

SECTION 5 STEERING ARM, CONTROL HEAD AND COMPARTMENT

5-1.1. Control Head Removal

Steps to remove the control head from the steering arm.

5-1.2. Control Head Installation

Steps to install the control head and handle onto the steering arm.

5-3.2. Steering Arm Removal

Steps for removing the steering arm assembly.

5-3.3. Steering Arm Installation

Steps for installing the steering arm assembly.

SECTION 6 BRAKE SERVICING

6-1.1. Air Gap Adjustment

Procedure to adjust the air gap in the brake assembly for proper release.

6-1.2. Stopping Distance Adjustment

How to adjust the truck's stopping distance and the acceptable range.

6-1.3. Brake Assembly Replacement

Steps for removing and replacing the entire brake assembly.

SECTION 7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL

7-1.1. Removal

Steps to remove the load wheel assembly.

7-1.3. Load Wheel Installation

Steps to install the load wheel assembly.

SECTION 8 ELEVATION SYSTEM SERVICING

8-2.1. Removal

Steps to remove the lift linkage assembly from the truck.

8-2.2. Repair

Procedures for repairing the lift linkage components.

8-2.3. Installation

Steps to install the lift linkage assembly.

SECTION 9 HYDRAULIC SYSTEM SERVICING

9-2.1. Removal

Instructions to remove the hydraulic and electrical system assembly.

9-2.2. Installation

Steps to install the hydraulic and electrical system assembly.

9-3. HYDRAULIC PUMP, MOTOR, AND RESERVOIR ASSY

Procedures for servicing the hydraulic pump, motor, and reservoir assembly.

9-3.1. Removal

Steps to remove the hydraulic pump, motor, and reservoir assembly.

9-3.3. Installation

Steps to install the pump and motor assembly.

9-3.4. Lift Cylinder

Covers the removal, repair, and installation of the lift cylinder.

9-3.4.1.Removal

Steps to remove the lift cylinder from the truck.

9-3.4.2.Repair

Procedures for repairing the lift cylinder components.

SECTION 10 ELECTRICAL COMPONENTS

10-1. ELECTRICAL CONTROL PANEL

Details maintenance, cleaning, removal, and installation of the electrical control panel.

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