Big Joe EZ30, Operation, Maintenance, Repair Parts List

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TABLE OF CONTENTS
BL-EZ30-0815 - 07-28-2019 i
Section Page Section Page
1 LIST OF ILLUSTRATIONS..........................................1-II
1 LIST OF TABLES .......................................................1-III
1
DESCRIPTION1-1
1-1. INTRODUCTION. .........................................1-1
1-2. GENERAL DESCRIPTION. ..........................1-1
1-3. SAFETY FEATURES....................................1-2
2
OPERATION2-1
2-1. GENERAL.....................................................2-1
2-2. OPERATING PRECAUTIONS......................2-1
2-3. BEFORE OPERATION.................................2-1
2-4. GENERAL CONTROL OPERATION............2-4
2-5. DRIVING AND STOPPING PROCEDURES. .2-
4
2-6. BELLY-BUTTON SWITCH. ..........................2-4
2-7. STEERING ARM GAS SPRING. ..................2-5
2-8. LIFT AND LOWER CONTROLS...................2-5
2-9. BACKREST. .................................................2-5
2-10. GUIDE RAILS. ..............................................2-5
2-11. SAFETY BELT AND CONISTER..................2-5
2-12. LOADING AND UNLOADING.......................2-5
2-13. PARKING......................................................2-5
3
PLANNED MAINTENANCE3-1
3-1. GENERAL.....................................................3-1
3-2. MONTHLY AND QUARTERLY CHECKS.....3-1
3-3. BATTERY CARE. ........................................3-1
3-3.1. GENERAL.....................................................3-1
3-3.2. SAFETY RULES...........................................3-2
3-3.3. BATTERY CARE AND CHARGING .............3-2
3-3.4. BATTERY CLEANING..................................3-2
3-3.5. MAINTENANCE FREE BATTERIES ............3-2
3-4. CHARGING BATTERIES .............................3-3
3-5. BATTERIES REPLACEMENT......................3-4
3-6. LUBRICATION..............................................3-5
4
TROUBLESHOOTING4-1
4-1. GENERAL.....................................................4-1
4-2. CONTROLLER TROUBLESHOOTING ........4-4
4-2.1. FAULT DETECTION.....................................4-4
4-2.2. HAND HELD PROGRAMMER (OPTIONAL) 4-4
4-2.3. FAULT RECORDING. ..................................4-4
4-2.4. GENERAL CHECKOUT. ..............................4-4
4-2.5. DIAGNOSTIC HISTORY ..............................4-6
4-2.6. TEST THE FAULT DETECTION CIRCUITRY4-
6
4-2.7. DIAGNOSTICS AND TROUBLESHOOTING. 4-
6
4-2.8. PROGRAMMER DIAGNOSTICS .................4-7
5
STEERING ARM, CONTROL HEAD AND COMPARTMENT
5-1
5-1. CONTROL HEAD......................................... 5-1
5-1.1. CONTROL HEAD REMOVAL ...................... 5-1
5-1.2. CONTROL HEAD INSTALLATION .............. 5-3
5-1.3. CAP ASSEMBLY REMOVAL....................... 5-3
5-1.4. CAP ASSEMBLY INSTALLATION............... 5-3
5-1.5. SPEED POTENTIOMETER REPLACEMENT. ..
5-3
5-1.6. BELLY-BUTTON SWITCH REPLACEMENT. 5-
3
5-1.7. HORN SWITCH REPLACEMENT. .............. 5-4
5-1.8. LIFT AND LOWER SWITCH REPLACEMENT..
5-5
5-2. UPPER COMPARTMENT COVERS ........... 5-6
5-2.1. REMOVAL.................................................... 5-6
5-2.2. INSTALLATION............................................ 5-6
5-3. LOWER COMPARTMENT COVERS........... 5-7
5-3.1. REMOVAL.................................................... 5-7
5-3.2. INSTALLATION............................................ 5-7
5-4. STEERING ARM.......................................... 5-7
5-4.1. RETURN SPRING REPLACEMENT. .......... 5-7
5-4.2. STEERING ARM REMOVAL. ...................... 5-7
5-4.3. STEERING ARM INSTALLATION. .............. 5-7
6
BRAKE SERVICING6-1
6-1. BRAKES....................................................... 6-1
6-1.1. BRAKE ASSEMBLY REPLACEMENT......... 6-1
7
TRANSMISSION, DRIVE WHEEL, LOAD WHEEL7-1
7-1. DRIVE WHEEL. ........................................... 7-1
7-2. TRANSMISSION.......................................... 7-1
7-3. LOAD WHEEL.............................................. 7-3
7-3.1. REMOVAL.................................................... 7-3
7-3.2. REPAIR....................................................... 7-3
7-3.3. LOAD WHEEL INSTALLATION ................... 7-3
8
ELEVATION SYSTEM SERVICING8-1
8-1. LIFT LINKAGE ............................................. 8-1
8-1.1. REMOVAL.................................................... 8-1
8-1.2. REPAIR........................................................ 8-2
8-1.3. INSTALLATION............................................ 8-2
9
HYDRAULIC SYSTEM SERVICING9-1
9-1. LINES AND FITTINGS................................. 9-1
9-2. HYDRAULIC AND ELECTRICAL ASSEMBLY
REMOVAL9-2
9-2.1. REMOVAL.................................................... 9-2
9-2.2. INSTALLATION............................................ 9-2
9-3. HYDRAULIC PUMP, MOTOR, AND RESER-
VOIR ASSY9-2
9-3.1. REMOVAL.................................................... 9-2
9-3.2. DISASSEMBLY AND REASSEMBLY.......... 9-2
9-3.3. INSTALLATION............................................ 9-2
9-3.4. LIFT CYLINDER........................................... 9-5
10