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Big Joe EZ30, Operation, Maintenance, Repair Parts List

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Big Joe EZ30 Operation, Maintenance, Repair Parts List Download Page 4

TABLE OF CONTENTS - Continued

ii

BL-EZ30-0815 - 07-28-2019

ELECTRICAL COMPONENTS10-1

10-1.

ELECTRICAL CONTROL PANEL.............. 10-1

10-1.1. MAINTENANCE ......................................... 10-1
10-1.2. CLEANING................................................. 10-1
10-1.3. CONTROLLER REMOVAL. ....................... 10-1
10-1.4. CONTROLLER INSTALLATION. ............... 10-1
10-1.5. CHARGER REMOVAL............................... 10-1
10-1.6. CHARGER INSTALLATION....................... 10-1
10-1.7. COOLING FAN REMOVAL........................ 10-3
10-1.8. COOLING FAN INSTALLATION................ 10-3
10-1.9. BUZZER REMOVAL. ................................. 10-3
10-1.10. BUZZER INSTALLATION. ......................... 10-3
10-1.11. KEY SWITCH REMOVAL. ......................... 10-3
10-1.12. KEY SWITCH INSTALLATION. ................. 10-3
10-1.13. BATTERY INDICATOR REMOVAL. .......... 10-3
10-1.14. BATTERY INDICATOR INSTALLATION. .. 10-3
10-1.15. EMERGENCY DISCONNECT REMOVAL. 10-3
10-1.16. EMERGENCY DISCONNECT INSTALLATION.

10-4

10-1.17. LIFT LIMIT SWITCH 

(USED UP TO SERIAL # E2120047).10-6

10-1.18. LIFT LIMIT SWITCH 

(USED FROM SERIAL # E2120048).10-7

10-2.

PUMP MOTOR...........................................10-7

10-3.

DRIVE MOTOR. .........................................10-7

10-4.

DEADMAN SWITCH ..................................10-7

10-4.1. REPLACEMENT.........................................10-7

11
OPTIONAL EQUIPMENT11-1

11-1.

WATERPROOF COMPARTMENT COVER.11-

1

12
ILLUSTRATED PARTS BREAKDOWN12-1

LIST OF ILLUSTRATIONS

Figure

Page

Figure

Page

1-1

 NAME PLATE.......................................................  1-1

1-2

. EZ30 LIFT TRUCK ..............................................  1-1

2-1

SAMPLE OF OPERATOR CHECK LIST...............  2-3

2-2

FORWARD/REVERSE CONTROL .......................  2-4

2-3

PUSHBUTTON SWITCHES..................................  2-4

2-4

BRAKE ACTUATION.............................................  2-4

2-5

BELLY-BUTTON SWITCH ....................................  2-5

3-1

BATTERY CHARGING..........................................  3-3

3-2

COVER REMOVAL ...............................................  3-4

3-3

SCREW REMOVAL...............................................  3-4

3-4

DISCONNECT BATTERY CABLES ......................  3-4

3-5

REPOSITION ELECTRICAL PANEL ....................  3-4

3-6

COVER REMOVAL ...............................................  3-4

3-7

LUBRICATION DIAGRAM.....................................  3-6

4-1

. CONTROLLER TERMINALS ..............................  4-4

4-2

. HAND HELD PROGRAMMER ............................  4-4

4-3

WIRING DIAGRAM .............................................  4-10

5-1

STEERING ARM ...................................................  5-1

5-2

CONTROL HEAD ..................................................  5-2

5-3

EMERGENCY REVERSE SWITCH ASSEMBLY..  5-4

5-4

CAP ASSEMBLY...................................................  5-5

5-5

COMPARTMENT COVER.....................................  5-6

6-1

TRANSMISSION, MOTOR, BRAKE MOUNTING .  6-2

7-1

TRANSMISSION, MOTOR, BRAKE MOUNTING .  7-2

7-2

WHEEL ASSEMBLY .............................................  7-3

8-1

FRAME ..................................................................  8-1

8-2

LIFT LINKAGE ASSEMBLY ..................................  8-2

9-1

COMPARTMENT COVER.....................................  9-1

9-2

HYDRAULIC SYSTEM ..........................................  9-3

9-3

PUMP & MOTOR ASSY........................................  9-4

9-4

LIFT CYLINDER 
(UP TO SERIAL # E2017219) ...............................  9-5

9-5

LIFT CYLINDER
(SERIAL #’S E2017220 TO E2116209)................. 9-6

9-6

LIFT CYLINDER
(SERIAL #’S FROM E2116210)............................. 9-7

10-1 ELECTRICAL SYSTEM ....................................... 10-2
10-2 WIRING HARNESS ............................................. 10-4
10-3 WIRING CABLES ................................................ 10-5
10-4 COMPARTMENT................................................. 10-6
12-1 STEERING ARM.................................................. 12-2
12-2 CONTROL HEAD ................................................ 12-4
12-3 CAP ASSEMBLY ................................................. 12-8
12-4 EMERGENCY REVERSE SWITCH 

ASSEMBLY........................................................ 12-10

12-5 TRANSMISSION MOTOR, BRAKE 

MOUNTING ....................................................... 12-12

12-6 COMPARTMENT COVER ................................. 12-16
12-7 COMPARTMENT COVER - WATERPROOF .... 12-18
12-8 LOAD BACKREST............................................. 12-20
12-9 GUIDE RAILS .................................................... 12-24
12-10 COMPARTMENT............................................... 12-26
12-11 FRAME .............................................................. 12-30
12-12 LIFT LINK ASSEMBLY ...................................... 12-32
12-13 LOAD WHEEL ................................................... 12-34
12-14 HYDRAULIC SYSTEM ...................................... 12-36
12-15 PUMP & MOTOR ASSY .................................... 12-38
12-16 LIFT CYLINDER - 

USED UP TO SERIAL # E2017219................... 12-40

12-17 LIFT CYLINDER - 

SERIAL #’S BETWEEN E2017220 & E2116209 12-42

12-18 LIFT CYLINDER - 

USED FOR SERIAL # FROM E2116210........... 12-44

12-19 ELECTRICAL SYSTEM ..................................... 12-46
12-20 WIRING HARNESS ........................................... 12-52
12-21 WIRING CABLES .............................................. 12-54

Summary of Contents for EZ30

Page 1: ...LC MANUAL NO BL EZ30 0815 07 28 2019 www bigjoeforklifts com EZ30 SELF PROPELLED PALLET LIFT TRUCK U S Patents Nos 8 540 213 8 833 736 9 079 754 D692 202 D692203 D692204 Operation Maintenance Repair P...

Page 2: ...ion is obstructed Start stop travel steer and brake smoothly Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or overturn Use special care when traveling without...

Page 3: ...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 INSTALL...

Page 4: ...DISCONNECT BATTERY CABLES 3 4 3 5 REPOSITION ELECTRICAL PANEL 3 4 3 6 COVER REMOVAL 3 4 3 7 LUBRICATION DIAGRAM 3 6 4 1 CONTROLLER TERMINALS 4 4 4 2 HAND HELD PROGRAMMER 4 4 4 3 WIRING DIAGRAM 4 10 5...

Page 5: ...OF TABLES Table Page Table Page 2 1 OPERATOR CHECKS 2 2 3 1 MONTHLY AND QUARTERLY INSPECTION AND SERVICE CHART 3 1 3 2 RECOMMENDED LUBRICANTS 3 5 3 3 LUBRICATION CHART 3 6 4 1 TROUBLESHOOTING CHART 4...

Page 6: ...TABLE OF CONTENTS Continued iv BL EZ30 0815 07 28 2019...

Page 7: ...truck Figure 1 2 lifts and transports payloads up to 3000 pounds on rigid forks The forward and reverse motion is controlled by either of two controller levers mounted on the control head Stopping and...

Page 8: ...backing up in slow speed All control functions automatically return to OFF when released Emergency Disconnect within operator s reach Readily accessible horn button Handle to provide a firm hand hold...

Page 9: ...spe cial care when traveling without load as the risk of overturn may be greater Always look in direction of travel Keep a clear view and when load interferes with visibility travel with load or lifti...

Page 10: ...all speed ranges in forward and reverse and that belly button switch functions Wheels Check drive wheel for cracks or damage Move truck to check load for freedom of rotation Hydraulic controls Check o...

Page 11: ...BL EZ30 0815 07 28 2019 2 3 Figure 2 1 Sample of Operator Check List R6479...

Page 12: ...ch Grasp the grips of the steering head so that the speed control can be comfortably oper ated by either thumb 2 Lower the steering arm to a comfortable position above horizontal to disengage the brak...

Page 13: ...l use of 46 forks 2 10 GUIDE RAILS Guide rails 17 and 19 Figure 12 9 are adjustable for standard pallets and for beverage pallets Rails must be swiveled into the lower position before lowering the bac...

Page 14: ...2 6 BL EZ30 0815 07 28 2019 NOTES...

Page 15: ...thoroughly with clean water Obtain medical attention when eyes are affected A baking soda solution one pound to one gallon of water applied to spilled acid until bub bling stops neutralizes the acid f...

Page 16: ...uring charging is highly explosive and can cause seri ous injury 1 Charge the battery only in areas designated for that use 2 Battery terminals should be checked and cleaned of corrosion regularly Goo...

Page 17: ...ng 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...

Page 18: ...ove four screws 1 Figure 3 3 four washers 2 Figure 3 3 Screw Removal c Tag and disconnect the three battery cables Figure 3 4 d Rotate control arm to the extreme position as shown in Figure 3 5 e Pull...

Page 19: ...for Application No 1 Transmission oil EP SAE 80W 90 Transmission oil EP SAE 10W 30 Note No 2 Grease Lithium base general purpose No 3 Hydraulic oil Heavy duty with a viscosity of 150 SUS foam suppres...

Page 20: ...3 APPLICATION OF LUBRICANT 1 Transmission Capacity 2 pints Can No 1 Fill to level plug opening 2 Hydraulic Reservoir Capacity 1 quarts Can No 3 With lift carriage fully lowered fill reservoir with hyd...

Page 21: ...l wiring A loose con nection may be the cause of malfunction Tighten all loose connections before further troubleshooting b Defective deadman switch Check and replace switch if defective c Defective c...

Page 22: ...o reservoir Weak slow or uneven action of hydraulic system a Defective pump or relief valve Check pressure Adjust as necessary b Worn lift cylinder Replace cylinder c Load larger than capacity Refer t...

Page 23: ...ging Change batteries Forks creep downward under load when in a raised position Leak in hydraulic system lift cylin der or lowering valve Check for leaking fitting in hydrau lic line and repair as req...

Page 24: ...ete the following checkout procedure If you find a problem during the checkout refer to paragraph 4 2 7 for further information The checkout can be conducted with or without the handheld programmer Se...

Page 25: ...the forward reverse switches and motor The motor should run proportionally faster with increasing throttle If not refer to Paragraph 4 2 7 5 Put the controller into the test mode by using the Navigati...

Page 26: ...The motor should not operate 5 Leave the key switch on and remove the in line fuse wire The vehicle status should continue to remain off 6 Cycle the key switch off and on Release the brake and apply t...

Page 27: ...w Speed setting Decel Low Speed 1 5 sec 1 5 sec Sets the rate in seconds that is used to slow down the vehicle when it s traveling forward at low speed and throttle is reduced Larger values represent...

Page 28: ...d to soften the bump associated with gear slack in the transaxle when throttle is applied from the neutral state Larger values provide a softer slack take up Gear Soften 15 15 This parameter is intend...

Page 29: ...arameter to apply a speed limit pot must be installed in parallel with the throttle and the Speed Limit Pot parameter must be programmed On see Throttle menu Rev Max Speed Mode 1 Mode 2 100 60 100 30...

Page 30: ...y the throttle itself Neutral Deadband 5 5 Sets the throttle range the controller interprets as neutral Increasing the parameter setting increases the neutral range This parameter allows the neutral d...

Page 31: ...bits driving and puts the controller into throttle autocalibration mode Setting the parameter Off returns the controller to normal oper ation CURRENT MENU Main Current Limit 70A 90A Sets the maximum c...

Page 32: ...e brake coil when the brake is first released After approximately 1 second this peak volt age drops to the programmed Hold Voltage The parameter should be set high enough to hold the brake released un...

Page 33: ...driving with a fully charged battery vs a partially discharged battery If Speed Scaler is set to 23 volts for example the maximum vehicle speed will be the same whether the actual battery voltage is 2...

Page 34: ...lues are for larger batter ies which charge more slowly Low BDI Level 44 40 Sets the battery charge level at which maximum vehicle speed will be limited in order to protect the battery from deep dis c...

Page 35: ...F Defines the emergency reverse switch belly button switch type On BB switch is normally closed when it is not pressed Off BB switch is normally open when it is not pressed MISCELLANEOUS MENU Sleep 0...

Page 36: ...4 16 BL EZ30 0815 07 28 2019 Table 4 3 Troubleshooting Chart...

Page 37: ...BL EZ30 0815 07 28 2019 4 17 Figure 4 3 Wiring Diagram R6774...

Page 38: ...4 18 BL EZ30 0815 07 28 2019 NOTES...

Page 39: ...CONTROL HEAD 5 1 1 Control Head Removal 1 Turn off the key switch 20 Figure 12 20 and emergency disconnect 17 2 Remove the cap assembly 24 Figure 5 2 as described in paragraph 5 1 3 3 Disconnect harn...

Page 40: ...two screws 5 two washers 7 and two flat washers 6 WARNING When removing the control head in the following steps be sure to hold it in place until the control harness is disconnected 6 Remove two scre...

Page 41: ...other side of potentiometer 21 5 Remove screw 16 screw 22 two lock washers 6 and two flat washers 7 and remove potenti ometer 21 and switch assembly 23 from bracket 20 6 Position new potentiometer 21...

Page 42: ...graph 5 1 3 2 Remove three screws 11 Figure 5 4 bracket 10c and two springs 10b 3 Remove two pins 10a and switch from bracket 10c 4 Position new switch in bracket 10c and secure with two pins 10a 5 Po...

Page 43: ...ring buttons 2 and 3 or 7 and 8 to bracket 5 or 9 and remove the buttons 4 Remove two pins 6 two switches and four springs 4 from bracket 5 or 9 5 Position switches and four springs 4 Figure 5 4 in br...

Page 44: ...er 5 Figure 5 5 3 Remove two screws 4 two washers 6 and cover 5 4 Disconnect cable 9 Figure 12 20 from the bat tery charger 5 2 2 Installation 1 Reconnect cable 9 Figure 12 20 to the battery charger 2...

Page 45: ...he steering arm 13 in the upright posi tion 2 Remove screw 1 and free the gas return spring 8 from bracket 5 3 Pull downward on the gas return spring 8 to free it from its seat inside steering arm 13...

Page 46: ...5 8 BL EZ30 0815 07 28 2019 NOTES...

Page 47: ...emove the lower compartment covers as described in paragraph 5 3 3 Disconnect electric brake 35 Figure 12 5 from harness 3 4 Remove the three mounting screws 9 Figure 6 1 and the brake 5 Place the new...

Page 48: ...6 2 BL EZ30 0815 07 28 2019 Figure 6 1 Transmission Motor Brake Mounting EZ30 5...

Page 49: ...e bearing 30 from wheel 31 9 Install new drive wheel in reverse order of removal 10 Install the lower compartment covers as described in paragraph 5 3 11 Turn on the key switch 20 Figure 12 20 and eme...

Page 50: ...7 2 BL EZ30 0815 07 28 2019 Figure 7 1 Transmission Motor Brake Mounting EZ30 5...

Page 51: ...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 as...

Page 52: ...7 4 BL EZ30 0815 07 28 2019 NOTES...

Page 53: ...de blocking under frame 8 Figure 8 1 transmission and at tips of the forks 2 Turn off the key switch 20 Figure 12 20 and emergency disconnect 17 3 Remove pins 10 Figure 8 1 and remove shafts 11 4 Remo...

Page 54: ...ace ment is necessary 7 Install reassemble by reversing the steps above 8 1 3 Installation 1 Position the link assembly under frame 8 2 Position wheel brackets 8 Figure 8 2 in frame 8 Figure 8 1 and i...

Page 55: ...ly lowered before performing any maintenance on the hydraulic system NOTE Leaking hydraulic fittings may be remedied by simply tightening fittings If this does not rem edy the leak the fittings or lin...

Page 56: ...ur screws 1 Figure 9 1 and four washers 2 2 Turn on the key switch 20 Figure 12 20 and emergency disconnect 17 3 Install the upper compartment cover as described in paragraph 5 2 9 3 HYDRAULIC PUMP MO...

Page 57: ...lines with hydraulic oil 7 Check level of hydraulic oil Hydraulic oil must be 1 inch below opening If required add hydraulic oil to bring to proper level Use hydraulic oil listed in Table 3 2 8 Insta...

Page 58: ...9 4 BL EZ30 0815 07 28 2019 Figure 9 3 Pump Motor Assy EZ30 15...

Page 59: ...ly so the cylinder can be removed 9 3 4 2 Repair Up to Serial E2017219 1 Secure the lift cylinder in a vise clamping lightly at the base of the cylinder 2 Remove screw 8 Figure 9 4 and support 9 3 Uns...

Page 60: ...5 5 Remove guide ring 6 and seal ring 7 from rod 1 NOTE If the cylinder body 5 or piston rod 1 are damaged the entire lift cylinder must be replaced 6 Replace guide ring 6 seal ring 7 wiper ring 2 an...

Page 61: ...5 6 Remove guide ring 6 and seal ring 7 from rod 1 NOTE If the cylinder body 5 or piston rod 1 are damaged the entire lift cylinder must be replaced 7 Replace guide ring 6 seal ring 7 wiper ring 2 and...

Page 62: ...below opening If required add hydraulic oil to bring to proper level Use hydraulic oil listed in Table 3 2 4 Turn on the key switch 20 Figure 12 20 and emergency disconnect 17 5 Operate the lift and...

Page 63: ...the connections to the buss bars are tight Use two well insulated wrenches for this task in order to avoid steering the buss bars 10 1 3 Controller Removal 1 Turn off the key switch 20 Figure 10 1 an...

Page 64: ...10 2 BL EZ30 0815 07 28 2019 Figure 10 1 Electrical System EZ30 19...

Page 65: ...sconnect 17 2 Remove the upper compartment covers as described in paragraph 5 2 3 Tag and disconnect harness 1 Figure 10 2 from key switch 20 Figure 10 1 4 Remove mounting nut and key switch 20 from b...

Page 66: ...ure with two screws 23 lock washers 26 and flat washers 27 2 Install the knob on the emergency disconnect 17 3 Reconnect harness 1 Figure 10 2 to emergency disconnect 17 Figure 10 1 4 Install upper co...

Page 67: ...BL EZ30 0815 07 28 2019 10 5 Figure 10 3 Wiring Cables EZ30 21...

Page 68: ...g and disconnect harness 3 Figure 10 2 from limit switch 10 Figure 10 4 5 Remove two screws 1 and limit switch 10 from bracket 2 10 1 17 2 Lift Limit Switch Installation 1 Position limit switch 10 Fig...

Page 69: ...0 2 PUMP MOTOR The pump motor is replaceable but not repairable Refer to paragraph 9 3 10 3 DRIVE MOTOR The drive motor exposed surfaces should be cleaned at least once a month to assure proper coolin...

Page 70: ...10 8 BL EZ30 0815 07 28 2019...

Page 71: ...BL EZ30 0815 07 28 2019 11 1 SECTION 11 OPTIONAL EQUIPMENT 11 1 Waterproof Compartment Cover Refer to Figure 12 7 for replacement parts for the waterproof compartment cover...

Page 72: ...11 2 BL EZ30 0815 07 28 2019 NOTES...

Page 73: ...BL EZ30 0815 07 28 2019 12 1 SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the EZ30 Lift Truck...

Page 74: ...12 2 BL EZ30 0815 07 28 2019 Figure 12 1 Steering Arm EZ30 1...

Page 75: ...T 1 10 0000 000677 00 BUSHING 2 11 1115 500001 00 BRACKET 1 12 0000 000989 00 SCREW M2 12 2 13 1115BT 310000 0A CONTROL HANDLE 1 14 1115 320000 00 CONTROL POD ASSEMBLY 1 Used up to Serial 427102394 14...

Page 76: ...12 4 BL EZ30 0815 07 28 2019 Figure 12 2 Control Head Used up to Serial Number 427102394 EZ30 2...

Page 77: ...LATWASHER 5 4 8 0000 000088 00 SCREW M4 8 2 9 0000 000122 00 LOCKWASHER 4 2 10 0000 000702 00 FLATWASHER 4 2 11 0000 000322 00 SCREW M8 25 2 12 0000 000159 00 LOCKWASHER 8 2 13 0000 000176 00 FLATWASH...

Page 78: ...12 6 BL EZ30 0815 07 28 2019 Figure 12 3 Control Head Used from Serial Number 427102395 R8486...

Page 79: ...15 340004 00 CONTROL KNOB LEFT SIDE 1 7 1220 520008 0C ACCELERATOR 1 8 0000 000323 00 SCREW M5 16 1 9 0000 000390 00 FLAT WASHER 5 1 10 1115 340007 00 WIRE HARNESS COVER 1 11 1115 520004 10 REVERSING...

Page 80: ...12 8 BL EZ30 0815 07 28 2019 Figure 12 4 Cap Assembly EZ30 3...

Page 81: ...T 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 00003...

Page 82: ...12 10 BL EZ30 0815 07 28 2019 Figure 12 5 Emergency Reverse Switch Assembly Used up to Serial Number 427102394 EZ30 4...

Page 83: ...os Part Number Description Qty Reqd Notes 1115 343000 00 B REVERSING SWITCH ASSEMBLY 1 With Switch 1 1120 343002 00 COVER 1 2 1120 343003 00 SPRING 2 3 1120 342005 00 PIN 2 4 1120 343001 0A BRACKET 1...

Page 84: ...12 12 BL EZ30 0815 07 28 2019 Figure 12 6 Transmission Motor Brake Assembly Used up to serial number 426150000 EZ30 5...

Page 85: ...1 Used from Serial E2116210 6 0000 000668 00 BEARING 30212 1 7 1115 200006 0A ROUND COVER PLATE 1 8 1115 210001 0C GEAR CASE 1 9 0000 000665 00 SCREW M4 45 3 10 1115 200007 00 CAP 1 11 0000 000386 00...

Page 86: ...12 14 BL EZ30 0815 07 28 2019 Figure 12 6 Transmission Motor Brake Assembly Continued Used up to serial number 426150000 EZ30 5...

Page 87: ...0000 00 MOTOR 1 Used from 09 05 2012 34 1115 240001 00 BRAKE LINING 1 35 1115 520012 00 BRAKE ASSEMBLY 1 36 1115 520018 00 SPEED REDUCTION SWITCH HARNESS 1 Only used when truck has Speed Reduction Swi...

Page 88: ...12 16 BL EZ30 0815 07 28 2019 Figure 12 7 Transmission Motor Brake Assembly Used from serial number 426150001 EZ30 5...

Page 89: ...to Serial Num ber 426200143 9a 1115 240003 0A SCREW M4x40 3 Used from Serial Num ber 426200144 10 1115 200007 00 CAP 1 11 0000 000386 00 SCRW M6 20 8 12 0000 000056 00 LOCKWASHER 6 8 13 0000 000013 00...

Page 90: ...12 18 BL EZ30 0815 07 28 2019 Figure 12 7 Transmission Motor Brake Assembly Continued Used from serial number 426150001 EZ30 5...

Page 91: ...5b 1115 520012 10 BRAKE ASSEMBLY 1 Used from Serial 427190827 36 1115 520018 00 SPEED REDUCTION SWITCH HARNESS 1 Only used when truck has Speed Reduction Switch 37 1115 700001 00 MOUNTING BASE 1 Only...

Page 92: ...12 20 BL EZ30 0815 07 28 2019 Figure 12 8 Compartment Cover EZ30 6...

Page 93: ...0000 000077 00 SCREW M6 12 4 Used from 10 25 2012 2 0000 000123 00 FLATWASHER 6 4 3 1115 120002 00 CHARGER CAP 1 4 1120 150004 00 SCREW M6 25 2 5 1115 120001 K0 UPPER COVER 1 Blue 5a 1115 120001 00 0...

Page 94: ...12 22 BL EZ30 0815 07 28 2019 Figure 12 9 Compartment Cover Waterproof EZ30 6A...

Page 95: ...1115 122001 00 WATERPROOF CHARGER CAP 1 4 1120 150004 00 SCREW 2 5 1115 120001 K0 COVER 1 Blue 5a 1115 120001 00 01 COVER 1 EP Red 5b 1115 120001 00 COVER 1 Big Joe Yellow 6 2214 150002 00 WASHER 2 8...

Page 96: ...12 24 BL EZ30 0815 07 28 2019 Figure 12 10 Load Backrest EZ30 22...

Page 97: ...K ASSEMBLY 1 11 1115 621000 K0 LOWER LINK ASSEMBLY 1 12 1115 600004 K0 BLOCK 2 13 0000 000321 00 SCREW M 8 20 2 14 0000 000739 00 SCREW M 6 20 12 9 4 20 0000 000109 00 SCREW M 8 16 4 21 0000 000176 00...

Page 98: ...12 26 BL EZ30 0815 07 28 2019 Figure 12 11 Guide Rails EZ30 23...

Page 99: ...00739 00 SCREW M 6 20 12 9 4 15 0000 000056 00 LOCKWASHER 6 40 16 0000 000380 00 FLATWASHER 6 40 17 1115 650000 K0 LEG R 1 18 1115 640000 K0 HINGE ASSEMBLY 6 19 1115 660000 K0 LEG L 1 25 1115 640000 K...

Page 100: ...12 28 BL EZ30 0815 07 28 2019 Figure 12 12 Compartment Used up to Serial Number 427190907 EZ30 9...

Page 101: ...d between 02 02 2012 427190907 4 0000 000123 00 FLATWASHER 6 2 5 1115 500011 00 WIRE CLAMP 1 Used between Serial E2120048 427190907 6 0000 000923 00 NUT M6 1 Used between Serial E2120048 427190907 7 1...

Page 102: ...12 30 BL EZ30 0815 07 28 2019 Figure 12 13 Compartment Used from Serial Number 427190908 DJ_0031...

Page 103: ...6 0000 000988 00 BOLT M6X30 1 7 1115 500011 0A WIRE CLAMP 1 8 3020 000000 56 SCREW M10 20 6 9a 1115 122000 D0 COVER 1 10 1115 500017 00 LIMIT SWITCH 1 12 0000 000923 00 NUT M6 1 13 0000 000373 00 FLAT...

Page 104: ...12 32 BL EZ30 0815 07 28 2019 Figure 12 14 Stabilizers Used up to Serial Number 427190907 EZ30 24...

Page 105: ...ion Qty Reqd Notes 3 1115 140000 KA BALANCE STAND L ASSEMBLY 1 Optional 4 1115 150000 KA BALANCE STAND R ASSEMBLY 1 Optional 5 1115 141000 KA BALANCE STAND L 1 Optional 6 1115 151000 KA BALANCE STAND...

Page 106: ...12 34 BL EZ30 0815 07 28 2019 Figure 12 15 Frame EX30 11...

Page 107: ...p to S N 424150330 7a 0000 001456 00 ROUND PIN 5 35 Used from S N 424150331 8 1115 110000 K0 FORK FRAME 1 9 1115 130002 K0 REAR PULL ROD SHAFT EZ 30 1 Used up to S N 427120607 9a 1115 130002 KA REAR P...

Page 108: ...12 36 BL EZ30 0815 07 28 2019 Figure 12 16 Lift Link Assembly EZ30 12...

Page 109: ...1 2012 7a 0000 000907 00 BUSHING 4 Used from 02 22 2012 8 1115 130005 4A WHEEL BRACKET 2 9 0000 000029 00 BUSHING 4 Used up to 02 21 2012 9a 0000 000908 00 BUSHING 4 Used from 02 22 2012 10 1115 13000...

Page 110: ...12 38 BL EZ30 0815 07 28 2019 Figure 12 17 Load Wheel EZ30 13...

Page 111: ...BL EZ30 0815 07 28 2019 12 39 LOAD WHEEL Pos Part Number Description Qty Reqd Notes 1115 133000 40 LOAD WHEEL ASSY 1 With Bearings 1 0000 000020 00 BEARING 2 2 1115 133002 40 POLY LOAD WHEEL 1...

Page 112: ...12 40 BL EZ30 0815 07 28 2019 Figure 12 18 Hydraulic System EZ30 14...

Page 113: ...INDER 1 Used from Serial 426192438 This cylinder does not have a Grease Fitting 3 0000 000705 00 BUSHING 2 4 0000 000013 00 GREASE FITTING M8 1 Only used up to Serial 426192437 5 0000 000044 00 WASHER...

Page 114: ...12 42 BL EZ30 0815 07 28 2019 Figure 12 19 Pump Motor Assy Used up to Serial Number 427180847 EZ30 15...

Page 115: ...PE 1 10 1115 560010 00 COUPLER 1 11 1115 560011 00 PUMP 1 12 1115 560012 00 WASHER 5 2 13 1115 560013 00 SCREW M5 70 2 14 1115 560014 00 SUCTION PIPE 1 15 1115 560015 00 OIL FILTER 1 16 1115 560016 00...

Page 116: ...12 44 BL EZ30 0815 07 28 2019 Figure 12 20 Pump Motor Assy Used from Serial Number 427180848 EZ30 15...

Page 117: ...6G20B 2 8 1115 560008 00 SCREW M3 8 1 9 1115 560009 00 RETURN PIPE 1 10 1115 560010 00 COUPLER 1 11 1115 560011 00 PUMP 1 12 1115 560012 00 WASHER 5 2 13 1115 560013 00 SCREW M5 70 2 14 1115 560014 0...

Page 118: ...12 46 BL EZ30 0815 07 28 2019 Figure 12 21 Lift Cylinder Used up to serial E2017219 EZ30 16...

Page 119: ...15 QSYG SEAL KIT FOR LIFT CYLINDER 1 Includes Pos 2 3 7 1 1115 410001 00 PISTON ROD 1 2 0000 000672 00 RING WIPER 40 48 5 6 5 1 3 0000 000673 00 O RING 45 3 1 1 4 1115 410002 00 CAP 1 5 1115 411000 00...

Page 120: ...12 48 BL EZ30 0815 07 28 2019 Figure 12 22 Lift Cylinder Used for serial s between E2017220 E2116209 EZ30 17...

Page 121: ...s 1115 410000 0A LIFT CYLINDER ASSEMBLY 1115 QSYG SEAL KIT FOR LIFT CYLINDER 1 Includes Pos 2 3 7 1 1115 410001 0A PISTON ROD 1 2 0000 000672 00 RING WIPER 40 48 5 6 5 1 3 0000 000673 00 O RING 45 3 1...

Page 122: ...12 50 BL EZ30 0815 07 28 2019 Figure 12 23 Lift Cylinder Used for serial from E2116210 EZ30 18...

Page 123: ...EMBLY 1 1115 QSYG SEAL KIT FOR LIFT CYLINDER 1 Includes Pos 2 3 7 1 1115 410001 0B PISTON ROD 1 2 0000 000672 00 RING WIPER 40 48 5 6 5 1 3 0000 000673 00 O RING 45 3 1 1 4 1115 410002 0B CAP 1 5 1115...

Page 124: ...12 52 BL EZ30 0815 07 28 2019 Figure 12 24 Electrical System EZ30 19...

Page 125: ...1115 500016 00 KEY 2 WAY SWITCH 2 Used from serial E20120048 8 0000 000666 00 SCREW M3 8 2 9 1115 500006 10 CHARGER CABLE 1 10 0000 000129 00 SCREW M6 16 2 11 1120 540001 00 B FUSE STAND 1 12 1115 510...

Page 126: ...12 54 BL EZ30 0815 07 28 2019 Figure 12 24 Electrical System Continued EZ30 19...

Page 127: ...al E2120047 20b 1115 520019 0A 2 WAY SWITCH 1 Used from Serial E20120048 21 1115 520015 00 BUZZER ASSEMBLY 1 22 1115 520007 00 FAN ASSEMBLY 1 23 0000 000616 00 SCREW M5 10 2 24 0000 000194 00 FLATWASH...

Page 128: ...12 56 BL EZ30 0815 07 28 2019 Figure 12 25 Wiring Harness NOT used when 3 Way Key Switch EZ30 20...

Page 129: ...500010 00 FUSE 10A 1 3 1115 520002 0B DRIVING WIRE HARNESS 1 Used up to Serial E2120047 it has an extra port that is not being used 3a 1115 520002 1F DRIVING WIRE HARNESS 1 Used from Serial E2120048 a...

Page 130: ...12 58 BL EZ30 0815 07 28 2019 Figure 12 26 Wiring Harness Only used when 3 Way Key Switch EZ30 25...

Page 131: ...RNESS 1 2 1120 500010 00 FUSE 10A 1 3 1115 520002 00 DRIVE WIRE HARNESS 1 4 1115 520016 00 PUMP CONTACTOR WIRE HAR NESS 1 Only used on Serial s E2013089 E2013090 E2013091 E2013092 E2013117 E2013118 E2...

Page 132: ...12 60 BL EZ30 0815 07 28 2019 Figure 12 27 Wiring Cables EZ30 21...

Page 133: ...K 2 Used from Serial E2219246 11 0000 000485 00 SCREW M4 16 2 12 1115 231000 00 BRACKET 1 13 0000 000108 00 NUT M6 2 Used up to 12 12 2013 14 0000 000056 00 LOCKWASHER 6 2 Used up to 12 12 2013 15 000...

Page 134: ...Big Lift LLC...

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