Big Joe E30 Operation, Maintenance And Parts Manual
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Big Joe E30 Operation, Maintenance And Parts Manual

Self-propelled, pallet lift truck
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E30
SELF-PROPELLED,
PALLET LIFT TRUCK
U.S. Patents Nos. 8,540,213; 8,833,736; 9,079,754; D692,202; D692,203; D692,204
Operation
Maintenance
Repair Parts List
Big Lift LLC
MANUAL NO. BL-E30-0515 - 03-01-2018
www.bigjoeforklifts.com

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Summary of Contents for Big Joe E30

  • Page 1 SELF-PROPELLED, PALLET LIFT TRUCK U.S. Patents Nos. 8,540,213; 8,833,736; 9,079,754; D692,202; D692,203; D692,204 Operation Maintenance Repair Parts List Big Lift LLC MANUAL NO. BL-E30-0515 - 03-01-2018 www.bigjoeforklifts.com...
  • Page 2 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 BL-E30-0515 - 03-01-2018...

  • Page 3: Table Of Contents

    LIFT & LOWER SWITCH REPLACEMENT .5-5 10-1.10 BUZZER INSTALLATION ......10-3 UPPER COMPARTMENT COVERS ....5-6 10-1.11 KEY SWITCH REMOVAL ......10-3 5-2.1 REMOVAL ............5-6 10-1.12 KEY SWITCH INSTALLATION ....10-3 5-2.2 INSTALLATION ..........5-6 10-1.13 BATTERY INDICATOR REMOVAL ... 10-3 BL-E30-0515 - 03-01-2018...
  • Page 4 REPLACEMENT ........10-7 10-1.16 EMERG. DISCONNECT INSTALLATION.. 10-4 10-1.17 LIFT LIMIT SWITCH REMOVAL....10-6 OPTIONAL EQUIPMENT ..........11-1 10-1.18 LIFT LIMIT SWITCH INSTALLATION..10-6 10-2 PUMP MOTOR .......... 10-7 ILLUSTRATED PARTS BREAKDOWN ......12-1 10-3 DRIVE MOTOR.......... 10-7 BL-E30-0515 - 03-01-2018...

  • Page 5: Description

    The lift truck must be pro- tected from the elements. This publication describes the 24 volt E30 lift truck dis- tributed by Big Lift LLC. Included are operating instruc- The model number will be found on the name plate...

  • Page 6: Safety Features

    1-3. SAFETY FEATURES. • Emergency Disconnect within operator's reach. The E30 is designed and engineered to provide maxi- • Readily accessible horn button. mum safety for operator and payload. Some of the • Handle to provide a firm hand hold for operator.

  • Page 7: Operation

    This section gives detailed operating instructions for load or lifting mechanism trailing. the E30 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 8 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-E30-0515 - 07-27-2016...
  • Page 9 R6479 Figure 2-1 Sample of Operator Check List BL-E30-0515 - 07-27-2016...

  • Page 10: 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-E30-0515 - 07-27-2016...

  • Page 11: Steering Arm Gas Spring

    Return truck to maintenance for repair. Disconnect and the key switch. Charge batteries as necessary. Refer to battery care instructions, SEC- 2-8. LIFT AND LOWER CONTROLS. TION 3. Lift/Lower Control buttons are located on the steering control head. (Figure 2-3) BL-E30-0515 - 07-27-2016...
  • Page 12 NOTES BL-E30-0515 - 07-27-2016...

  • Page 13: Planned Maintenance

    3-3.1. General A voltage check from battery connector terminal to The E30 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 14: 3-3.2 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-E30-0515 - 03-01-2018...

  • Page 15: 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-E30-0515 - 03-01-2018...

  • Page 16: 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-E30-0515 - 03-01-2018...

  • Page 17: 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-E30-0515 - 03-01-2018...
  • Page 18 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-E30-0515 - 03-01-2018...

  • Page 19: Troubleshooting

    Defective electric brake (35, Replace brake. Figure 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-E30-0515 - 03-01-2018...
  • Page 20 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-E30-0515 - 03-01-2018...
  • Page 21 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-E30-0515 - 03-01-2018...

  • Page 22: Controller Troubleshooting

    R7090 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-E30-0515 - 03-01-2018...
  • Page 23 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-E30-0515 - 03-01-2018...

  • Page 24: 4-2.5 Diagnostic History

    Put the vehicle up on blocks to get the drive wheel off the ground. Turn off the key switch (20, Figure 12-18) and emergency disconnect (17). Using an inline fuse holder fitted with a 10 amp fuse and alligator clips, connect the controller's M and B- terminals. BL-E30-0515 - 03-01-2018...
  • Page 25 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-E30-0515 - 03-01-2018...
  • Page 26 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-E30-0515 - 03-01-2018...
  • Page 27 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-E30-0515 - 03-01-2018...
  • Page 28 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-E30-0515 - 03-01-2018...
  • Page 29 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-E30-0515 - 03-01-2018 4-11...
  • Page 30 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-E30-0515 - 03-01-2018...
  • Page 31 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-E30-0515 - 03-01-2018 4-13...
  • Page 32 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-E30-0515 - 03-01-2018...
  • Page 33 (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-E30-0515 - 03-01-2018 4-15...

  • Page 34: 4-2.8 Programmer Diagnostics

    Main Fault* Main OFF Fault Main ON Fault Precharge Fault* * = Must cycle keyswitch to clear = Must use programmer to clear, as follows: select Program menu, † alter data value of any parameter, cycle keyswitch. 4-16 BL-E30-0515 - 03-01-2018...
  • Page 35 Precharge fault 1. Brake driver shorted. 2. Precharge circuit damaged. 3. MOSFET failure. Speed POT Fault Speed limit pot wiper out of range 1. Speed limit pot wire(s) broken or sho- ted. 2. Broken speed limit pot. BL-E30-0515 - 03-01-2018 4-17...
  • Page 36 Undervoltage Fault Battery voltage too low 1. Battery voltage <17 volts. 2. Bad connection at battery or control- ler. Wiring Fault HPD fault present >10 sec. 1. Misadjusted throttle. 2. Broken throttle pot or throttle mecha- nism. 4-18 BL-E30-0515 - 03-01-2018...
  • Page 37 R6774 Figure 4-3 Wiring Diagram BL-E30-0515 - 03-01-2018 4-19...
  • Page 38 4-20 BL-E30-0515 - 03-01-2018...

  • 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 12-18) and ometer (21, Figure 5-2). emergency disconnect (17). R6740A Figure 5-1 Steering Arm BL-E30-0515 - 03-01-2018...
  • 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). R6741A Figure 5-2 Control Head BL-E30-0515 - 03-01-2018...

  • Page 41: 5-1.2 Control Head Installation

    Remove screw (4), washer (3) and control knob Reconnect harness (15, Figure 5-1) to emergency (14) from other side of potentiometer (21). reverse switch (23, Figure 5-2). 10. Install the cap assembly as described in para- graph 5-1.4. BL-E30-0515 - 03-01-2018...

  • Page 42: 5-1.7 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-E30-0515 - 03-01-2018...
  • Page 43 (1) cover (1) and secure with pin (6). Remove pin (6) securing buttons (2,3 or 7,8) to Install the cap assembly as described in para- bracket (5 or 6) and remove the buttons. graph 5-1.4. BL-E30-0515 - 03-01-2018...

  • Page 44: Upper Compartment Covers

    Disconnect cable (9, Figure 12-18) from the bat- Turn on the key switch (20, Figure 12-18) and tery charger. emergency disconnect (17). Remove two side covers (7, Figure 5-5) if avail- able. R6749 Figure 5-5 Compartment Cover BL-E30-0515 - 03-01-2018...

  • Page 45: Lower Compartment Covers

    Lift cover (7, Figure 5-6) up and off cover (9). Turn on the key switch (20, Figure 12-18) and Remove four screws (8), cover (9) and stability emergency disconnect (17). bars from transmission (11). R6743 Figure 5-6 Compartment BL-E30-0515 - 03-01-2018...

  • Page 46: Steering Arm

    Install steering arm gas return spring as described Position the opposite end of the gas return spring in paragraph 5-4.1. (8) on bracket (5) and install screw (1). BL-E30-0515 - 03-01-2018...

  • Page 47: Brake Servicing

    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 from harness (3, Figure 12-20 Figure 12-21). BL-E30-0515 - 03-01-2018...
  • Page 48 R6742A Figure 6-1 Transmission, Motor, Brake Mounting BL-E30-0515 - 03-01-2018...

  • Page 49: Transmission, Drive Wheel, Load Wheel

    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-E30-0515 - 03-01-2018...
  • Page 50 R6742A Figure 7-1 Transmission, Motor, Brake Mounting BL-E30-0515 - 03-01-2018...

  • 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. R6607 Figure 7-2 Wheel Assembly BL-E30-0515 - 03-01-2018...
  • Page 52 NOTES BL-E30-0515 - 03-01-2018...

  • Page 53: Elevation System Servicing

    Remove pins (7) and remove shafts (6). under frame (8, Figure 8-1) and at tips of the Lower link assembly to the floor. forks. Turn off the key switch (20, Figure 12-18) and emergency disconnect (17). R6744 Figure 8-1 Frame BL-E30-0515 - 07-27-2016...

  • Page 54: 8-1.2 Repair

    Remove bushings (3) from clevises (5) if replace- ground. ment is necessary. Turn on the key switch (20, Figure 12-18) and Install reassemble by reversing the steps above. emergency disconnect (17). R6745 Figure 8-2 Lift Linkage Assembly BL-E30-0515 - 07-27-2016...

  • Page 55: Hydraulic System Servicing

    Lower forks fully. maintenance on the hydraulic system. Turn off the key switch (20, Figure 12-18) and emergency disconnect (17). Remove the upper compartment cover (5, Figure 9-1) as described in paragraph 5-2. R6749 Figure 9-1 Compartment Cover BL-E30-0515 - 03-01-2018...

  • Page 56: Hydraulic And Electrical Assembly Removal

    Use hydraulic oil listed in Turn on the key switch (20, Figure 12-18) and Table 3-2. emergency disconnect (17). Turn on the key switch (20, Figure 12-18) and Install the upper compartment cover as described emergency disconnect (17). in paragraph 5-2. BL-E30-0515 - 03-01-2018...
  • 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. R6746A Figure 9-2 Hydraulic System BL-E30-0515 - 03-01-2018...
  • Page 58 R6747A Figure 9-3 Pump & Motor Assy BL-E30-0515 - 03-01-2018...

  • Page 59: 9-3.4 Lift Cylinder

    Coat all parts with hydraulic oil (Table 3-2). Install new guide ring and seal ring on rod. Insert piston rod into body. 10. Install wiper and O-ring in gland nut. 11. Install gland nut in body. R8030 Figure 9-4 Lift Cylinder BL-E30-0515 - 03-01-2018...

  • Page 60: 9-3.4.3 Installation

    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-E30-0515 - 03-01-2018...

  • Page 61: Electrical Components

    12-18) 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, Figure 12-18) and described in paragraph 5-2. emergency disconnect (17). BL-E30-0515 - 03-01-2018 10-1...
  • Page 62 R6750A Figure 10-1 Electrical System 10-2 BL-E30-0515 - 03-01-2018...

  • Page 63: 10-1.7 Cooling Fan Removal

    Remove the knob from the emergency disconnect Turn off the key switch (20, Figure 12-18) and (17) emergency disconnect (17). Remove two screws (23) and remove emergency Remove the upper compartment covers as disconnect (17) from bracket (6). described in paragraph 5-2. BL-E30-0515 - 03-01-2018 10-3...
  • Page 64 (6) and secure with two screws (23). paragraph 5-2. Install the knob on the emergency disconnect (17) Turn on the key switch (20, Figure 12-18) and emergency disconnect (17). R6751A Figure 10-2 Wiring Harness 10-4 BL-E30-0515 - 03-01-2018...
  • Page 65 R6752A Figure 10-3 Wiring Cables BL-E30-0515 - 03-01-2018 10-5...

  • Page 66: 10-1.17 Lift Limit Switch Removal

    Tag and disconnect harness (3, Figure 10-2) from limit switch (10, Figure 12-8). Turn on the key switch (20, Figure 12-18) and emergency disconnect (17). Remove two screws (1) and limit switch (10) from bracket (2). R6743 Figure 10-4 Compartment 10-6 BL-E30-0515 - 03-01-2018...

  • Page 67: Pump Motor

    10-4.DEADMAN SWITCH Install upper compartment covers as described in 10-4.1.Replacement paragraph 5-2. Turn on the key switch (20, Figure 12-18) and Turn off the key switch (20, Figure 12-18) and emergency disconnect (17). emergency disconnect (17). BL-E30-0515 - 03-01-2018 10-7...
  • Page 68 NOTES 10-8 BL-E30-0515 - 03-01-2018...

  • Page 69: Optional Equipment

    SECTION 11 OPTIONAL EQUIPMENT BL-E30-0515 - 03-01-2018 11-1...
  • Page 70 NOTES 11-2 BL-E30-0515 - 03-01-2018...

  • Page 71: Illustrated Parts Breakdown

    SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the E30 Lift Truck. BL-E30-0515 - 03-01-2018 12-1...
  • Page 72 R6740A Figure 12-1 Steering Arm 12-2 BL-E30-0515 - 03-01-2018...
  • Page 73 NESS 0000-000912-00 SCREW M8×25 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-E30-0515 - 03-01-2018 12-3...
  • Page 74 R6741A Figure 12-2 Control Head 12-4 BL-E30-0515 - 03-01-2018...
  • Page 75 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 1115-343000-00-B REVERSING SWITCH ASSEMBLY With Switch With Wire harness. See Emergency 1120-342000-00-B CAP ASSEMBLY Reverse Switch Assembly section for details. BL-E30-0515 - 03-01-2018 12-5...
  • Page 76 R6753A Figure 12-3 Cap Assembly 12-6 BL-E30-0515 - 03-01-2018...
  • Page 77 BUTTON BRACKET (L) 1120-342002-00 HORN BUTTON 1120-342005-00 1120-342003-00 SPRING 1120-342004-00 BUTTON BRACKET 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 BL-E30-0515 - 03-01-2018 12-7...
  • Page 78 R6754A Figure 12-4 Emergency Reverse Switch Assembly 12-8 BL-E30-0515 - 03-01-2018...
  • Page 79 Emergency Reverse Switch Assembly 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-E30-0515 - 03-01-2018 12-9...
  • Page 80 R6742A Figure 12-5 Transmission, Motor & Brake Assembly - Used up to serial number 426150000 12-10 BL-E30-0515 - 03-01-2018...
  • Page 81 GEAR SET Includes two gears pos. # 19 0000-000680-00 BEARING 16003Z 1115-GSX-20 GEAR RING SET Includes two gears 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-E30-0515 - 03-01-2018 12-11...
  • Page 82 R6742A Transmission, Motor & Brake Assembly Figure 12-6 - Continued - Used up to serial number 426150000 12-12 BL-E30-0515 - 03-01-2018...
  • Page 83 SCREW M4×10 has Speed Reduction Switch. 1115-500012-00 WIRE CLAMP Y Used from 10-25-2012 0000-001007-00 FLATWASHER Ø8 1115-230001-00 BRUSH 1115-200000-00 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 BL-E30-0515 - 03-01-2018 12-13...
  • Page 84 R8482 Figure 12-7 Transmission, Motor & Brake Assembly - Used from serial number 426150001 12-14 BL-E30-0515 - 03-01-2018...
  • Page 85 SNAP RING FOR HOLE Ø42 0000-000659-00 SNAP RING Ø15 0000-000667-00 BEARING 61905Z 1115-GSX-10 GEAR SET Includes two gears pos. # 19 0000-000680-00 BEARING 16003Z 1115-GSX-20 GEAR RING SET Includes two gears pos. # 21 0000-000660-00 KEY 5×5×18 0000-000026-00 SCREW M8×30 BL-E30-0515 - 03-01-2018 12-15...
  • Page 86 R8482 Transmission, Motor & Brake Assembly Figure 12-8 - Continued - Used from serial number 426150001 12-16 BL-E30-0515 - 03-01-2018...
  • Page 87 SCREW M4×10 has Speed Reduction Switch. 1115-500012-00 WIRE CLAMP Y 0000-001007-00 FLATWASHER Ø8 1115-230001-00 BRUSH 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 BL-E30-0515 - 03-01-2018 12-17...
  • Page 88 R6749 Figure 12-9 Compartment Cover 12-18 BL-E30-0515 - 03-01-2018...
  • Page 89 424191006. 1115-120003-00-02 COVER Orange - Used on Fork Frame 27” only. Used from serial num- ber 424191007 1115-120003-n0-02 COVER Orange - Used on Fork Frame 27” only. 2214-150002-00 WASHER 1115-500013-00 WIRE CLAMP Used from 10-25-2012 BL-E30-0515 - 03-01-2018 12-19...
  • Page 90 R6743 Figure 12-10 Compartment 12-20 BL-E30-0515 - 03-01-2018...
  • Page 91 LIMIT SWITCH ASSEMBLY E2120047 Used from Serial # 1115-500017-00 LIMIT SWITCH E2120048 0000-000007-00 FLATWASHER Ø10 Used from Serial # 1115-500014-00 BRACKET E2120048 Used from Serial # 0000-000988-00 BOLT M6×30 E2120048 Used from Serial # 0000-000063-00 LOCKWASHER Ø10 E2221099 BL-E30-0515 - 03-01-2018 12-21...
  • Page 92 R8024 Figure 12-11 Stabilizers 12-22 BL-E30-0515 - 03-01-2018...
  • Page 93 Description Notes Reqd. 1115-140000-0A BALANCE STAND-L 1115-150000-0A BALANCE STAND-R 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-E30-0515 - 03-01-2018 12-23...
  • Page 94 R6744 Figure 12-12 Frame 12-24 BL-E30-0515 - 03-01-2018...
  • Page 95 Used up to S/N 0000-000654-00 ROUND PIN Ø4×45 424150330 Used from S/N 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 BL-E30-0515 - 03-01-2018 12-25...
  • Page 96 R6745 Figure 12-13 Lift Link Assembly 12-26 BL-E30-0515 - 03-01-2018...
  • Page 97 0000-001456-00 ROUND PIN Ø5×35 424150331 1115-130007-40 SHAFT 1115-133000-40 LOAD WHEEL 1115-132200-00-04 LONG ROD Used on 48” (45”) Forks 1115-132200-00-09 LONG ROD Used on 42” Forks 1115-132200-00-02 LONG ROD Used 36” Forks 1115-130008-00 WASHER Used from 11-29-2013 BL-E30-0515 - 03-01-2018 12-27...
  • Page 98 R6607 Figure 12-14 Load Wheel 12-28 BL-E30-0515 - 03-01-2018...
  • Page 99 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-E30-0515 - 03-01-2018 12-29...
  • Page 100 R6746A Figure 12-15 Hydraulic System 12-30 BL-E30-0515 - 03-01-2018...
  • Page 101 LIFT CYLINDER E2017220 to E2116209 Used from Serial # 1115-410000-0B LIFT CYLINDER E2116210 0000-000705-00 BUSHING 0000-000013-00 GREASE FITTING M8 0000-000044-00 WASHER Ø14 2401-146000-00 BOLT 2401-143500-00 BOLT 1115-420000-00 HOSE 1115-510001-00 PUMP & MOTOR ASSEMBLY 0000-000159-00 LOCKWASHER Ø8 BL-E30-0515 - 03-01-2018 12-31...
  • Page 102 R6747A Figure 12-16 Pump & Motor Assy 12-32 BL-E30-0515 - 03-01-2018...
  • Page 103 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 1115-560020-00 TANK 1115-560021-00 SCREW 3/8 1115-560022-00 WASHER G3/8 1115-560024-00 AIR CLEANER 1115-561001-00 BRUSH 1115-560025-00 O-RING 16.36X2.21 1115-560026-00 PLUG BL-E30-0515 - 03-01-2018 12-33...
  • Page 104 R6748 Figure 12-17 Lift Cylinder Used up to Serial # E2017219 12-34 BL-E30-0515 - 03-01-2018...
  • Page 105 Includes Pos. # 2, 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-E30-0515 - 03-01-2018 12-35...
  • Page 106 R8025 Figure 12-18 Lift Cylinder Used from Serial # E2017220 to E2116209 12-36 BL-E30-0515 - 03-01-2018...
  • Page 107 LIFT CYLINDER ASSEMBLY 1115-QSYG SEAL KIT FOR LIFT CYLINDER Includes Pos. # 2, 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-E30-0515 - 03-01-2018 12-37...
  • Page 108 R8026 Figure 12-19 Lift Cylinder Used from Serial # E2116210 12-38 BL-E30-0515 - 03-01-2018...
  • Page 109 SEAL KIT FOR LIFT CYLINDER Includes Pos. # 2, 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-E30-0515 - 03-01-2018 12-39...
  • Page 110 R6750A Figure 12-20 Electrical System 12-40 BL-E30-0515 - 03-01-2018...
  • Page 111 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, 1115-510008-0A EMERGENCY STOP SWITCH E2013125,E2013128, E2013126,E2013123, E2014129,E2014131, E2014134,E2014147, E2013127,E2013127, E2013143,E2013133, E2013142 BL-E30-0515 - 03-01-2018 12-41...
  • Page 112 R6750A Figure 12-21 Electrical System Continued 12-42 BL-E30-0515 - 03-01-2018...
  • Page 113 Serial #’s men- WIRE tioned on Pos. # 17a. 1115-500009-00 CHARGER HOOP Used from 08/15/2012 1115-510009-00 LAMP HOLDER 0000-000128-00 FLATWASHER Ø5 0000-001134-00 O-RING Ø2.0×1.8 1115-510006-00 BATTERY INDICATOR Without hour meter Optional: With hour 1115-510006-20 BATTERY INDICATOR meter BL-E30-0515 - 03-01-2018 12-43...
  • Page 114 R6751A Figure 12-22 Wiring Harness (NOT used when 3 Way Key Switch) 12-44 BL-E30-0515 - 03-01-2018...
  • Page 115 Used up to Serial # E2120047 (it has 1115-520002-0B DRIVING WIRE HARNESS an extra port that is not being used) Used from Serial # E2120048 and 1115-520002-1F DRIVING WIRE HARNESS when truck has Speed Reduction switch. BL-E30-0515 - 03-01-2018 12-45...
  • Page 116 R8027 Figure 12-23 Wiring Harness (Only used when 3 Way Key Switch) 12-46 BL-E30-0515 - 03-01-2018...
  • Page 117 1115-520002-00 DRIVE WIRE HARNESS 1115-520016-00 PUMP CONTACTOR WIRE HARNESS 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-E30-0515 - 03-01-2018 12-47...
  • Page 118 R6752A Figure 12-24 Wiring Cables 12-48 BL-E30-0515 - 03-01-2018...
  • Page 119 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-E30-0515 - 03-01-2018 12-49...
  • Page 120 R8028 Figure 12-25 Option - Load backrest 27” Wide Forks (Only Factory Installed) 12-50 BL-E30-0515 - 03-01-2018...
  • Page 121 Option - Load Backrest 27” Wide Forks (Only Factory Installed) Pos. Qty. Description Part Number Notes Reqd. 1115-170000-P0 LOAD BACKREST, FORK WIDTH 27” 48” Tall 1115-180000-P0 LOAD BACKREST, FORK WIDTH 27” 60” Tall 0000-000700-00 SCREW M8×16 BL-E30-0515 - 03-01-2018 12-51...
  • Page 122 R8029 Figure 12-26 Option - Load backrest 22” Wide Forks (Only Factory Installed) 12-52 BL-E30-0515 - 03-01-2018...
  • Page 123 Option - Load Backrest 22” Wide Forks (Only Factory Installed) Pos. Qty. Description Part Number Notes Reqd. 1115AC-170000-01 LOAD BACKREST, FORK WIDTH 22” 60” Tall 1115AE-170000-00 LOAD BACKREST, FORK WIDTH 22” 48” Tall 0000-001101-00 SCREW M8×20 BL-E30-0515 - 03-01-2018 12-53...
  • Page 124 Big Lift LLC...

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