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Big Joe EZ30 Operation, Maintenance, Repair Parts List

Self-propelled pallet lift truck
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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 Parts List
Big Lift LLC
MANUAL NO. BL-EZ30-0815 - 07-28-2019
www.bigjoeforklifts.com

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Summary of Contents for Big Joe EZ30

  • Page 1 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 Parts List Big Lift LLC MANUAL NO. BL-EZ30-0815 - 07-28-2019 www.bigjoeforklifts.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    HYDRAULIC PUMP, MOTOR, AND RESER- 4-2.7. DIAGNOSTICS AND TROUBLESHOOTING. 4- VOIR ASSY9-2 9-3.1. REMOVAL............ 9-2 4-2.8. PROGRAMMER DIAGNOSTICS ....4-7 9-3.2. DISASSEMBLY AND REASSEMBLY..9-2 9-3.3. INSTALLATION..........9-2 9-3.4. LIFT CYLINDER........... 9-5 STEERING ARM, CONTROL HEAD AND COMPARTMENT BL-EZ30-0815 - 07-28-2019...

  • Page 4: List Of Illustrations

    Figure Page Figure Page NAME PLATE............1-1 LIFT CYLINDER . EZ30 LIFT TRUCK ..........1-1 (SERIAL #’S E2017220 TO E2116209)....9-6 SAMPLE OF OPERATOR CHECK LIST....2-3 LIFT CYLINDER FORWARD/REVERSE CONTROL ....... 2-4 (SERIAL #’S FROM E2116210)......9-7 PUSHBUTTON SWITCHES........2-4 10-1 ELECTRICAL SYSTEM ........

  • Page 5: List Of Tables

    TABLE OF CONTENTS LIST OF TABLES Table Page Table Page OPERATOR CHECKS ..........2-2 LUBRICATION CHART .......... 3-6 MONTHLY AND QUARTERLY INSPECTION TROUBLESHOOTING CHART ......4-1 AND SERVICE CHART ..........3-1 LED CODES............4-7 RECOMMENDED LUBRICANTS ......3-5 TROUBLESHOOTING CHART ......4-8 BL-EZ30-0815 - 07-28-2019...
  • Page 6 TABLE OF CONTENTS - Continued BL-EZ30-0815 - 07-28-2019...

  • Page 7: Introduction

    The reversible AC motor propels the lift truck in for- ward or reverse direction throughout the available R6209 speed range. The EZ30 lift truck can be driven with Figure 1-1 Name Plate EZ30-7 Figure 1-2 . EZ30 Lift Truck...

  • Page 8: Safety Features

    1-3. SAFETY FEATURES. • Handle to provide a firm hand hold for operator. The EZ30 is designed and engineered to provide max- • Flow control valve regulates maximum lowering imum safety for operator and payload. Some of the speed within prescribed limits.

  • Page 9: Operation2-1

    This section gives detailed operating instructions for load or lifting mechanism trailing. the EZ30 lift truck. The instructions are divided into the various phases of operations, such as operating lift, • Do not overload truck. Check nameplate for load driving, and stopping.

  • Page 10: Operator Checks

    Check that battery can be control head operate in all disconnect disconnected and recon- speed ranges in forward and nected. Check for connector reverse and that belly button damage. switch functions. Battery charge Check the battery indicator. BL-EZ30-0815 - 07-28-2019...
  • Page 11 R6479 Figure 2-1 Sample of Operator Check List BL-EZ30-0815 - 07-28-2019...

  • Page 12: General Control Operation

    Deadman braking occurs is being driven toward the operator, the switch when the handle is released and spring action raises changes the direction of the lift truck. steering arm to the upright position. BL-EZ30-0815 - 07-28-2019...

  • Page 13: Steering Arm Gas Spring

    2-9. BACKREST. Disconnect and the key switch. Charge batteries as necessary. Refer to battery care instructions, SEC- An adjustable load backrest (Figure 12-8) is incorpo- TION 3. rated. Backrest (3) is adjustable to 46” forks for stan- BL-EZ30-0815 - 07-28-2019...
  • Page 14 NOTES BL-EZ30-0815 - 07-28-2019...

  • Page 15: Planned Maintenance3-1

    3-3.1. General A voltage check from battery connector terminal to The EZ30 may be equipped with maintenance free or battery case should indicate near zero volts. Typically, industrial wet cell batteries. however, the sum of the voltages at both terminals will The care and maintenance of the battery is very equal battery volts.

  • Page 16: Safety Rules

    Gas formed during charging amount of gasses be released from the battery. Also, is highly explosive and can cause seri- being a valve regulated battery, it never requires ous injury. watering. BL-EZ30-0815 - 07-28-2019...

  • Page 17: Charging Batteries

    NOT attempt to charge the batteries. Contact appropriate personnel for repairs to be made. Pull the charger cord out of the top cover (Figure 3-1) and connect to the appropriate power supply. R6757 Figure 3-1 Battery Charging R6115 BL-EZ30-0815 - 07-28-2019...

  • Page 18: Batteries Replacement

    Figure 3-6 Cover Removal Pull electrical panel (5, Figure 3-5) a little out. Install in the reverse order of remove. Turn the electrical panel to the direction as shown in Figure 3-5 until it is clear of the bat- teries. BL-EZ30-0815 - 07-28-2019...

  • Page 19: Lubrication

    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-EZ30-0815 - 07-28-2019...
  • Page 20 Hydraulic Reservoir No. 3 With lift carriage fully lowered, fill Capacity-1 quarts reservoir with hydraulic oil to 1 inch below opening Lift Linkage Fittings* No. 2 Pressure lubricate. * Raise lift carriage to gain access to grease fittings. BL-EZ30-0815 - 07-28-2019...

  • Page 21: General

    Defective electric brake. Replace brake. 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-EZ30-0815 - 07-28-2019...

  • Page 22: Troubleshooting Chart

    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. BL-EZ30-0815 - 07-28-2019...
  • Page 23 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-EZ30-0815 - 07-28-2019...

  • Page 24: Controller Troubleshooting

    I7090 open. Figure 4-2. Hand Held Programmer Do not stand, or allow anyone else to stand directly in front of or behind the vehicle during the tests. BL-EZ30-0815 - 07-28-2019...
  • Page 25 The vehicle should be disabled and a fault indi- motor. The motor should run proportionally faster cated. with increasing throttle. If not, refer to Paragraph 4-2.7. BL-EZ30-0815 - 07-28-2019...

  • Page 26: Diagnostic History

    Repeat the last three steps as necessary until the Leave the key switch on and remove the in-line vehicle is operational. fuse wire. The vehicle status should continue to remain off. Refer to the Table 4-3 for suggestions covering a wide range of possible faults. BL-EZ30-0815 - 07-28-2019...
  • Page 27 Larger values represent slower response. Rev Decel High Speed 0.5 sec. 0.5 sec. Note: Allowable range is restricted by Rev Decel Low Speed setting. BL-EZ30-0815 - 07-28-2019...
  • Page 28 Sets the speed at which a gentler deceleration is initiated when the throttle is released to neutral; larger values start the soft stop deceleration sooner. Soft Stop Speed BL-EZ30-0815 - 07-28-2019...
  • Page 29 Note: For this parameter to apply, a speed limit pot must be installed in parallel with the throttle and the Speed Limit Pot Rev Min Speed parameter must be programmed On (see Throttle menu). Mode 1 Mode 2 BL-EZ30-0815 - 07-28-2019...
  • Page 30 HPD fault is not cleared within 10 seconds, a wiring fault is declared and a power cycle is required. This parameter is used to enable/disable the speed limit pot. If no speed limit pot is used, set Speed Limit Pot to Off. Speed Limit Pot 4-10 BL-EZ30-0815 - 07-28-2019...
  • Page 31 The Boost Current parameter defines the motor current limit during the boost period This parameter sets the maximum time that the boost current is Boost Time 5.0 sec. 0.0 sec. allowe BL-EZ30-0815 - 07-28-2019 4-11...
  • Page 32 Reverse Beep switches, the horn will sound when the reverse switch is acti- vated. Sets the reverse beep to be a constant tone (when pro- Beep Constant grammed On) or a 1Hz pulse (when programmed Off). 4-12 BL-EZ30-0815 - 07-28-2019...
  • Page 33 Note: Allowable range is restricted by the Full Voltage setting. Voltage, when a charger is connected, above which the battery is considered finished charging. Note: Allowable range is restricted by the Start Charge setting. Full Charge Voltage 28.2V 28.2V BL-EZ30-0815 - 07-28-2019 4-13...
  • Page 34 Sets the motor load compensation after the throttle is released to neutral and the speed is estimated to be near zero. Higher values provide more hill-holding force. Anti-Rollback Comp Note: Allowable range is restricted by the IR Comp setting. 4-14 BL-EZ30-0815 - 07-28-2019...
  • Page 35 (90A Only) the vehicle will stop abruptly. Off =When the emergency stop button is pressed, the battery is disconnected and the vehicle will decelerate for a short dis- tance before it fully stops. BL-EZ30-0815 - 07-28-2019 4-15...
  • Page 36 Table 4-3 Troubleshooting Chart 4-16 BL-EZ30-0815 - 07-28-2019...
  • Page 37 R6774 Figure 4-3 Wiring Diagram BL-EZ30-0815 - 07-28-2019 4-17...
  • Page 38 NOTES 4-18 BL-EZ30-0815 - 07-28-2019...

  • Page 39: Steering Arm, Control Head And Compartment

    5-2) as described in paragraph 5-1.3. 5-1.1. Control Head Removal Disconnect harness (17, Figure 5-1) from potenti- Turn off the key switch (20, Figure 12-20) and ometer (21, Figure 5-2). emergency disconnect (17). EZ30-1 Figure 5-1 Steering Arm BL-EZ30-0815 - 07-28-2019...
  • Page 40 Remove two screws (5), two washers (7) and two flat washers (6). Remove two screws (11), two washers (12) and two flat washers (13). Remove the control head and handle (19). EZ30-2 Figure 5-2 Control Head BL-EZ30-0815 - 07-28-2019...

  • Page 41: Control Head Installation

    Reconnect harness (15, Figure 5-1) to emergency Remove screw (4), washer (3) and control knob reverse switch (26, Figure 5-2). (14) from other side of potentiometer (21). 10. Install the cap assembly as described in para- graph 5-1.4. BL-EZ30-0815 - 07-28-2019...

  • Page 42: Horn Switch Replacement

    (1) and secure with three screws (11). Remove three screws (11, Figure 5-4), bracket Install the cap assembly as described in para- (10c) and two springs (10b). graph 5-1.4. Remove two pins (10a) and switch from bracket (10c). BL-EZ30-0815 - 07-28-2019...
  • Page 43 Remove pin (6) securing buttons (2 and 3 or 7 graph 5-1.4. and 8) to bracket (5 or 9) and remove the buttons. Remove two pins (6), two switches and four springs (4) from bracket (5 or 9). BL-EZ30-0815 - 07-28-2019...

  • Page 44: Upper Compartment Covers

    Figure 5-5). tion the cap on cover (5, Figure 5-5). Remove two screws (4), two washers (6) and Turn on the key switch (20, Figure 12-20) and cover (5). emergency disconnect (17). EZ30-6 Figure 5-5 Compartment Cover BL-EZ30-0815 - 07-28-2019...

  • Page 45: Lower Compartment Covers

    5-1) is Figure 12-21 Figure 12-22). replaced while the steering arm (13) is in the upright position. Install steering arm gas return spring as described in paragraph Secure the steering arm (13) in the upright posi- 5-4.1. tion. BL-EZ30-0815 - 07-28-2019...
  • Page 46 NOTES BL-EZ30-0815 - 07-28-2019...

  • Page 47: Brake Servicing6-1

    Block load wheels. Remove load wheel blocks and check operation. Remove the lower compartment covers as Install lower compartment covers described in paragraph 5-3. described in paragraph 5-3. Disconnect electric brake (35, Figure 12-5) from harness (3). BL-EZ30-0815 - 07-28-2019...
  • Page 48 EZ30-5 Figure 6-1 Transmission, Motor, Brake Mounting BL-EZ30-0815 - 07-28-2019...

  • Page 49: Transmission, Drive Wheel, Load Wheel7-1

    Install new drive wheel in reverse order of Free housing (8) from frame (5). removal. Remove plate (7) from housing (8). 10. Install lower compartment covers described in paragraph 5-3. 10. Install new transmission by reversing the steps above. BL-EZ30-0815 - 07-28-2019...
  • Page 50 EZ30-5 Figure 7-1 Transmission, Motor, Brake Mounting BL-EZ30-0815 - 07-28-2019...

  • Page 51: Load Wheel

    Big Lift LLC recommends that both load wheel assemblies be replaced at the same time. This ensures level and safe operation of the lift truck. EZ30-13 Figure 7-2 Wheel Assembly BL-EZ30-0815 - 07-28-2019...
  • Page 52 NOTES BL-EZ30-0815 - 07-28-2019...

  • Page 53: Elevation System Servicing8-1

    8-1), transmission and at Remove pins (7) and remove shafts (6). tips of the forks. Lower link assembly to the floor. Turn off the key switch (20, Figure 12-20) and emergency disconnect (17). EZ30-11 Figure 8-1 Frame BL-EZ30-0815 - 07-28-2019...

  • Page 54: Repair

    Remove bushings (3) from clevises (5) if replace- ment is necessary. Turn on the key switch (20, Figure 12-20) and emergency disconnect (17). Install reassemble by reversing the steps above. EZ30-12 Figure 8-2 Lift Linkage Assembly BL-EZ30-0815 - 07-28-2019...

  • Page 55: Hydraulic System Servicing9-1

    Lower forks fully. maintenance on the hydraulic system. Turn off the key switch (20, Figure 12-20) and emergency disconnect (17). Remove the upper compartment cover (5, Figure 9-1) as described in paragraph 5-2. EZ30-6 Figure 9-1 Compartment Cover BL-EZ30-0815 - 07-28-2019...

  • Page 56: Hydraulic And Electrical Assembly

    Use hydraulic oil listed in emergency disconnect (17). Table 3-2. Install the upper compartment cover as described Turn on the key switch (20, Figure 12-20) and in paragraph 5-2. emergency disconnect (17). BL-EZ30-0815 - 07-28-2019...
  • Page 57 Table 3-2. Check level of hydraulic oil. Hydraulic oil must be Install the compartment cover as described in 1 inch below opening. If required, add hydraulic paragraph 5-2. EZ30-14 Figure 9-2 Hydraulic System BL-EZ30-0815 - 07-28-2019...
  • Page 58 EZ30-15 Figure 9-3 Pump & Motor Assy BL-EZ30-0815 - 07-28-2019...
  • Page 59 EZ30-16 Figure 9-4 Lift Cylinder Replace guide ring (6), seal ring (7), wiper ring (2) (Up to Serial # E2017219) and O-ring (3). Coat all parts with hydraulic oil (Table 3-2). BL-EZ30-0815 - 07-28-2019...
  • Page 60 (1). Insert piston rod (1) into body (5). 10. Install wiper (2) and O-ring (3) in gland nut (4). 11. Install gland nut (4) in body (5). EZ30-17 Figure 9-5 Lift Cylinder (Serial #’s E2017220 to E2116209) BL-EZ30-0815 - 07-28-2019...
  • Page 61 10. Insert piston rod (1) and bushing (8) into body (5). 11. Install wiper (2) and O-ring (3) in guide ring (4). 12. Install guide ring (4) in body (5). 13. Install block (9). EZ30-18 Figure 9-6 Lift Cylinder (Serial #’s from E2116210) BL-EZ30-0815 - 07-28-2019...
  • Page 62 Fill the hydraulic reservoir. Hydraulic oil must be 1 Table 3-2. inch below opening. If required, add hydraulic oil Install the compartment cover as described in to bring to proper level. Use hydraulic oil listed in paragraph 5-2. Table 3-2. BL-EZ30-0815 - 07-28-2019...

  • Page 63: Electrical Components10-1

    Figure 10-1) and Install upper compartment covers as described in emergency disconnect (17). paragraph 5-2. Remove the upper compartment covers as Turn on the key switch (20) and emergency dis- described in paragraph 5-2. connect (17). BL-EZ30-0815 - 07-28-2019 10-1...
  • Page 64 EZ30-19 Figure 10-1 Electrical System 10-2 BL-EZ30-0815 - 07-28-2019...

  • Page 65: 10-1.7.Cooling Fan Removal

    Turn off the key switch (20, Figure 10-1) and (17) emergency disconnect (17). Remove two screws (23), lock washers (26), flat Remove the upper compartment covers as washers (27) and remove emergency disconnect described in paragraph 5-2. (17) from bracket (6). BL-EZ30-0815 - 07-28-2019 10-3...

  • Page 66: 10-1.16.Emergency Disconnect Installation

    (6) and secure with two screws (23), paragraph 5-2. lock washers (26) and flat washers (27). Turn on the key switch (20) and emergency dis- Install the knob on the emergency disconnect (17) connect (17). EZ30-20 Figure 10-2 Wiring Harness 10-4 BL-EZ30-0815 - 07-28-2019...
  • Page 67 EZ30-21 Figure 10-3 Wiring Cables BL-EZ30-0815 - 07-28-2019 10-5...

  • Page 68: 10-1.17.Lift Limit Switch

    Install upper compartment covers as described in paragraph 5-2. Tag and disconnect harness (3, Figure 10-2) from limit switch (10, Figure 10-4). Turn on the key switch (20, Figure 10-1) and emergency disconnect (17). EZ30-9 Figure 10-4 Compartment 10-6 BL-EZ30-0815 - 07-28-2019...

  • Page 69: 10-1.18.Lift Limit Switch

    (3). 10-2.PUMP MOTOR. Install upper compartment covers as described in paragraph 5-2. The pump motor is replaceable but not repairable. Refer to paragraph 9-3. Turn on the key switch (20, Figure 10-1) and emergency disconnect (17). BL-EZ30-0815 - 07-28-2019 10-7...
  • Page 70 10-8 BL-EZ30-0815 - 07-28-2019...

  • Page 71: Optional Equipment11-1

    SECTION 11 OPTIONAL EQUIPMENT 11-1.Waterproof Compartment Cover Refer to Figure 12-7 for replacement parts for the waterproof compartment cover. BL-EZ30-0815 - 07-28-2019 11-1...
  • Page 72 NOTES 11-2 BL-EZ30-0815 - 07-28-2019...
  • Page 73 SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the EZ30 Lift Truck. BL-EZ30-0815 - 07-28-2019 12-1...
  • Page 74 EZ30-1 Figure 12-1 Steering Arm 12-2 BL-EZ30-0815 - 07-28-2019...
  • Page 75 0000-000151-00 SCREW M8×25 426193483 Used up to Serial # 0000-000063-00 LOCKWASHER Ø10 E2219053 Used from Serial # 0000-001101-00 SCREW M8×20 E2219054 Used from Serial # 1115-300003-00 PROXIMITY BLOCK E2219054 Used from Serial # 1115-300004-00 SCREW E2219054 BL-EZ30-0815 - 07-28-2019 12-3...
  • Page 76 EZ30-2 Figure 12-2 Control Head - Used up to Serial Number 427102394 12-4 BL-EZ30-0815 - 07-28-2019...
  • Page 77 LOCKWASHER Ø8 0000-000176-00 FLATWASHER Ø8 1120-340003-00 CONTROL KNOB LEFT SIDE 1115-343000-00-B BELLY BUTTON ASSEMBLY With wire harness 0000-000004-00 SCREW M5×12 0000-000035-00 SCREW M5×20 1120-340002-00 COVER 1120-341000-00 HANDLE 1120-340001-00 CONTROL HEAD BRACKET 1220-520008-0C ACCELERATOR ASSEMBLY 0000-000010-00 SCREW M5×6 BL-EZ30-0815 - 07-28-2019 12-5...
  • Page 78 R8486 Figure 12-3 Control Head - Used from Serial Number 427102395 12-6 BL-EZ30-0815 - 07-28-2019...
  • Page 79 FLAT WASHER Ø5 1115-340007-00 WIRE HARNESS COVER 1115-520004-10 REVERSING SWITCH WITH WIRE 0000-000989-00 SCREW M2×12 1115-340003-00 COVER 1121-310004-00 SPRING 1115-340002-10 COVER 0000-000322-00 SCREW M8×25 0000-000159-00 LOCK WASHER Ø8 0000-000176-00 FLAT WASHER Ø8 1115-340001-00 WASHER 0000-000035-00 SCREW M5×20 BL-EZ30-0815 - 07-28-2019 12-7...
  • Page 80 EZ30-3 Figure 12-4 Cap Assembly 12-8 BL-EZ30-0815 - 07-28-2019...
  • Page 81 HORN BUTTON ASSEMBLY 0000-000039-00 SCREW ST3.5×9.5 0000-000490-00 HARNESS CLAMP 1120-342200-00 LIFT AND LOWER BOX(R) ASSY. 1120-342100-00 LIFT AND LOWER BOX(L) ASSY. 1220-520006-0C BUTTONS ASSEMBLY 1220-560002-00 MICRO SWITCH II 1120-342002-00 HORN BUTTON 1120-342005-00 1120-342003-00 SPRING 1120-342004-00 BUTTON BRACKET BL-EZ30-0815 - 07-28-2019 12-9...
  • Page 82 EZ30-4 Figure 12-5 Emergency Reverse Switch Assembly - Used up to Serial Number 427102394 12-10 BL-EZ30-0815 - 07-28-2019...
  • Page 83 EMERGENCY REVERSE SWITCH ASSEMBLY - USED UP TO SERIAL NUMBER 427102394 Qty. Pos. Part Number Description Notes Reqd. 1115-343000-00-B REVERSING SWITCH ASSEMBLY With Switch 1120-343002-00 COVER 1120-343003-00 SPRING 1120-342005-00 1120-343001-0A BRACKET 1120-343004-00 1115-520004-0A REVERSING SWITCH WIRE 1220-560002-00 INCHING SWITCH II BL-EZ30-0815 - 07-28-2019 12-11...
  • Page 84 EZ30-5 Figure 12-6 Transmission, Motor & Brake Assembly - Used up to serial number 426150000 12-12 BL-EZ30-0815 - 07-28-2019...
  • Page 85 Includes two gears pos. 1115-GSX-10 GEAR SET # 19 0000-000680-00 BEARING 16003Z Includes two gears 1115-GSX-20 GEAR RING SET pos. # 21 0000-000660-00 KEY 5×5×18 0000-000154-00 SCREW M8×35 Used up to 08-05-2012 0000-000026-00 SCREW M8×30 Used from 09-05-2012 BL-EZ30-0815 - 07-28-2019 12-13...
  • Page 86 EZ30-5 Figure 12-6 Transmission, Motor & Brake Assembly - Continued - Used up to serial number 426150000 12-14 BL-EZ30-0815 - 07-28-2019...

  • Page 87: Mounting

    FLATWASHER Ø8 1115-230001-00 BRUSH Used up to 09-04-2012 1115-250001-00 BRUSH Used from 09-05-2012 1115-200000-00 DRIVING ASSEMBLY Includes pos. # 8-35 0000-000004-00 SCREW M5×12 1115-231000-00 BRACKET 1115-250003-00 BRUSH HOLDER Used from 09-05-2012 1115-250002-00 BRUSH SPRING Used from 09-05-2012 BL-EZ30-0815 - 07-28-2019 12-15...
  • Page 88 EZ30-5 Figure 12-7 Transmission, Motor & Brake Assembly - Used from serial number 426150001 12-16 BL-EZ30-0815 - 07-28-2019...
  • Page 89 BEARING 16003Z Includes two gears 1115-GSX-20 GEAR RING SET pos. # 21 0000-000660-00 KEY 5×5×18 0000-000026-00 SCREW M8×30 0000-000159-00 LOCKWASHER Ø8 Used from Serial Num- 0000-001788-00 OIL SEAL Ø155×173×10 ber 426150001 3020-010000-91 SCREW M5×25 0000-000206-00 LOCKWASHER Ø5 BL-EZ30-0815 - 07-28-2019 12-17...
  • Page 90 EZ30-5 Figure 12-7 Transmission, Motor & Brake Assembly - Continued - Used from serial number 426150001 12-18 BL-EZ30-0815 - 07-28-2019...
  • Page 91 1115-200000-A0 DRIVE ASSEMBLY Includes pos. # 8-35 0000-000004-00 SCREW M5×12 1115-231000-00 BRACKET 1115-250003-00 BRUSH HOLDER 1115-250002-00 BRUSH SPRING 1115-200001-A0 INNER RIM Used from Serial Num- 1115-240002-0A SEAL ber 426200144 Used from Serial # 1115-200020-00 PLATE 427190827 BL-EZ30-0815 - 07-28-2019 12-19...
  • Page 92 EZ30-6 Figure 12-8 Compartment Cover 12-20 BL-EZ30-0815 - 07-28-2019...
  • Page 93 SCREW M6×12 Used from 10-25-2012 0000-000123-00 FLATWASHER Ø6 1115-120002-00 CHARGER CAP 1120-150004-00 SCREW M6×25 1115-120001-K0 UPPER COVER Blue 1115-120001-00-01 UPPER COVER EP Red 1115-120001-00 UPPER COVER Big Joe Yellow 2214-150002-00 WASHER 1115-500013-00 WIRE CLAMP Used from 10-25-2012 BL-EZ30-0815 - 07-28-2019 12-21...
  • Page 94 EZ30-6A Figure 12-9 Compartment Cover - Waterproof 12-22 BL-EZ30-0815 - 07-28-2019...
  • Page 95 COVER Big Joe Yellow 1115-120001-00 COVER 2214-150002-00 WASHER 1115-500013-00 WIRE CLAMP 1115-122101-00 WATERPROOF COVER PLATE 1115-122102-00 WATERPROOF COVER RING WATER PROOF 2-WAY KEY 1115-122002-00-B SWITCH ASSY. MOLDED PLASTIC HEAD KEY W. 11a 1115-122002-00 RUBBER WATERPROOF COVER BL-EZ30-0815 - 07-28-2019 12-23...
  • Page 96 EZ30-22 Figure 12-10 Load Backrest 12-24 BL-EZ30-0815 - 07-28-2019...

  • Page 97: Load Backrest

    LOAD BACKREST FRAME ASSEMBLY 1115-630000-K0-B LOAD BACKREST ASSEMBLY 1115-681000-K0 BRACKET 0000-000070-00 SCREW 0000-000054-00 Not shown in picture 901803 LOAD RESTRAINT KIT BUCKLE FOR LOAD RESTRAINT BELT Included in pos. # 28 0000-000030-00 SCREW 0000-000054-00 Not shown in picture BL-EZ30-0815 - 07-28-2019 12-25...
  • Page 98 EZ30-23 Figure 12-11 Guide Rails 12-26 BL-EZ30-0815 - 07-28-2019...

  • Page 99: Guide Rails

    Notes Reqd. 0000-000739-00 SCREW M 6×20 12.9 0000-000056-00 LOCKWASHER Ø6 0000-000380-00 FLATWASHER Ø6 1115-650000-K0 LEG R 1115-640000-K0 HINGE ASSEMBLY 1115-660000-K0 LEG L Includes pos. 14-19. 1115-640000-K0-B LEG ASSEMBLY Excludes pos. 27 1118-600001-00 SPACER A.R. As required BL-EZ30-0815 - 07-28-2019 12-27...
  • Page 100 EZ30-9 Figure 12-12 Compartment - Used up to Serial Number 427190907 12-28 BL-EZ30-0815 - 07-28-2019...
  • Page 101 LIMIT SWITCH E2120048 - 427190907 0000-000007-00 FLATWASHER Ø10 Used between Serial # 1115-500014-00 BRACKET E2120048 - 427190907 Used between Serial # 0000-000988-00 BOLT M6×30 E2120048 - 427190907 Used between Serial # 0000-000063-00 LOCKWASHER Ø10 E2221099 - 427190907 BL-EZ30-0815 - 07-28-2019 12-29...
  • Page 102 DJ_0031 Figure 12-13 Compartment - Used from Serial Number 427190908 12-30 BL-EZ30-0815 - 07-28-2019...
  • Page 103 COVER 1115-500017-00 LIMIT SWITCH 0000-000923-00 NUT M6 0000-000373-00 FLATWASHER Ø12 0000-000630-00 NUT M12 1115-160000-B0 CASTER 0000-000063-00 LOCKWASHER Ø10 0000-000007-00 FLATWASHER Ø10 1115-140005-K0 INSERT FOR ADJ. STABILITY BAR Optional 0000-001102-00 SCREW M8×50 Optional 0000-000740-00 NUT M8 Optional BL-EZ30-0815 - 07-28-2019 12-31...
  • Page 104 EZ30-24 Figure 12-14 Stabilizers - Used up to Serial Number 427190907 12-32 BL-EZ30-0815 - 07-28-2019...
  • Page 105 STABILIZERS - Used up to Serial Number 427190907 Qty. Pos. Part Number Description Notes Reqd. 1115-140000-KA BALANCE STAND-L ASSEMBLY Optional 1115-150000-KA BALANCE STAND-R ASSEMBLY Optional 1115-141000-KA BALANCE STAND-L Optional 1115-151000-KA BALANCE STAND-R Optional 1115-140005-K0 NYLON INSERT 0000-001102-00 SCREW M8×50 0000-000740-00 NUT M8 BL-EZ30-0815 - 07-28-2019 12-33...
  • Page 106 EX30-11 Figure 12-15 Frame 12-34 BL-EZ30-0815 - 07-28-2019...
  • Page 107 Used from Serial # 0000-001458-00 ROUND PIN Ø4×45 424150331 1115-130001-00 SHORT SHAFT Used up to Serial # 0000-000032-00 SCREW M6×25 E2116209 Used from Serial # 0000-000155-00 SCREW M10×40 E2116210 0000-000013-00 GREASE FITTING M8 Used from S/N 427120608 BL-EZ30-0815 - 07-28-2019 12-35...
  • Page 108 EZ30-12 Figure 12-16 Lift Link Assembly 12-36 BL-EZ30-0815 - 07-28-2019...

  • Page 109: Lift Link Assembly

    LIFT LINK ASSEMBLY Qty. Pos. Part Number Description Notes Reqd. 1115-131000-K0 DOWN LINK EZ30 0000-000294-00 SNAP RING FOR SHAFT Ø25 0000-000675-00 BUSHING Used up to 02-21-2012 0000-000906-00 BUSHING Used from 02-22-2012 0000-000101-00 NUT M22×1.5 1115-132100-00 CONNECTOR 1115-132000-K0 LONG LINK ASSEMBLY...
  • Page 110 EZ30-13 Figure 12-17 Load Wheel 12-38 BL-EZ30-0815 - 07-28-2019...

  • Page 111: Load Wheel

    LOAD WHEEL Qty. Pos. Part Number Description Notes Reqd. 1115-133000-40 LOAD WHEEL ASSY. With Bearings 0000-000020-00 BEARING 1115-133002-40 POLY LOAD WHEEL BL-EZ30-0815 - 07-28-2019 12-39...
  • Page 112 EZ30-14 Figure 12-18 Hydraulic System 12-40 BL-EZ30-0815 - 07-28-2019...

  • Page 113: Hydraulic System

    Used up to Serial # 1115-510001-00 PUMP & MOTOR ASSEMBLY 427180847 Used from Serial # 1115-430000-0A PUMP & MOTOR ASSEMBLY 427180848 0000-000159-00 LOCKWASHER Ø8 Used between Serial # 1115-511004-0A WASHER 425190003 - 4281000747 1115-400002-0B BLOCK Used from 2012-04-12 BL-EZ30-0815 - 07-28-2019 12-41...
  • Page 114 EZ30-15 Figure 12-19 Pump & Motor Assy - Used up to Serial Number 427180847 12-42 BL-EZ30-0815 - 07-28-2019...
  • Page 115 1115-560019-00 O-RING Ø85×3.0 1115-560020-00 TANK 1115-560021-00 SCREW 3/8 1115-560022-00 WASHER G3/8 1115-560024-00 AIR CLEANER Used up to Serial 1115-561001-00 BRUSH ASSEMBLY E2313715 Used between Serial # 1115-561001-0A BRUSH E2313716 - 427180847 1115-560025-00 O-RING 16.36X2.21 1115-560026-00 PLUG BL-EZ30-0815 - 07-28-2019 12-43...
  • Page 116 EZ30-15 Figure 12-20 Pump & Motor Assy - Used from Serial Number 427180848 12-44 BL-EZ30-0815 - 07-28-2019...
  • Page 117 1115-560013-00 SCREW M5×70 1115-560014-00 SUCTION PIPE 1115-560015-00 OIL FILTER 1115-560016-00 CHECK VALVE 1115-560017-00 SOLENOID VALVE 1115-560018-00 CLAMP Ø100 1115-560019-00 O-RING Ø85×3.0 1115-430001-0A TANK 1115-560024-00 AIR CLEANER 1115-561001-0A BRUSH 1115-560025-00 O-RING 16.36X2.21 1115-560026-00 PLUG 1115-561002-00 BRUSH HOLDER BL-EZ30-0815 - 07-28-2019 12-45...
  • Page 118 EZ30-16 Figure 12-21 Lift Cylinder - Used up to serial # E2017219 12-46 BL-EZ30-0815 - 07-28-2019...

  • Page 119: Lift Cylinder - Used Up To Serial # E2017219

    SEAL KIT FOR LIFT CYLINDER 3 & 7 1115-410001-00 PISTON ROD 0000-000672-00 RING WIPER Ø40×48×5-6.5 0000-000673-00 O-RING Ø45×3.1 1115-410002-00 1115-411000-00 CYLINDER BODY 1115-410003-00 RING BACK UP 0000-000512-00 ROD PACKING Ø40×50×6 0000-000016-00 SCREW M6×8 Not Pictured 1115-400002-00 BLOCK BL-EZ30-0815 - 07-28-2019 12-47...
  • Page 120 EZ30-17 Figure 12-22 Lift Cylinder - Used for serial #’s between E2017220 & E2116209 12-48 BL-EZ30-0815 - 07-28-2019...
  • Page 121 LIFT CYLINDER ASSEMBLY Includes Pos. # 2, 1115-QSYG SEAL KIT FOR LIFT CYLINDER 3 & 7 1115-410001-0A PISTON ROD 0000-000672-00 RING WIPER Ø40×48×5-6.5 0000-000673-00 O-RING Ø45×3.1 1115-410002-0A 1115-411000-0A CYLINDER BODY 1115-410003-00 RING BACK UP 0000-000512-00 ROD PACKING Ø40×50×6 BL-EZ30-0815 - 07-28-2019 12-49...
  • Page 122 EZ30-18 Figure 12-23 Lift Cylinder - Used for serial # from E2116210 12-50 BL-EZ30-0815 - 07-28-2019...

  • Page 123: Lift Cylinder - Used For Serial # From E2116210

    Includes Pos. # 2, 1115-QSYG SEAL KIT FOR LIFT CYLINDER 3 & 7 1115-410001-0B PISTON ROD 0000-000672-00 RING WIPER Ø40×48×5-6.5 0000-000673-00 O-RING Ø45×3.1 1115-410002-0B 1115-411000-0B CYLINDER BODY 1115-410003-00 RING BACK UP 0000-000512-00 ROD PACKING Ø40×50×6 1115-410004-00 BUSHING 1115-400002-0B BLOCK BL-EZ30-0815 - 07-28-2019 12-51...
  • Page 124 EZ30-19 Figure 12-24 Electrical System 12-52 BL-EZ30-0815 - 07-28-2019...
  • Page 125 Used on all trucks 1115-510008-00 EMERGENCY STOP SWITCH except those mentioned on Pos. # 17a. Only used on Serial #’s: E2013118,E2013122, E2013189,E2013190, E2013191,E2013192, E2013117,E2013119, E2013120,E2013121, 3218-604000-00 EMERGENCY STOP SWITCH E2013125,E2013128, E2013126,E2013123, E2014129,E2014131, E2014134,E2014147, E2013127,E2013127, E2013143,E2013133, E2013142 BL-EZ30-0815 - 07-28-2019 12-53...
  • Page 126 EZ30-19 Figure 12-24 Electrical System - Continued 12-54 BL-EZ30-0815 - 07-28-2019...
  • Page 127 LAMP HOLDER 0000-000128-00 FLATWASHER Ø5 0000-001134-00 O-RING Ø2.0×1.8 For BDI without hour 1115-520005-0A WIRE HARNESS meter Optional: For BDI with 1115-520005-20 WIRE HARNESS hour meter 1115-510008-10 SWITCH BUTTON Used from Serial # 1115-520021-00 GROUND WIRE 426191250 BL-EZ30-0815 - 07-28-2019 12-55...
  • Page 128 EZ30-20 Figure 12-25 Wiring Harness (NOT used when 3 Way Key Switch) 12-56 BL-EZ30-0815 - 07-28-2019...
  • Page 129 Used from Serial # E2120048 and when 1115-520002-1F DRIVING WIRE HARNESS truck has Speed Reduction switch. Optional: From Serial # 1113-520025-00 FUSE 10A 427141876 Used from Serial # 1115-520020-0A BRAKE WIRE HARNESS 427190827 BL-EZ30-0815 - 07-28-2019 12-57...
  • Page 130 EZ30-25 Figure 12-26 Wiring Harness (Only used when 3 Way Key Switch) 12-58 BL-EZ30-0815 - 07-28-2019...
  • Page 131 DRIVE WIRE HARNESS PUMP CONTACTOR WIRE HAR- 1115-520016-00 NESS Only used on Serial #’s: E2013089, E2013090, E2013091, E2013092, E2013117, E2013118, E2013119, E2013120, E2013121, E2013122, E2013123, E2013124, E2013125, E2013126, E2013127, E2013128, E2013133, E2013142, E2013143, E2014129, E2014131,E2014134, E2014147. BL-EZ30-0815 - 07-28-2019 12-59...
  • Page 132 EZ30-21 Figure 12-27 Wiring Cables 12-60 BL-EZ30-0815 - 07-28-2019...
  • Page 133 Serial # E2219245 Used from Serial # 1115-100005-00 RUBBER CUSHION E2219246 Used from Serial # 0000-000550-00 NUT M 8 E2219246 Used from Serial # 0000-000917-00 SCREW M8×45 E2219246 Used from Serial # 1115-520020-00 3M PATCH E2313483 BL-EZ30-0815 - 07-28-2019 12-61...
  • Page 134 Big Lift LLC...

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