EZ40

SELF-PROPELLED,
PALLET LIFT TRUCK

U.S. Patents Nos. D739,112; D770,719; D770,720; 9,586,605

Operation
Maintenance
Repair Parts List

NOTE: For the most current parts information and service updates, please refer to the Big Joe
Support site at www.bigjoesupport.com

Big Lift LLC MANUAL NO. BL-EZ40-0515 - 01-31-2018

www.bigjoeforklifts.com
 WARNING
Do not operate this truck unless you have been autho-
rized and trained to do so, and have read all warnings
and instructions in Operator’s Manual and on this
truck.
Do not operate this truck until you have checked its
condition. Give special attention to wheels, horn, bat-
tery, controller, lift system, brakes, steering mecha-
nism, guards and safety devices.
Operate truck only from designated operating position.
Do not carry passengers. Keep feet clear of truck and
wear foot protection.
Observe applicable traffic regulations. Yield right of
way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision 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 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
trailing.
Use special care when operating on ramps travel
slowly, and do not angle or turn. Travel with load
downhill.
Do not handle loads which are higher than the chassis
unless load is secured so that no part of it could fall
backward. Before lifting, be sure load is centered,
forks are completely under the chassis backrest.
When leaving truck, neutralize travel control, fully
lower lifting mechanism and set brake. When leaving
truck unattended, also shut off power.
 TABLE OF CONTENTS
Section Page
1 LIST OF ILLUSTRATIONS..........................................1-II
1 LIST OF TABLES ........................................................1-II
1 DESCRIPTION ............................................................1-1
1-1. INTRODUCTION. .........................................1-1
1-2. GENERAL DESCRIPTION. ..........................1-1
1-3. SAFETY FEATURES....................................1-2
2 OPERATION ...............................................................2-1
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. LOADING AND UNLOADING.......................2-5
2-12. PARKING......................................................2-5
3 PLANNED MAINTENANCE ........................................3-1
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 TROUBLESHOOTING ................................................4-1
4-1. GENERAL.....................................................4-1
4-2. CONTROLLER TROUBLESHOOTING ........4-4
4-2.1. ZAPI HANDSET............................................4-4
4-2.2. FAULT DETECTION.....................................4-4
4-2.3. TESTING TRUCK OPERATION...................4-4
4-2.4. SETTINGS AND ADJUSTMENTS................4-5
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 POT. 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. COMPARTMENT COVERS .........................5-6
BL-EZ40-0515 - 01-31-2018
Section Page
5-2.1. REMOVAL.................................................... 5-6
5-2.2. INSTALLATION............................................ 5-6
5-3. STEERING ARM.......................................... 5-7
5-3.1. RETURN SPRING REPLACEMENT. .......... 5-7
5-3.2. STEERING ARM REMOVAL. ...................... 5-7
5-3.3. STEERING ARM INSTALLATION. .............. 5-7
6 BRAKE SERVICING ................................................... 6-1
6-1. BRAKES....................................................... 6-1
6-1.1. AIR GAP ADJUSTMENT. ............................ 6-1
6-1.2. STOPPING DISTANCE ADJUSTMENT. ..... 6-2
6-1.3. BRAKE ASSEMBLY REPLACEMENT......... 6-2
7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL .... 7-1
7-1. LOAD WHEEL.............................................. 7-2
7-1.1. REMOVAL.................................................... 7-2
7-1.2. REPAIR....................................................... 7-2
7-1.3. LOAD WHEEL INSTALLATION ................... 7-2
7-2. DRIVE WHEEL. ........................................... 7-3
7-3. TRANSMISSION.......................................... 7-3
8 ELEVATION SYSTEM SERVICING ........................... 8-1
8-1. GENERAL .................................................... 8-1
8-2. LIFT LINKAGE ............................................. 8-1
8-2.1. REMOVAL.................................................... 8-1
8-2.2. REPAIR........................................................ 8-2
8-2.3. INSTALLATION............................................ 8-2
9 HYDRAULIC SYSTEM SERVICING........................... 9-1
9-1. LINES AND FITTINGS................................. 9-1
9-2. HYDRAULIC AND ELECTRICAL
ASSEMBLY REMOVAL ............................... 9-2
9-2.1. REMOVAL.................................................... 9-2
9-2.2. INSTALLATION............................................ 9-2
9-3. HYDRAULIC PUMP, MOTOR,
AND RESERVOIR ASSY............................. 9-2
9-3.1. REMOVAL.................................................... 9-2
9-3.2. DISASSEMBLY AND REASSEMBLY.......... 9-2
9-3.3. INSTALLATION............................................ 9-4
9-3.4. LIFT CYLINDER........................................... 9-4
10 ELECTRICAL COMPONENTS ................................. 10-1
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. EMERGENCY DISCONNECT REMOVAL. 10-2
10-1.8. EMERGENCY DISCONNECT
INSTALLATION.......................................... 10-2
10-1.9. CONTACTOR REMOVAL.......................... 10-2
10-1.10. CONTACTOR INSTALLATION.................. 10-2
10-1.11. FUSE REMOVAL. ...................................... 10-2
10-1.12. FUSE INSTALLATION. .............................. 10-2
10-1.13. COOLING FAN REMOVAL........................ 10-4
10-1.14. COOLING FAN INSTALLATION................ 10-4
10-1.15. BUZZER REMOVAL. ................................. 10-4
i
 TABLE OF CONTENTS - Continued

Section Page Section Page

10-1.16 BUZZER INSTALLATION. ......................... 10-4 10-3. DRIVE MOTOR. ......................................... 10-7
10-1.17 KEY SWITCH REMOVAL. ......................... 10-4 10-4. DEADMAN SWITCH .................................. 10-7
10-1.18 KEY SWITCH INSTALLATION. ................. 10-4 10-4.1. REPLACEMENT......................................... 10-7
10-1.19 BATTERY INDICATOR REMOVAL. .......... 10-4
10-1.20 BATTERY INDICATOR INSTALLATION. .. 10-4 11 OPTIONAL EQUIPMENT .......................................... 11-1
10-1.21 LIFT LIMIT SWITCH REMOVAL................ 10-6 12 ILLUSTRATED PARTS BREAKDOWN .................... 12-1
10-1.22 LIFT LIMIT SWITCH INSTALLATION........ 10-6
10-2. PUMP MOTOR. ......................................... 10-7

ii BL-EZ40-0515 - 01-31-2018
 SECTION 1
DESCRIPTION

1-1. INTRODUCTION.
This publication describes the 24 volt EZ40 lift truck
distributed by Big Lift LLC. Included are operating
instructions, planned maintenance instructions, lubri-
cation procedures, corrective maintenance procedures
and a complete parts list with part location illustrations.
Users shall comply with all requirements indicated in
applicable OSHA standards and current edition of
A.N.S.I. B56.1 Part II. By following these requirements
forks raised or lowered. The lift truck must be pro-
tected from the elements.
The model number will be found on the name plate
(Figure 1-1) along with the serial number, lifting capac-
ity, and load center. Figure 1-2 shows the locations of
the truck’s main components and controls.
MODEL NO. SERIAL NO.

and the recommendations contained in this manual,

you will receive many years of dependable service MAX CAP LB/ KG LOAD CTR IN/ MM LIFT HGT IN/ MM

from your EZ40 lift truck.

ALT CAP LB/ KG LOAD CTR IN/ MM LIFT HGT IN/ MM

1-2. GENERAL DESCRIPTION.

The self-propelled EZ40 truck, Figure 1-2, lifts and
TRUCK WT LESS BATTERY LB/ KG BATTERY MIN WT LB/ KG

transports payloads up to 4000 pounds on rigid forks.

TRUCK WT WITH BATTERY LB/ KG BATTERY MAX WT LB/ KG

The forward and reverse motion is controlled by either

of two controller levers mounted on the control head. TRUCK BATTERY
CERTIFIED VOLTAGE
TYPE TYPE
Stopping and turning is controlled by the steering arm.
Lift and Lower is controlled by pushbuttons on the con-
trol head. The battery powered lift truck is quiet and
COMPLIES WITH THE APPLICABLE REQUIRE-
MENTS OF ANSI B56.1 AND OSHA STANDARDS

reliable. U.S. PATENT NO. 4,444,284

AUSTRALIAN PATENT NO. 537,987

The reversible AC motor propels the lift truck in for- BIG LIFT LLC

ward or reverse direction throughout the available WISCONSIN DELLS, WISCONSIN 53965

R6209
speed range. The EZ40 lift truck can be driven with
Figure 1-1 Name Plate

EZ40-9

Figure 1-2 . EZ40 Lift Truck

BL-EZ40-0515 - 01-31-2018 1-1

1-3. SAFETY FEATURES.
The EZ40 is designed and engineered to provide max-
imum safety for operator and payload. Some of the
safety features incorporated into the design are:
• Dead-man brake to apply the brake and cut off drive
power when the steering arm is released.
• Belly-button switch to reverse truck should the oper-
ator accidentally pin himself against a wall or
obstruction when backing up in slow speed.
• All control functions automatically return to “OFF”
when released.
• Emergency Disconnect within operator's reach.
1-2
• Readily accessible horn button.
• Handle to provide a firm hand hold for operator.
• Flow control valve regulates maximum lowering
speed within prescribed limits.
• Relief valve maintains hydraulic pressure within pre-
scribed limits.
• High visibility color scheme of truck provides visual
alert of truck’s presence.
• Battery Indicator.
• Guard rails adjustable for various pallets.
• Adjustable load backrest.
BL-EZ40-0515 - 01-31-2018
 SECTION 2
OPERATION
2-1. GENERAL.
This section gives detailed operating instructions for
the EZ40 lift truck. The instructions are divided into the
various phases of operations, such as operating lift,
driving, and stopping. Routine precautions are
included for safe operation.
2-2. OPERATING PRECAUTIONS.
WARNING: Improper operation of the lift truck may
result in operator injury, or load and/or lift
truck damage. Observe the following
precautions when operating the EZ40 lift
truck.
The following safety precautions must be adhered to
at all times.
• Do not operate this truck unless you have been
trained and authorized to do so and have read all
warnings and instructions in this manual and on the
truck.
• All warnings and instructions must be read and
understood before using the equipment.
• Equipment must be inspected by a qualified person
on a regular basis.
• Do not operate this truck until you have checked its
condition. Give special attention to Wheels, Horn,
Batteries, Controller, Lift System, Brakes, Steering
Mechanism, Guards and Safety Devices
• Operate truck only from designated operating posi-
tion. Do not carry passengers. Keep feet clear of
truck and wear foot protection.
• Observe applicable traffic regulations. Yield right of
way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision 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 spe-
cial care when traveling without load as the risk of
overturn may be greater.
BL-EZ40-0515 - 01-31-2018
• Always look in direction of travel. Keep a clear view,
and when load interferes with visibility, travel with
load or lifting mechanism trailing.
• Do not overload truck. Check nameplate for load
weight and load center information.
• Before lifting, be sure load is centered, forks are
completely under load, and load is as far back as
possible against the chassis.
• Do not handle loads which are higher than the chas-
sis unless load is secured so that no part of it could
fall backward.
• When leaving truck, neutralize travel control. Fully
lower lifting mechanism and set brake. When leaving
truck unattended, turn off key switch and disconnect
switch, and remove key.
• The lift truck must be protected from the elements.
2-3. BEFORE OPERATION
Table 2-1 covers important inspection points on the
EZ40 lift truck which should be checked prior to opera-
tion. Depending on use, some trucks may require
additional checks.
Figure 2-1 shows a sample format for an Operator
Checklist, which can be modified as necessary to fit
your operation.
WARNING: Periodic maintenance of this truck by a
QUALIFIED TECHNICIAN is required.
CAUTION: A QUALIFIED SERVICE TECHNICIAN
should check the truck monthly for
proper lubrication, proper fluid levels,
brake operation, motor maintenance and
other areas specified in the SECTION 3.
WARNING: If the truck is found to be unsafe and in
need of repair, or contributes to an
unsafe condition, report it immediately to
the designated authority. Do not operate
it until it has been restored to a safe
operating condition. Do not make any
unauthorized repairs or adjustments. All
service must be performed by a qualified
maintenance technician.
2-1
 Table 2-1 Operator Checks

ITEM PROCEDURE ITEM PROCEDURE

Transmission Check for signs of fluid leakage.
and hydraulic
systems.
Forks Check for cracks and damage.
Safety signs Check that warning labels,
nameplate, etc., are in good
condition and legible.
Horn Check that horn sounds when
operated.
Steering Check for binding or looseness in
steering arm when steering.
Travel controls Check that speed controls on
control head operate in 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 Check operation of lift and lower
controls to their maximum positions.
Brake Check that brake actuates when
steering arm is raised to upright
position, and when lowered to
horizontal position.
Deadman/ Check that steering arm raises to
Parking brake upright position when released
and brake applies.
Battery Check that battery can be
disconnect disconnected and recon-
nected. Check for connector
damage.
Battery charge Check the battery indicator.

2-2 BL-EZ40-0515 - 01-31-2018

 Electric Truck
Big Joe Manufacturing Company Daily Operator Check-Off List

Date Operator

Truck No. Model No.

Dept. Shift
Hour Meter
Reading Drive Hoist

Check O.K. ( ) Need Maintenance

Tires
Load Wheels
Horn
Lift Lower Control
Attachment Operation
Forward & Reverse Controls

Steering
Brakes
Hydraulic Leaks, Cylinders,
Valves, Hoses, Etc.

R6479

Figure 2-1 Sample of Operator Check List

BL-EZ40-0515 - 01-31-2018 2-3

2-4. GENERAL CONTROL OPERATION.
The speed control (See Figure 2-2) located on each
side of the control head provides fingertip control for
driving the truck. Rotate the control in the direction you
want to travel. The farther you rotate the control from
the neutral position, the faster the truck will travel.
R6617
Figure 2-2 Forward/Reverse Control
The pushbutton switches (See Figure 2-3), located on
the front of the control head activate the lift-lower con-
trols and the horn.
R6618
Figure 2-3 Pushbutton Switches
The brake is fully applied by lowering or raising the
steering arm. (See Figure 2-4) All traction control
power is shut off when the brake is engaged. When
the steering arm is in the upright position, the brake
acts as a parking brake. Deadman braking occurs
when the handle is released and spring action raises
steering arm to the upright position.
2-4
EZ40-10
Figure 2-4 Brake Actuation
2-5. DRIVING AND STOPPING PROCEDURES.
1. Turn on the emergency disconnect and the key
switch. 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 brake and to
energize the electrical circuits. If the truck is not
moved, the electrical circuits will time out and will
deenergize. See Figure 2-4.
3. To move forward (with load in front), slowly press
the speed control forward. See Figure 2-2. Press
the forward speed control farther to increase
speed.
4. To slow down or stop, release the speed control
and lower or raise the steering arm to the horizon-
tal or vertical position. See Figure 2-4. In those
positions, the brake engages, slowing or stopping
the truck.
5. Procedures for movement in reverse are the
same as in the forward direction except slowly
press the speed control backward. See Figure 2-
2.
2-6. BELLY-BUTTON SWITCH.
The belly-button switch (Figure 2-5) minimizes the
possibility of the driver being pinned by the steering
arm while driving the lift truck in slow speed. If the
switch presses against the operator while the lift truck
is being driven toward the operator, the switch
changes the direction of the lift truck.
BL-EZ40-0515 - 01-31-2018

R6619
Figure 2-5 Belly-Button Switch
2-7. STEERING ARM GAS SPRING.
The steering arm gas spring automatically raises the
steering arm to the upright position when the steering
arm is released. If the steering arm does not return
fully, the steering arm gas spring requires replace-
ment. Return truck to maintenance for repair.
2-8. LIFT AND LOWER CONTROLS.
Lift/Lower Control buttons are located on the steering
control head. (Figure 2-3)
To lift forks, push in either LIFT button and hold until
forks reach desired height. To lower forks, push in
either LOWER button and hold until forks descend to
desired height.
BL-EZ40-0515 - 01-31-2018
2-9. BACKREST.
An adjustable load backrest (Figure 12-10 or Figure
12-11) is incorporated. Backrest (3) is adjustable to
46” forks for standard pallets and 36” for beverage pal-
lets. Handle (4) is used to secure the backrest in the
raised position for full use of 46” forks.
2-10.GUIDE RAILS.
Guide rails (17 and 19, Figure 12-10 or Figure 12-11)
are adjustable for standard pallets and for beverage
pallets. Rails must be swiveled into the lower position
before lowering the backrest.
2-11.LOADING AND UNLOADING.
1. Move truck to location where load is to be picked
up.
2. Move the truck into position so forks are within
pallet or skid, and the load is centered over the
forks and as far back as possible.
3. Raise forks to lift load.
4. Drive to area where load is to be placed.
5. Move truck to align load with its new position.
6. Lower the load until it rests squarely in place and
the forks are free.
7. Slowly move the truck out from under the load.
2-12.PARKING.
When finished with moving loads, return the truck to its
maintenance or storage area. Turn off the emergency
Disconnect and the key switch. Charge batteries as
necessary. Refer to battery care instructions, SEC-
TION 3.
2-5
 NOTES

2-6 BL-EZ40-0515 - 01-31-2018

 SECTION 3
PLANNED MAINTENANCE

3-1. GENERAL. CAUTION: Gases produced by a battery can be

Planned maintenance consists of periodic visual and
operational checks, parts inspection, lubrication, and
scheduled maintenance designed to prevent or dis-
cover malfunctions and defective parts. The operator
performs the checks in SECTION 2, and refers any
required servicing to a qualified maintenance techni-
cian who performs the scheduled maintenance and
any required servicing.
3-2. MONTHLY AND QUARTERLY CHECKS.
Table 3-1 is a monthly and quarterly inspection and
service chart based on normal usage of equipment
eight hours per day, five days per week. If the lift truck
is used in excess of forty hours per week, the fre-
quency of inspection and service should be increased
accordingly. These procedures must be performed by
a qualified service technician or your Big Lift LLC Ser-
vice Representative.
3-3. BATTERY CARE.
3-3.1. General
explosive. Do not smoke, use an open
flame, create an arc or sparks in the
vicinity of the battery. Ventilate an
enclosed area well when charging.
CAUTION: Batteries contain sulfuric acid which may
cause severe burns. Avoid contact with
eyes, skin or clothing. In case of contact,
flush immediately and 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 for safe
handling and disposal.
Leakage voltage from battery terminals to battery case
can cause misleading trouble symptoms with the truck
electrical system. Since components of the truck elec-
trical system are insulated from truck frame, leakage
voltage will not normally affect truck operation unless a
short circuit or breakdown of circuit wire insulation to
truck frame occurs.

The EZ40 may be equipped with maintenance free or A voltage check from battery connector terminal to
industrial wet cell batteries. battery case should indicate near zero volts. Typically,
however, the sum of the voltages at both terminals will
The care and maintenance of the battery is very equal battery volts. This leakage voltage will discharge
important to obtain efficient truck operation and maxi- the battery. As battery cleanliness deteriorates, the
mum battery life. usable charge of the battery decreases due to this
self-discharge.
Table 3-1 Monthly and Quarterly Inspection and Service Chart
VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check electrical brake for proper operation.
Monthly Check pull rods for proper adjustment.
Monthly Check load wheels for wear. A poly load wheel must be replaced if worn to within 1/16 inch
of hub. Check for separation from hub.
Monthly Check drive wheel for wear. A poly drive wheel must be replaced if worn to within 3/4 inch of
hub. Check for separation from hub.
Monthly Inspect wiring for loose connections and damaged insulation.
Monthly Inspect contactors for proper operation.
Monthly Check deadman brake switch for proper operation.
Quarterly Check lift cylinder for leakage.
Quarterly Check for excessive jerking of steering arm when stopping or starting.

BL-EZ40-0515 - 01-31-2018 3-1

Although a leakage voltage reading of zero volts may
not be possible, a cleaner battery will have more
usable charge for truck operation and not affect opera-
tion of electronic devices on the unit.
3-3.2. Safety Rules
• Wear protective clothing, such as rubber apron,
gloves, boots and goggles when performing any
maintenance on batteries. Do not allow electrolyte to
come in contact with eyes, skin, clothing or floor. If
electrolyte comes in contact with eyes, flush immedi-
ately and thoroughly with clean water. Obtain medi-
cal attention immediately. Should electrolyte be
spilled on skin, rinse promptly with clean water and
wash with soap. A baking soda solution (one pound
to one gallon of water) will neutralize acid spilled on
clothing, floor or any other surface. Apply solution
until bubbling stops and rinse with clean water.
• If truck is equipped with wet cell batteries, keep vent
plugs firmly in place at all times except when adding
water or taking hydrometer readings. Do not allow
dirt, cleaning solution or other foreign material to
enter cells. Impurities in electrolyte has a neutraliz-
ing effect reducing available charge.
• Do not bring any type of flame, spark, etc., near the
battery. Gas formed while the battery is charging, is
highly explosive. This gas remains in cell long after
charging has stopped.
• Do not lay metallic or conductive objects on battery.
Arcing will result.
• Do not touch non-insulated parts of DC output con-
nector or battery terminals to avoid possible electri-
cal shock.
• De-energize all AC and DC power connections
before servicing battery.
• Do not charge a frozen battery.
• Do not use charger if it has been dropped or other-
wise damaged.
3-3.3. Battery Care and Charging
CAUTION: Never smoke or bring open flame near
the battery. Gas formed during charging
is highly explosive and can cause seri-
ous injury.
3-2
1. Charge the battery only in areas designated for
that use.
2. Battery terminals should be checked and cleaned
of corrosion regularly. Good battery terminal con-
tact is essential not only for operation, but also for
proper charging of the battery.
3. The charging requirements will vary depending on
the use of the truck. The battery should be given
as equalizing charge on a weekly basis. This
charge should normally be an additional three
hours at the finish rate.
4. Make certain battery used meets weight and size
requirements of truck. NEVER operate truck with
an undersized battery.
3-3.4. Battery Cleaning
Always keep vent plugs tightly in place when cleaning
battery. When properly watered and charged, the bat-
tery will remain clean and dry. All that is necessary is
to brush or blow off any dust or dirt that may accumu-
late on them. However, if electrolyte is spilled or over-
flows from a cell, it should be neutralized with a
solution of baking soda and water, brushing the soda
solution beneath the connectors and removing grime
from the covers. Then rinse the battery with cool water
from a low pressure supply to remove the soda and
loosen dirt. If batteries stay wet consistently, they may
be either overcharged or over filled. This condition
should be investigated and corrected.
3-3.5. MAINTENANCE FREE BATTERIES
Trucks may be equipped with optional maintenance
free batteries. These batteries are completely sealed,
will not require any watering and have a full 80% dis-
charge available.
Sealed Maintenance Free batteries contain a pressure
release valve and under normal operating conditions
do not require any special ventilation.
CAUTION: Do not try to open this battery or remove
the pressure release valve.
Only under severe overcharging, such as connected
to an improperly sized charger, will any significant
amount of gasses be released from the battery. Also,
being a valve regulated battery, it never requires
watering.
BL-EZ40-0515 - 01-31-2018
3-4. CHARGING BATTERIES
Charging requirements will vary depending on depth of
discharge and temperature. Follow safety rules when
placing a battery on charge.
Proceed as follows:
1. Park truck at charging 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 attempt to charge the batteries. Contact
appropriate personnel for repairs to be made.
3. Pull the charger cord out of the top cover and con-
nect to the appropriate power supply.

EZ40-24

Figure 3-1 Charging Battery

BL-EZ40-0515 - 01-31-2018 3-3

3-5. BATTERIES REPLACEMENT a. Remove the hose and harness and battery
cable. Remove four screws and take out the
Access to the batteries requires moving the controller
controller board.
board.
Proceed as follows:
1. Remove two screws and remove cover.

EZ40-26
EZ40-25
Figure 3-3 Controller Board Removal
Figure 3-2 Cover Removal
b. Install in the reverse order of remove. Pay
attention to battery position and cable con-
nection. Position cables to avoid damage.

3-4 BL-EZ40-0515 - 01-31-2018

3-6. LUBRICATION.
Refer to Table 3-2 for the recommended types of
grease and oil. Table 3-3 in conjunction with Figure 3-4
identifies the items requiring lubrication.
BL-EZ40-0515 - 01-31-2018
Table 3-2 Recommended Lubricants
(See Table 3-3 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 suppressing agent and
rust and oxidation inhibitors
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
3-5
 EZ40-27

Figure 3-4 Lubrication Diagram

Table 3-3 Lubrication Chart
FIG 3-2 LOCATION METHOD OF TYPE APPLICATION
INDEX APPLICATION (Table OF
NO. 3-3) LUBRICANT
1 Transmission Can No. 1 Fill to level plug opening
Capacity 2 pints
2 Hydraulic Reservoir Can No. 3 With lift carriage fully lowered, fill
Capacity-1 quarts reservoir with hydraulic oil to 1
inch below opening
3 Lift Linkage Fittings* Gun No. 2 Pressure lubricate.
* Raise lift carriage to gain access to grease fittings.

3-6 BL-EZ40-0515 - 01-31-2018


4-1. GENERAL
Use Table 4-1 as a guide to determine possible
causes of trouble. The table is divided into five main
categories: Truck and Hydraulic System Will Not Oper-
MALFUNCTION
TRUCK AND HYDRAULIC
SYSTEM WILL NOT OPER-
ATE
Truck will not travel nor will lift sys-
tem operate.
TRUCK DOES NOT OPERATE
FORWARD OR REVERSE
Truck does not travel forward or
reverse. All other functions
operate normally.
Truck travels forward but not in
reverse.
Truck travels reverse but not in
forward.
Truck travels forward and in
reverse at lower speeds; will
not travel at high speed.
TROUBLE WITH BRAKING
Truck does not slow with brake, or
brake does not engage.
Brake will not release.
BL-EZ40-0515 - 01-31-2018
SECTION 4
TROUBLESHOOTING
ate: Truck Does Not Operate Forward or Reverse:
Trouble With Braking: Trouble With Lifting Or Lower-
ing, and Miscellaneous malfunctions.
Table 4-1 Troubleshooting Chart
PROBABLE CAUSE
a. Fuse blown.
b. Battery dead or disconnected.
c. Keyswitch defective.
d. Defective wiring.
a. Check all wiring. A loose con-
nection may be the cause of
malfunction.
b. Defective deadman switch.
c. Defective controller.
d. Defective potentiometer.
Defective potentiometer in control
head.
Defective potentiometer in control
head.
Defective potentiometer in control
head.
a. Defective deadman switch.
b. Defective electric brake.
a. Brake temperature above
281F (140 C).
b. Open brake circuitry or wiring.
CORRECTIVE ACTION
Check fuse and replace if
necessary.
Check battery connections and
check battery voltage.
Bypass keyswitch to determine if it
is malfunctioning.
Check for open circuit. Repair as
required.
Tighten all loose connections
before further troubleshooting.
Check and replace switch if
defective.
Check for proper operation and
replace if necessary.
Check and replace potentiometer
if defective.
Check and replace potentiometer
if defective.
Check and replace potentiometer
if defective.
Check and replace potentiometer
if defective.
Check deadman switch for
continuity. If none found when
the control arm is in the brake
position, replace switch.
Replace brake.
Allow to cool.
Make voltage checks.
4-1
 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH BRAKING -
Continued
Brake drags. Defective electric brake. Replace.

Brake grabs. Defective electric brake. Replace.

Abnormal noise and chatter when Defective electric brake. Replace.

brake is applied.
TROUBLE WITH LIFTING OR
LOWERING
Oil sprays or flows from the top of
the lift cylinder.
Squealing sounds when lifting
forks.
Forks do not lift to top.
Weak, slow or uneven action of
hydraulic system.
Forks do not lift, pump motor does
not run.
Forks do not lift, motor runs.
.
Defective packing in lift cylinder
a. Oil level too low.
b. Lift linkage binding.
Oil level too low.
a. Defective pump or relief valve.
b. Worn lift cylinder.
c. Load larger than capacity.
d. Defective lift motor solenoid.
e. Battery charge low.
a. Battery is dead or discon-
nected.
b. Defective wiring.
c. Defect in electrical system for
operating pump motor.
Defect in hydraulic system.
Repair lift cylinder.
Identify oil leak.
Apply grease.
Add oil to reservoir.
Check pressure. Adjust as
necessary.
Replace cylinder.
Refer to I.D.plate for capacity.
Replace solenoid on electrical
panel.
Charge battery.
Check and recharge if required.
Check and repair as required.
Check lift switch in control head,
as well as the solenoid.
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.

4-2 BL-EZ40-0515 - 01-31-2018

 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION
TROUBLE WITH LIFTING OR
LOWERING - Continued
Forks lift, but will not go down.
Load will not hold
Platform does not lift to top. Pump
motor runs.
Forks creep downward under load
when in a raised position.
MISCELLANEOUS
Steering arm does not return to
the upright position.
Truck moves forward when arm is
pulled down.
Steering arm jerks excessively
starting or stopping the truck.
Drive motor is jerky.
BL-EZ40-0515 - 01-31-2018
PROBABLE CAUSE
Defect in hydraulic system
a. Oil bypassing internally in con-
trol valve
b. Worn lift cylinder or packing.
a. Oil level too low.
b. Load larger than capacity.
c. Batteries need charging.
Leak in hydraulic system, lift cylin-
der or lowering valve.
a. Week return spring.
b. Binding.
a. Belly-button switch defective.
b. Short in control head.
Drive wheel worn.
Motor internally damaged or worn.
CORRECTIVE ACTION
Check lowering control switch in
control head and lowering sole-
noid on valve assembly.
Replace as required.
Replace valve assembly.
Repack cylinder.
Add oil to reservoir.
Refer to nameplate on side of
mast for maximum load capac-
ity.
Change batteries.
Check for leaking fitting in hydrau-
lic line and repair as required.
Repack lift cylinder or replace
valve assembly.
Replace spring.
Check and free the binding item.
Verify that the cable has not
been damaged. Repair or
replace as needed.
Check for short, and repair or
replace as necessary.
Check wiring and repair as
required.
Replace drive wheel if worn to
within 3/4 inch of hub.
Replace motor.
4-3
4-2. CONTROLLER TROUBLESHOOTING
4-2.1. Zapi Handset
The Zapi Handset for use with the Zapi controller
serves multiple functions of reading diagnostic data,
testing truck operation, setting options, adjustments
and parameter changes of the controller. The Zapi
Handset is available through your Big Lift LLC dealer.
If you require dealer location information, contact Big
Lift LLC.
Remove the rubber plug from the CNC connector of
the controller and plug in the Zapi Handset connector
as shown in Figure 4-1.
R6628
Figure 4-1 Zapi Controller
4-2.2. Fault Detection.
4-2.2.1. General
The controller provides diagnostics information to
assist technicians in troubleshooting problems. When
a fault is detected, an alarm is recorded in the logbook.
It has a FIFO (First Input First Output) structure that
means the oldest alarm is lost when the database is
full and a new alarm occurs. The logbook is composed
of alarms with the following information:
• The alarm code
4-4
• The number of times that each alarm occurs consec-
utively
• The Hour Meter reading (value) when the latest
event of every alarm occurred
• The invert temperature when the latest event of
every alarm occurred.
This function permits a deeper diagnosis of problems
as the recent history can be revisited.
4-2.2.2. Logbook Access
To view the alarm logbook proceed as follows:
1. Connect the Zapi Handset, refer to paragraph 4-
2.1.
2. Press the ROLL down button and the ENTER but-
ton at the same time to enter the MAIN MENU.
3. Press the ROLL down button or the ROLL up but-
ton to find the ALARMS display.
4. Press the ENTER button to view the alarms.
5. Press the OUT button to exit the alarms.
NOTE: Refer to bigjoesupport.com for the Zapi sup-
plement containing detailed information of
alarm codes. There are two versions shown.
The PDS uses the Standard version which
lists the error by: Alarm Name, Repetitions,
Temperature and Hour Meter reading.
4-2.3. Testing Truck Operation.
The Zapi Handset can be used to test certain truck
operations as follows:
1. Connect the Zapi Handset, refer to paragraph 4-
2.1.
2. Press the ROLL down button and the ENTER but-
ton at the same time to enter the MAIN MENU.
3. Press the ROLL down button or the ROLL up but-
ton to find the TESTER display.
4. Press the ENTER button to view the tests.
5. To verify various switch functions, locate the
switch on the display and then operate that func-
tion to verify operation
6. Press the OUT button to exit the tests.
BL-EZ40-0515 - 01-31-2018
4-2.4. Settings and Adjustments

4-2.4.1. Set Options

To set options proceed as follows and refer to Table 4-
2:
1. Connect the Zapi Handset, refer to paragraph
4-2.1.
2. Press the ROLL up button (1, Figure 4-2) and the
SET up button at the same time to enter the CON-
FIG MENU.
3. Press the ROLL down button or the ROLL up but-
ton to find the SET OPTIONS display.
4. Press the ENTER button to view the options.
5. Press the ROLL down or the ROLL up button to
find the option to be changed.
6. Press the SET up button or the SET down button
until the desired value setting is reached. The
option is now set at the desired value.
7. Press the OUT button to exit the options.

R6624

Figure 4-2 Zapi Handset

Table 4-2 Set Options
Parameter Factory Setting Description
TILLER switch HANDLE This option handles the input CNB#3 (Table 4-5). This input opens
when the operator leaves the truck (released). It is connected to a
Keyswitch controlled voltage when the operator is present.
SET INPUT #1 OPTION #1 (Standard Version only). This option handles the digital input
CNA#15. It can be can be set as:
• OPTION #1: CNA is managed as a cutback speed input (SR#1).
• OPTION #2: CNA is managed as a digital handbrake input.
• OPTION #3: CNA is managed as an inching backward.
The input CNA#15 (Table 4-5) can only be used as Aux Lowering
request when the MDIPRC is PRESENT.
This input must be connected to a Keyswitch controlled voltage.
The SR#1 becomes active when CNA#15 (Table 4-5) is open.
The inching backward becomes active when the CNA#15 (Table 4-
5) is closed to a Keyswitch controlled voltage.

BL-EZ40-0515 - 01-31-2018 4-5

 Table 4-2 Set Options - Continued
Parameter Factory Setting Description
SET INPUT #2 PRESENT It can be can be set as:
• PRESENT: CNA#14 (Table 4-5) is managed as a cutback speed
input (SR#2).
• OPTION #1: CNA#14 (Table 4-5) is managed as an inching back-
ward.
The input CNA#14 (Table 4-5) can only be used as Aux Lifting
request when the MDIPRC is PRESENT.
This input must be connected to a Keyswitch controlled voltage.
The SR#2 becomes active when CNA#14 (Table 4-5) is open.
The inching backward becomes active when the CNA#14 (Table 4-
5) is closed to a Keyswitch controlled voltage.
SET INPUT #4 OPTION #1 This option handles the digital input CNB#7 (Table 4-5). It can be
can be set as:
• BELLY CNB#7 (Table 4-5) is managed as a Belly Switch input.
• BRAKE CNB#7 (Table 4-5) is managed as service brake input.
This information can be used also to recognize when the operator
is driving with a pressed pedal braking.
• EX.HYDRO: CNB#7 (Table 4-5) is managed as Exclusive Hydro.
This input must be connected to a Keyswitch controlled voltage.
The Belly switch active level is specified on the QUICK INV LOGIC
below.
The service brake of the exclusive hydro becomes active when
CNB#7 is opened.
HOUR COUNTER RUNNING This option specifies the hour counter mode. It can be set as:
• RUNNING: The counter registers travel time only.
• key on: The counter registers when the keyswitch is closed.
BATTERY CHECK Level = 1 This option specifies the handling of the low battery charge detec-
tion. It can be set as:
• Level 0: Nothing happens, the battery charge level is ignored.
• Level 1: A BATTERY LOW alarm is raised when the battery level
is calculated being less than 10% of the full charge. A BATTERY
LOW alarm inhibits the Lifting function.
• Level 2: A BATTERY LOW alarm is raised when the battery level
is calculated being less than 10% of the full charge. A BATTERY
LOW alarm reduces the maximum truck speed down to 24% of
the full truck speed then, if the MDI-PRC is absent, inhibits the Lift-
ing function.
• Level 3 Equivalent to Level 1; a BATTERY LOW alarm is raised
when the battery level is calculated being less than 10% of the full
charge. A BATTERY LOW alarm inhibits the Lifting function.
HYDRO KEY ON OFF ON/OFF: If this options is programmed ON the traction Inverter
manages a hydraulic steering function when the keyswitch is
switched ON (only if the AUX OUTPUT #1 option is programmed
as HYDRO CONTACT or as WXCLUSIVE HYDRO).
STOP ON RAMP OFF Not used.

4-6 BL-EZ40-0515 - 01-31-2018

 Table 4-2 Set Options - Continued
Parameter Factory Setting Description
AUX OUTPUT #1 BRAKE This option handles output CNA#3 (Table 4-5). It can be used as:
• BRAKE: CNA#3 (Table 4-5) drives an electromechanical Brake.
• HYDROCOMNT: CNA#3 (Table 4-5) drives the contractor for a
hydraulic steering function when the direction input or brake pedal
input are active or a movement of the truck is detected.
• EX.HYDRO: CNA#3 (Table 4-5) drives the contractor for a hydrau-
lic steering function when the exclusive hydro input is active.
• FREE: CNA#3 (Table 4-5) is not used.
The current this output can sink is up to 3Adc.
PEDAL BRAKING NONE The analog input CNA#18 (Table 4-5) has one of two functions:
• Pedal Braking input.
• Command input for lifting/lowering proportional valves in MDI-
PRC version.
To turn from the first to the second function is just enough to set
PEDAL BRAKING to HNONE.
This option handles the analog input CNA#18 (Table 4-5) when
used as pedal braking input:
• ANALOG: With this setting it is possible to modulate the strength
of the braking when the accelerator is released. The strength of
the braking is proportional to the brake pedal potentiometer con-
nected to this input. When the pedal potentiometer voltage is
equal/less than the SET POT BRK MIN, the minimum release
braking strength is applied (following the RELEASE BRAKING
setting).
When the pedal potentiometer voltage is equal/higher than the
SET POT BRK MAX, the maximum release braking strength is
applied (following the PEDAL BRAKING setting). In the intermedi-
ate position, the electrical braking strength is a linear function
between the minimum (RELEASED BRAKING) and maximum
(PEDAL BRAKING) intensity. When there is also a switch con-
nected to the pedal braking (i.e. SET INPUT #4 to level BRAKE), it
must be closed, otherwise the release braking is stuck to the mini-
mum strength disregarding the pedal potentiometer position.
• DIGITAL: No pedal potentiometer is expected. Only when both the
SET INPUT #4 is Level BRAKE and the brake switch connected to
CNB#4 (Table 4-5) is closed, the release electrical braking follows
the PEDAL BRAKING setting (maximum strength); in all of the
other conditions the release electrical braking follows the
RELEASE BRAKING setting (minimum strength).
• NONE: The analog input CNA#18 (Table 4-5) is not used for the
release braking modulation.
QUICK INVERSION BELLY This option specifies the quick inversion mode when the SET
INPUT #4 is set BELLY. It can be set as:
• NONE: The quick inversion function is not managed (no effect
when CNB#7 (Table 4-5) switches over).
• TIMED: The quick inversion function is timed.
• BELLY: The quick inversion function is managed but not timed.

Table 4-2 Set Options - Continued

BL-EZ40-0515 - 01-31-2018 4-7

 Parameter Factory Setting Description
AUX VOLTAGE #1 100% This option specifies the percentage of the keyswitch controlled
voltage to be applied to the loads on CNA#1 (Table 4-5) (main
contactor coil) and CNA#3 (Table 4-5) (electromechanical brake).
The voltage modulation is set with a PWM at 1 kHz frequency.
After an initial delay of about 1 sec in which the entire keyswitch
controlled voltage is applied to the loads, the PWM reduces the
voltage at the loads down to the specified percentage.
PERFORMANCE OPTION #1 This option can be set
• OPTION#1
• OPTION#2
QUICK INV. LOGIC OPTION #1 This option specifies the active level for the Belly switch input
(CNB#7)
• OPTION#1: The quick inversion is executed when CNB#7 (Table
4-5) is closed to a Keyswitch controlled voltage.
• OPTION#2: The quick inversion is executed when CNB#7 (Table
4-5) is opened from a Keyswitch controlled voltage.
MDI-PRC ABSENT This option specifies:
• PRESENT: The MDI-PRC is connected to the ACO via the CAN
Bus: the handling of the Hydraulics is specified on the TRUCK
TYPE setting.
• ABSENT: The MDI-PRC is not connected to the ACO: the TRUCK
TYPE disappears from the SET OPTIONS function list.
MOT SET-UP LOCK OFF Not used.

4-8 BL-EZ40-0515 - 01-31-2018

4-2.4.2. Adjustments
To change an adjustment proceed as follows and refer
to Table 4-3:
1. Connect the Zapi Handset, refer to paragraph
4-2.1.
2. Press the ROLL up button and the SET up button
at the same time to enter the CONFIG MENU.
3. Press the ROLL down button or the ROLL up but-
ton to find the ADJUSTMENTS display.
4. Press the ENTER button to view the adjustments.
5. Press the ROLL down button or the ROLL up but-
ton to find the adjustment to be changed.
6. Press the SET up button or the SET down button
until the desired value setting is reached. The
adjustment is now set at the desired value.
7. Press the OUT button to exit the adjustments.

R6624

Figure 4-3 Zapi Handset

Table 4-3 Adjustments

Parameter Factory Setting Description
SET POT BRK MIN 0.5 V This setting records the minimum value of braking pedal potentiom-
eter when the braking pedal switch is closed; the procedure is
similar to the PROGRAM VACC function. This procedure must be
carried out only if the PEDAL BRAKING option is programmed as
ANALOG. No adjustment is necessary when PEDAL BRAKING
options is programmed as NONE.
SET POT BRK MAX 4.5 V This setting records the maximum value of braking pedal potenti-
ometer when the braking pedal is fully pressed; the procedure is
similar to the PROGRAM VACC function. This procedure must be
carried out only if the PEDAL BRAKING option is programmed as
ANALOG. No adjustment is necessary when PEDAL BRAKING
options is programmed as NONE.
SET BATTERY TYPE 24V Selects the nominal battery voltage.
ADJUST BATTERY XX V Do not modify - Factory adjusted (Fine adjustment of the battery
voltage measured by the controller.)
THROTTLE 0 ZONE 9% Establishes a deadband in the accelerator input curve.

Table 4-3 Adjustments - Continued

BL-EZ40-0515 - 01-31-2018 4-9

 Parameter Factory Setting Description
THROTTLE X POINT 45% This parameter together with the THROTTLE Y POINT, changes
the characteristic of the accelerator input curve: when the acceler-
ator is de-pressed to X point percent, the corresponding truck
speed is Y point percent of the Maximum truck speed. The rela-
tionship between the accelerator position and the truck speed is
linear between the THROTTLE 0 ZONE and the X point and also
between the X point and the maximum accelerator position but
with two different slopes (Figure 4-4).
THROTTLE Y POINT 68% This parameter together with the THROTTLE X POINT, changes
the characteristic of the accelerator input curve: when the acceler-
ator is de-pressed to X point percent, the corresponding truck
speed is Y point percent of the Maximum truck speed. The rela-
tionship between the accelerator position and the truck speed is
linear between the THROTTLE 0 ZONE and the X point and also
between the X point and the maximum accelerator position but
with two different slopes (Figure 4-4).
ADJUSTMENT #01 LEVEL = 5 Adjust the upper level of the battery charge table (Level 0 to 9).
ADJUSTMENT #02 LEVEL = 5 Adjust the lower level of the battery charge table (Level 0 to 9).
LOAD HM FROM OFF When set On, the Hourmeter of the Controller is transferred and
MDI recorded on the Hourmeter of the Standard MDI (connected on
the Serial Link).
CHECK UP DONE OFF Turn it On when asked Maintenance service has been executed to
cancel the CHECK UP NEEDED warning.
CHECK UP TYPE NONE It specifies the handling of the CHECK UP NEEDED warning:
• NONE: No CHECK UP NEEDED warning.
• OPTION#1: CHECK UP NEEDED warning on the handset and
MDIPRC after 300 hours.
• OPTION#2: Equal to OPTION#1 but Speed reduction after 340
hours.
• OPTION#3: Equal to OPTION#2 but the truck definitively stops
after 380 hours.

R6642

Figure 4-4 Throttle Regulation

4-10 BL-EZ40-0515 - 01-31-2018

4-2.4.3. Parameter Change
To change a parameter proceed as follows and refer to
Table 4-4:
1. Connect the Zapi Handset, refer to paragraph
4-2.1.
2. Press the ROLL down button and the ENTER but-
ton at the same time to enter the MAIN MENU.
3. Press the ROLL down button or the ROLL up but-
ton to find the PARAMETER CHANGE display.
4. Press the ENTER button to view the parameters.
5. Press the ROLL down button or the ROLL up but-
ton to find the parameter to be changed.
6. Press the SET up button or the SET down button
until the desired value setting is reached. The
parameter is now set at the desired value.
7. Press the OUT button to exit the parameters.

R6624

Figure 4-5 Zapi Handset

Table 4-4 Parameter Adjustments
Parameter Factory Setting Description
ACCELER. DELAY LEVEL = 8 Level 0 to 9. It determines the acceleration ramp. At Level 9 the
truck takes a long time to accelerate.
RELEASE BRAKING LEVEL = 5 Level 0 to 9. It controls the deceleration ramp when the travel
request is released. At Level 9 the truck brakes abruptly.
INVERS. BRAKING LEVEL = 4 Level 0 to 9. It controls the deceleration ramp when the direction
switch is inverted during travel. At Level 9 the truck brakes
abruptly.
PEDAL BRAKING LEVEL = 9 Level 0 to 9. It controls the deceleration ramp when the travel
request is released and the brake pedal switch is pressed to its
maximum. At Level 9 the truck brakes abruptly.
SPEED LIMIT BRK LEVEL = 1 Level 0 to 9. It controls the deceleration ramp when the accelerator
has turned down but not completely released. At Level 9 the truck
decelerates abruptly.
BRAKE CUTBACK LEVEL = 5 Level 0 to 9. It controls the deceleration ramp when the a speed
reduction input becomes active and the motor slows down. At
Level 9 the truck decelerates abruptly.
MAX SPEED FORW 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed
in forward direction.
MAX SPEED BACK 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed
in backward direction.

BL-EZ40-0515 - 01-31-2018 4-11

 Table 4-4 Parameter Adjustments - Continued
Parameter Factory Setting Description
CUTBACK SPEED 100% Typically from 10% to 100%. It determines the percentage of the
max speed applied when the cutback switch 1 (SR#1 on CNA#15
(Table 4-5) is active. When set to 100% the speed reduction is
ineffective.
CUTBACK SPEED 2 37% Typically from 10% to 100%. It determines the percentage of the
max speed applied when the cutback switch 2 (SR#2 on CNA#14
(Table 4-5) is active. When set to 100% the speed reduction is
ineffective.
HS CUTBACK 100% Typically from 10% to 100%. It determine the percentage of the max
speed applied when the Hard & Soft function (H&S switch on
CNB#4 (Table 4-5) is active. When set to 100% the speed reduc-
tion is ineffective.
FREQUENCY 5.00 Hz Hz value. This is the minimum speed applied when the forward or
CREEP reverse switch is closed, but the accelerator at its minimum. In the
ACO sense Coils this setting is higher equal than 5 Hz.
RPM CREEP 100% A Percentage value. Set to 100% and not Used.
MAXIMUM 96% It specifies the percentage of the absolute current (150A) at which
CURRENT the current will be limited. Normally MAXIMUM CURRENT is
100%. DO NOT CHANGE.
INCHING SPEED 0 Hz Hz value. It determines the speed when the “Inching function” is
active.
INCHING TIME LEVEL = 0 Level 0 to 9. It determines the duration time when the “Inching func-
tion” is active.
AUXILIARY TIME 1 Time units value (seconds). For the encoder version, it determines
the time duration (in seconds) in which the
the frequency was arrived to zero.
ANTIROLLBACK 80% A Percentage of the Maximum Current. This setting increases the
phase current when low frequency during starting operation. It is
used to push up, in feedforward way, the torque when it is not
possible to control the flux, in feedback way, because of the low
frequency.

4-12 BL-EZ40-0515 - 01-31-2018

 R6628

Figure 4-6 Zapi Controller Connections

Table 4-5 Zapi Controller Connector Pins

CNA Connector
PIN ABBREVATION DESCRIPTION
CNA#1 NMC Negative of main contactor coil.
CNA#2 PMC Positive of main contactor coil.
CNA#3 NEB Output for driving the electromechanical brake coil; drives the load
to -Batt. Maximum current: 3 A.
CNA#4 NPC Negative of pump contactor soil.
CNA#5 PPC/PEV Positive of pump contactor coil and lowering electrovalve coil.
CNA#6 NEV Negative of the lowering electrovalve coil.
CNA#7 CAN LOW Low level CAN-BUS voltage I/O.
CNA#8 -BAT -Bat.
CNA#9 ENC+ Encoder Positive Supply (+5 or +12 Vdc)
CNA#10 ENC- Encoder Negative Supply (GND to minus battery)
CNA#11 HM(+B) Output for driving an hourmeter; when the hourmeter is active this
output provides a +Batt signal; 3 maximum current.

BL-EZ40-0515 - 01-31-2018 4-13

 Table 4-5 Zapi Controller Connector Pins - Continued
CNA Connector - Continued
PIN ABBREVATION DESCRIPTION
CNA#12 -BATT -Batt.
CNA#13 MOT TH Motor thermal sensor input. The internal pull-up is a fixed 2mA
(Max 5V) source current.
CNA#14 SR2 Speed reduction 2 input. Active low (switch opened).
CNA#15 SR1 Speed reduction 1 input. Active low (switch opened).
CNA#16 +12V This output provides a +12V signal for the MDI PRC, it present; mA
maximum current.
CNA#17 CAN HIGH High level CAN-BUS voltage I/O.
CNA#18 CPOTB Brake potentiometer wiper.
CNA#19 ENC A Encoder Channel A.
CNA#20 ENC B Encoder Channel B.
CNB Connector
CONNECTOR ABBREVATION DESCRIPTION
PIN
CNB#1 KEY SW Connected to the power supply through a microswitch (KEY) with a
6.3-10 A fuse in series (this could be mounted on the AC-0 cover).
CNB#2 CM Common for FW/BW/SR1/SR2/TILLER/H&S/BELLY/LIFTING/
LOWERING microswitches. This connection supplies a keyswitch
voltage level.
CNB#3 TILLER SW Tiller request input. Must be connected to the tiller microswitch,
active high.
CNB#4 H&S SW Hard & Soft request input. Must be connected to the Hard & Soft
microswitch, active high.
CNB#5 BACKWARD SW Backward direction request input. Must be connected to the back-
ward direction microswitch, active high.
CNB#6 FORWARD SW Forward direction request input. Must be connected to the forward
direction microswitch, active high.

CNB#7 BELLY SW Quick inversion function input; must be connected to the Belly
microswitch; it is active high.
CNB#8 LOWERING SW Lowering request input, active high.
CNB#9 LIFTING SW Lifting request input, active high.
CNB#10 CPOT Lifting request input, active high.
CNB#11 NPOT Negative of accelerator unit, tested for wire disconnection
diagnosis.
CNB#12 PPOT Potentiometer positive: 10V output; keep load >1k

4-14 BL-EZ40-0515 - 01-31-2018

 Table 4-5 Zapi Controller Connector Pins - Continued
CNC Connector
CONNECTOR ABBREVATION DESCRIPTION
PIN
CNC#1 PCLRXD Positive serial reception.
CNC#2 NCLRXD Negative serial reception.
CNC#3 PCLTXD Positive serial transmission.
CNC#4 NCLTXD Negative serial transmission.
CNC#5 GND Negative console power supply.
CNC#6 +12V Positive console power supply.
CNC#7 FLASH Must be connected to C8 for the Flash memory programming (if
used).
CNC#8 FLASH Must be connected to C7 for the Flash memory programming (If
used).

BL-EZ40-0515 - 01-31-2018 4-15

 NOTES

4-16 BL-EZ40-0515 - 01-31-2018

 SECTION 5
STEERING ARM, CONTROL HEAD AND COMPARTMENT

5-1. CONTROL HEAD 2. Remove the cap assembly as described in para-

graph 5-1.3.
5-1.1. Control Head Removal
3. Disconnect harness from potentiometer.
1. Turn off key switch and emergency disconnect.

DH_0001

Figure 5-1 Steering Arm

BL-EZ40-0515 - 01-31-2018 5-1

4. Disconnect wire harness assembly from emer- WARNING: When removing the control head in the
gency reverse switch. following steps, be sure to hold it in place
5. Remove two screws, two washers and two flat until the control harness is disconnected.
washers. 6. Remove two screws, two washers and two flat
washers.
7. Remove the control head and handle.

DH_0002

Figure 5-2 Control Head

5-2 BL-EZ40-0515 - 01-31-2018

5-1.2. Control Head Installation 5. Remove screw, screw, two lock washers and two
flat washers and remove potentiometer and
1. Secure control head and handle with two screws,
switch assembly from bracket.
two washers and two flat washers.
6. Position new potentiometer and switch assembly
2. Install two screws, two washers and two flat
in bracket and secure with screw, screw, two lock
washers.
washers and two flat washers.
3. Reconnect wire harness assembly to emergency
7. Install control knob on potentiometer and secure
reverse switch.
with screw, and washer.
4. Reconnect wire harness assembly to potentiome-
8. Install control knob on the other side of potentiom-
ter.
eter and secure with screw, and washer.
5. Install the cap assembly as described in para-
9. Reconnect harness to potentiometer.
graph 5-1.4.
10. Install the cap assembly as described in para-
6. Turn on key switch and emergency disconnect.
graph 5-1.4.
5-1.3. Cap Assembly Removal.
5-1.6. Belly-Button Switch Replacement.
1. Turn off key switch and emergency disconnect.
1. Remove the cap assembly as described in para-
2. Remove four screws and lift up cap assembly. graph 5-1.3.
3. Disconnect harness from wire harness assembly 2. Disconnect wire harness assembly from emer-
and remove cap assembly. gency disconnect switch.
5-1.4. Cap Assembly Installation. 3. Remove screws, two lock washers and two flat
washers and remove potentiometer and switch
1. Hold cap assembly in place and connect wire har- assembly from bracket.
ness asembly to harness.
4. Remove pin, bracket, and spring from button.
2. Position cap assembly on control head and
secure with four screws. 5. Remove two pins and switch assembly from
bracket.
1. Turn on key switch and emergency disconnect.
6. Position the new switch assembly in bracket and
5-1.5. Speed Potentiometer Replacement. secure with two pins.
1. Remove the cap assembly as described in para- 7. Position bracket and springs in button and install
graph 5-1.3. pin.
2. Disconnect wire harness assembly from potenti- 8. Position potentiometer and switch assembly in
ometer. bracket and secure with screws, two lock washers
and two flat washers.
3. Remove screw, washer and control knob from
potentiometer. 9. Reconnect wire harness assembly to emergency
reverse switch.
4. Remove screw, washer and control knob from
other side of potentiometer. 10. Install the cap assembly as described in para-
graph 5-1.4.

BL-EZ40-0515 - 01-31-2018 5-3

 DH_0005

Figure 5-3 Emergency Reverse Switch Assembly

5-1.7. Horn Switch Replacement. 4. Position new switch in bracket of assembly and
secure with the two pins.
1. Remove the cap assembly as described in para-
graph 5-1.3. 5. Position the bracket with two springs in cover and
secure with three screws.
2. Remove three screws, switch bracket and two
springs of assembly. 6. Install the cap assembly as described in para-
graph 5-1.4.
3. Remove the two pins of assembly and remove
switch from the bracket.

5-4 BL-EZ40-0515 - 01-31-2018

 DH_0004

Figure 5-4 Cap Assembly

5-1.8. Lift and Lower Switch Replacement. 4. Remove two pins, two switches and four springs
from bracket.
1. Remove the cap assembly as described in para-
graph 5-1.3. 5. Position new switches and four springs in bracket
and secure with two pins.
2. Remove switch assembly from the cap.
6. Position switch assembly in cover and secure with
3. Remove pin securing buttons from bracket and
pin.
remove the buttons.
7. Install the cap assembly as described in para-
graph 5-1.4.

BL-EZ40-0515 - 01-31-2018 5-5

5-2. COMPARTMENT COVERS 3. Remove two screws, two washers and cover.
4. Disconnect cable from charger.
5-2.1. Removal.
5. Remove four screws, four washers and upper
1. Turn off key switch and emergency disconnect.
cover.
2. Pull charger cable up and remove cap from the
6. Remove screws and middle cover.
cable. Let charger cable back down into cover.
7. Pull lower cover up and out.

DH_0008

Figure 5-5 Compartment Cover

5-2.2. Installation. 4. Reconnect cable to charger.

1. Position lower cover on the frame. 5. Feed the cable through cover and position cover
on the frame. Secure with two screws and two
2. Place middle cover around brake and secure with
washers.
screws.
6. Install cap on cable and position the cap on cover.
3. Install upper cover and secure with four screws
and four washers. 7. Turn on key switch and emergency disconnect.

5-6 BL-EZ40-0515 - 01-31-2018

5-3. STEERING ARM 5-3.2. Steering Arm Removal.

5-3.1. Return Spring Replacement. 1. Remove steering arm gas return spring as
described in paragraph 5-3.1.
The steering arm gas return spring is replaced while
2. Disconnect wire harness assembly from harness.
the steering arm is in the upright position.
3. Attach a hoist to steering arm.
1. Secure steering arm in the upright position.
4. Remove shaft and the steering arm.
2. Remove screw and free the gas return spring
from bracket. 5-3.3. Steering Arm Installation.
3. Pull downward on gas return spring to free it from 1. Position steering arm over bracket and secure
its seat inside steering arm. with shaft.
4. Position the new gas return spring inside the 2. Reconnect wire harness assembly to harness.
steering arm being sure it fully engages its seat.
3. Install steering arm gas return spring as described
5. Position the opposite end of gas return spring on in paragraph 5-3.1.
bracket and install screw.

BL-EZ40-0515 - 01-31-2018 5-7

5-8 BL-EZ40-0515 - 01-31-2018
 SECTION 6
BRAKE SERVICING

6-1. BRAKES. j. Recheck the gap.

The brake system consists of the brake assembly 11. Remove load wheel blocks and check operation.
mounted on top of the drive motor. This brake is elec- 12. Install the compartment covers as described in
trically applied and released. paragraph 5-2.
6-1.1. Air Gap Adjustment.
The “air gap” is the distance between the magnet body
and the rotor plate with the brake applied. As the brake
pads and rotor wear normally, the air gap will increase
and should be readjusted when it measures more than
0.25 mm.

NOTE: If the air gap measures more than 0.25 mm,

the brake may not release properly. Air gap
adjustment can be performed as long as the
brake pads and rotor function properly or until
the adjustable spacer threads are fully
engaged (adjustment limit reached).

1. Block load wheels.

2. Remove the compartment covers as described in
paragraph 5-2.
3. Using low pressure air, remove any dirt between
armatures and magnet body.
4. Using standard feeler gauges, check the gap
between the magnet body and the rotor plate. The
gap should be 0.25 mm.
5. If necessary, refer to Figure 6-1 and adjust the
gap as follows:
a. Loosen the three mounting screws by half a
turn.
f. The threaded air gap adjusting nuts can then
be screwed into Magnet Body by turning
counterclockwise.
g. Turn the three mounting screws clockwise
until the gap measures 0.012” (0.25 mm).
h. The threaded air gap adjusting nuts are then
R6625
screwed clockwise until they bottom.
i. Finally tighten the three mounting screws to Figure 6-1 Brake Assembly
52 in-lb (6 Nm).

BL-EZ40-0515 - 01-31-2018 6-1

6-1.2. Stopping Distance Adjustment. 5. Install the compartment covers as described in
paragraph 5-2.
The stopping distance of the truck should require mini-
mal adjustment. However, this distance should be 6-1.3. Brake Assembly Replacement
checked with each planned maintenance.
1. Block load wheels.
Using an unloaded truck, run truck to its top speed on
an even dry concrete surface. Move control handle 2. Remove the compartment covers as described in
into the lower braking position. Measure length of paragraph 5-2.
braking path from the actuation point of the brakes 3. Disconnect electric brake from switch wire har-
until the truck has stopped. The actual length of the ness.
braking path should be between approximately 1.5 - 4. Remove the three mounting screws and the
2.5 ft (0.5-0.7 m). brake.
To adjust stopping distance, proceed as follows: 5. Place the new brake into position and secure with
1. Block load wheels. the three mounting screws.
2. Remove the compartment covers as described in 6. Finally tighten the three mounting screws to 52 in-
paragraph 5-2. lb (6 Nm).
3. Rotate the adjusting nut (Figure 6-1) clockwise to 7. Reconnect electric brake to switch wire harness.
SHORTEN the stopping distance or counterclock- 8. Remove load wheel blocks and check operation.
wise to LENGTHEN the stopping distance.
9. Install the compartment covers as described in
4. Remove load wheel blocks and check operation. paragraph 5-2.

6-2 BL-EZ40-0515 - 01-31-2018

 SECTION 7
TRANSMISSION, DRIVE WHEEL, LOAD WHEEL

7-1. Removal 7-1.1. Repair

1. Raise forks. 1. Remove bearings from wheels.
1. Turn off key switch and emergency disconnect. 2. Inspect bearings and replace if necessary.
2. Block the drive wheel to prevent the truck from 3. Reassemble bearings in wheels.
rolling.
7-1.2. Load Wheel Installation
3. Jack up the forks to raise the load wheels off the
floor. Securely block the forks in the raised posi- 1. Position load wheel assembly in wheel bracket.
tion by positioning supports under both fork tips. 2. Install shaft and secure with pin.
NOTE: When shaft is removed, load wheel assembly 3. Remove blocking from under the truck.
will drop free. 4. Lower the forks.
4. Remove pin securing shaft and remove shaft and 1. Turn on key switch and emergency disconnect.
load wheel assembly.

NOTE: Inspect the 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
assemblies be replaced at the same time.
This ensures level and safe operation of the
lift truck.

DH_0012

Figure 7-1 Wheel Assembly

BL-EZ40-0515 - 01-31-2018 7-1

7-2. Drive Wheel. 2. Remove the compartment covers as described in
paragraph 5-2.
1. Turn off key switch and emergency disconnect.
3. Remove the brake as described in paragraph 6-
2. Remove the compartment covers as described in
1.3.
paragraph 5-2.
4. Remove the steering arm as described in para-
3. Loosen but do not remove the five nuts.
graph 5-3.2.
4. Jack up the truck so the drive wheel is off the
5. Disconnect harness from drive motor.
ground; then securely block the truck to prevent
movement. 6. Remove drive motor as described in paragraph
10-3.
5. Remove five nuts, five washers, and drive wheel
from transmission. 7. Remove drive wheel as described in paragraph 7-
2.
6. Install new drive wheel in reverse order of
removal. 8. Support the transmission and remove five screws,
five washers and five flat washers.
7. Install the compartment covers as described in
paragraph 5-2. 9. Slowly lower the transmission out the bottom of
the frame.
8. Turn on key switch and emergency disconnect.
10. Install new transmission by reversing the steps
7-3. Transmission. above.
1. Turn off key switch and emergency disconnect.

7-2 BL-EZ40-0515 - 01-31-2018

 DH_0006

Figure 7-2 Transmission Motor, Brake Mounting

BL-EZ40-0515 - 01-31-2018 7-3

7-4 BL-EZ40-0515 - 01-31-2018
 SECTION 8
ELEVATION SYSTEM SERVICING

8-1. GENERAL under frame, the fork frame and at the tips of the
forks.
The elevation system includes the lift linkage, front
frame and back frame. 2. Turn off key switch and emergency disconnect.
3. Remove screw and shaft from each side of frame.
8-2. LIFT LINKAGE
4. Remove clips from each side of frame. Support
8-2.1. Removal link assembly and remove shaft.
1. Lift complete truck to height sufficient to permit 5. Lower link assembly to the floor.
access to lift linkage under forks. Provide blocking 6. Remove pins and remove shafts.
7. Lower links to the floor.

DH_0010

Figure 8-1 Frame

BL-EZ40-0515 - 01-31-2018 8-1

8-2.2. Repair 8-2.3. Installation
1. Remove pins, shafts and load wheel from wheel 1. Position link assembly under frame.
brackets. 2. Position wheel brackets in frame and install
2. Remove pins and shafts. Free brackets from ten- shafts. Secure shafts with pins.
sion bars. 3. Position link assembly and install shafts. Secure
3. Remove bushings from brackets if replacement is shafts with screws,
necessary, 4. Remove blocking and lower the truck to the
4. Remove pins and shafts from connector and free ground.
tension bars from connector. 5. Turn on key switch and emergency disconnect.
5. Loosen nuts and remove clevises from tension
bars.
6. Remove bushings from link if replacement is nec-
essary.
7. Install reassemble by reversing the steps above.

DH_0011

Figure 8-2 Lift Linkage Assembly

8-2 BL-EZ40-0515 - 01-31-2018

 SECTION 9
HYDRAULIC SYSTEM SERVICING

9-1. LINES AND FITTINGS NOTE: Leaking hydraulic fittings may be remedied by
simply tightening fittings. If this does not rem-
WARNING: When forks are raised, pressure exists in edy the leak, the fittings or line must be
the hydraulic system lines and fittings. To replaced.
ensure release of pressure, forks must
be fully lowered before performing any 1. Lower forks fully.
maintenance on the hydraulic system. 2. Turn off key switch and emergency disconnect.
3. Remove the compartment covers as described in
paragraph 5-2.

DH_0014

Figure 9-1 Hydraulic System

BL-EZ40-0515 - 01-31-2018 9-1

CAUTION: Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container
under the line or fitting before discon-
necting.
4. Refer to Figure 9-1 and remove leaking line or fit-
ting and replace it with a new line or fitting. Check
level of hydraulic oil. With lift carriage fully low-
ered, fill reservoir with hydraulic oil to 1 inch below
opening. Use hydraulic oil listed in Table 3-2.
5. Turn on key switch and emergency disconnect.
6. Operate the lift and lower buttons to refill the
cylinder and 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. Install the compartment covers as described in
paragraph 5-2.
9-2. HYDRAULIC AND ELECTRICAL ASSEMBLY
REMOVAL
The hydraulic system and electrical system can be
removed as an assembly to provide additional clear-
ance for various maintenance procedures.
WARNING: When forks are raised, pressure exists in
the hydraulic system lines and fittings. To
ensure release of pressure, forks must
be fully lowered and the batteries discon-
nected before performing any mainte-
nance on the hydraulic system.
9-2.1. Removal
1. Lower forks fully.
2. Turn off key switch and emergency disconnect.
3. Remove the compartment covers as described in
paragraph 5-2.
4. Disconnect hose from pump and motor assembly.
5. Tag and disconnect all harnesses and cables from
electrical components on board.
6. Support board and remove four screws, four lock
washers and four flat washers.
7. Remove board.
9-2
9-2.2. Installation
1. Position board on frame and secure with four
screws, four lock washers and four flat washers.
2. Reconnect hose to pump and motor assembly.
3. Reconnect all harnesses and cables to electrical
components on board.
4. Turn on key switch and emergency disconnect.
5. Install the compartment covers as described in
paragraph 5-2.
9-3. HYDRAULIC PUMP, MOTOR, AND RESER-
VOIR ASSY
The hydraulic pump/motor assembly can be disas-
sembled and repaired. However, a defective pump,
valve or motor requires replacement of that compo-
nent.
WARNING: When forks are raised, pressure exists in
the hydraulic system lines and fittings. To
ensure release of pressure, forks must
be fully lowered and the batteries discon-
nected before performing any mainte-
nance on the hydraulic system.
9-3.1. Removal
1. Lower forks fully.
2. Turn off key switch and emergency disconnect.
3. Remove the hydraulic and electrical assembly as
described in paragraph 9-2.
NOTE: The reservoir will be filled with hydraulic oil.
Place a container under the pump assembly
to catch any hydraulic oil.
4. Remove two screws, lock washers and flat wash-
ers and remove pump and motor.
9-3.2. Disassembly and Reassembly
1. Remove the hydraulic pump/motor assembly as
described in paragraph 9-3.1.
2. Refer to Figure 9-2 for disassembly and reassem-
bly.
BL-EZ40-0515 - 01-31-2018
 DH_0015

Figure 9-2 Pump & Motor Assy

BL-EZ40-0515 - 01-31-2018 9-3

9-3.3. Installation 1. Secure the lift cylinder in a vise, clamping lightly
at the base of the cylinder.
1. Position pump and motor on board and secure
with two screws, lock washers and flat washers. 2. Unscrew gland nut from body.
2. Remove the hydraulic and electrical assembly as 3. Remove wiper and O-ring from gland nut.
described in paragraph 9-2. 4. Withdraw the cylinder rod from body.
3. Fill the hydraulic reservoir. Hydraulic oil must be 1 5. Remove bushing, guide ring and seal ring from
inch below opening. If required, add hydraulic oil rod.
to bring to proper level. Use hydraulic oil listed in
Table 3-2. NOTE: If the cylinder body or piston rod are dam-
aged, the entire lift cylinder must be replaced.
4. Turn off key switch and emergency disconnect.
5. Operate the lift and lower buttons to refill the 6. Replace guide ring, seal ring, wiper ring and O-
cylinder and lines with hydraulic oil. ring.
6. Check level of hydraulic oil. Hydraulic oil must be 7. Coat all parts with hydraulic oil (Table 3-2).
1 inch below opening. If required, add hydraulic 8. Install new guide ring, seal ring and bushing on
oil to bring to proper level. Use hydraulic oil listed rod.
in Table 3-2.
9. Insert piston rod into body.
7. Install the compartment cover as described in
10. Install wiper and O-ring in gland nut.
paragraph 5-2.
11. Install gland nut in body.
9-3.4. Lift Cylinder
9-3.4.3.Installation
9-3.4.1.Removal
1. Position the cylinder on frame and lower the
1. Lower forks fully. frame onto the cylinder.
2. Turn off key switch and emergency disconnect. 2. Install pin and retaining rings.
3. Remove the compartment covers as described in 3. Reconnect the hose to cylinder.
paragraph 5-2.
4. Fill the hydraulic reservoir. Hydraulic oil must be 1
4. Ensure that hydraulic pressure has been relieved inch below opening. If required, add hydraulic oil
from the lift circuit. Disconnect the hydraulic line to bring to proper level. Use hydraulic oil listed in
from the lift cylinder. Table 3-2.
5. Disconnect hose from cylinder. 5. Turn on key switch and emergency disconnect.
WARNING: Frame is heavy. Use care while securing 6. Operate the lift and lower buttons to refill the
and lifting in order to prevent injury. cylinder and lines with hydraulic oil.
7. Check level of hydraulic oil. Hydraulic oil must be
6. With suitable hoist, carefully raise frame slightly to
1 inch below opening. If required, add hydraulic
relieve pressure on the cylinder.
oil to bring to proper level. Use hydraulic oil listed
7. Remove retaining rings and pin. in Table 3-2.
8. Remove cylinder. 8. Install the compartment cover as described in
paragraph 5-2.
9-3.4.2.Repair

9-4 BL-EZ40-0515 - 01-31-2018

 DH_0016

Figure 9-3 Lift Cylinder

BL-EZ40-0515 - 01-31-2018 9-5

 NOTES

9-6 BL-EZ40-0515 - 01-31-2018

 SECTION 10
ELECTRICAL COMPONENTS

10-1.ELECTRICAL CONTROL PANEL 10-1.3.Controller Removal.

10-1.1.Maintenance 1. Turn off key switch and emergency disconnect.

2.
NOTE: Erratic operation of the truck may be caused
by defective controller components. Before
removing the electrical panel, perform trou- 3.
bleshooting procedures per SECTION 4, to 4.
determine corrective action to be taken.
Remove the compartment covers as described in
paragraph 5-2.
Tag and disconnect harness from controller.
Remove four screws, lock washers and remove
controller.

There are no user-serviceable parts inside the control- 10-1.4.Controller Installation.

ler. No attempt should be made to open the controller.
1. Position controller and the board and secure with
Opening the controller may damage it and will void the
four screws and lock washers.
warranty.
2. Reconnect harness to controller .
The controller is programmed at the factory specifi-
cally for the truck model on which it is equipped. It is 3. Install compartment covers as described in para-
important to replace the controller with the correct pre- graph 5-2.
programmed unit to assure proper performance set- 1. Turn on key switch and emergency disconnect .
tings intended for that particular truck. See Figure 12-
22 for the preprogrammed controller number. 10-1.5.Charger Removal.
It is recommended that the controller exterior be 1. Turn off key switch and emergency disconnect.
cleaned periodically, and if a Zapi Handset is avail- 2. Remove the compartment covers as described in
able, this periodic cleaning provides a good opportu- paragraph 5-2.
nity to check the controller’s diagnostic history file. It is
3. Tag and disconnect harness from charger.
also recommended that the controller’s fault detection
circuitry be checked whenever the vehicle is serviced. 4. Tag and disconnect remaining two charger leads
from the pump motor and the fuse.
10-1.2.Cleaning 5. Remove four screws, four lock washers, two
1. Turn off key switch and emergency disconnect. straps and charger.
2. Remove the compartment covers as described in 10-1.6.Charger Installation.
paragraph 5-2.
1. Position charger on board and secure with three
3. Remove any dirt or corrosion from the bus bar
screws, screw, four lock washers and two straps .
area. The controller should be wiped clean with a
moist rag. Allow it to dry before reconnecting the 2. Reconnect the two charger leads to the pump
battery. motor and the fuse.
4. Make sure the connections to the buss bars are 3. Reconnect harness to charger.
tight. Use two well insulated wrenches for this 4. Install compartment covers as described in para-
task in order to avoid steering the buss bars. graph 5-2.
5. Turn on key switch and emergency disconnect.

BL-EZ40-0515 - 01-31-2018 10-1

10-1.7.Emergency Disconnect Removal. 3. Tag and disconnect wires from contactor.
1. Turn off key switch and emergency disconnect. 4. Remove two screws, lock washers, flat washers
and remove contactor.
2. Remove the compartment covers as described in
paragraph 5-2. 10-1.10.Contactor Installation.
3. Tag and disconnect harness from emergency dis- 1. Position contactor on the board and secure with
connect. two screws, lock washers and flat washers.
4. Remove the knob from the emergency disconnect
2. Reconnect wires to contactor.
5. Remove two screws and remove emergency dis- 3. Install compartment covers as described in para-
connect from bracket. graph 5-2.
10-1.8.Emergency Disconnect Installation. 4. Turn on key switch and emergency disconnect.
1. Position emergency disconnect on bracket and 10-1.11.Fuse Removal.
secure with two screws.
1. Turn off key switch and emergency disconnect.
2. Install the knob on the emergency disconnect
2. Remove the compartment covers as described in
3. Reconnect harness to emergency disconnect. paragraph 5-2.
4. Install compartment covers as described in para-
3. Loosen two nuts and rotate and remove fuse.
graph 5-2.
5. Turn on key switch and emergency disconnect. 10-1.12.Fuse Installation.
1. Install fuse on the stand and secure two nuts.
10-1.9.Contactor Removal.
2. Install compartment covers as described in para-
1. Turn off key switch and emergency disconnect.
graph 5-2.
2. Remove the compartment covers as described in 3. Turn on key switch and emergency disconnect.
paragraph 5-2.

10-2 BL-EZ40-0515 - 01-31-2018

 DH_0019

Figure 10-1 Electrical Components (Sheet 1)

BL-EZ40-0515 - 01-31-2018 10-3

10-1.13.Cooling Fan Removal. 4. Turn on key switch and emergency disconnect .
1. Turn off key switch and emergency disconnect . 10-1.17.Key Switch Removal.
2. Remove the compartment covers as described in 1. Turn off key switch and emergency disconnect.
paragraph 5-2.
2. Remove the compartment covers as described in
3. Tag and disconnect harness from cooling fan. paragraph 5-2.
4. Remove four screws, four lock washers and four
3. Tag and disconnect harness from key switch.
flat washers. Remove cooling fan and guard from
bracket. 4. Free key switch from bracket.

10-1.14.Cooling Fan Installation. 10-1.18.Key Switch Installation.

1. Position cooling fan and guard on bracket and 1. Insert key switch in bracket.
secure with four screws, four lock washers and 2. Reconnect harness to key switch.
four flat washers. 3. Install compartment covers as described in para-
2. Reconnect harness to cooling fan. graph 5-2.
3. Install compartment covers as described in para- 4. Turn on key switch and emergency disconnect.
graph 5-2.
10-1.19.Battery Indicator Removal.
4. Turn on key switch and emergency disconnect.
1. Turn off key switch and emergency disconnect.
10-1.15.Buzzer Removal.
2. Remove the compartment covers as described in
1. Turn off key switch and emergency disconnect. paragraph 5-2.
2. Remove the compartment covers as described in 3. Tag and disconnect harness from battery indica-
paragraph 5-2. tor.
3. Tag and disconnect harness from buzzer. 4. Remove mounting nuts and bracket and remove
4. Remove two screws and buzzer from bracket. battery indicator from bracket.

10-1.16.Buzzer Installation. 10-1.20.Battery Indicator Installation.

1. Position buzzer on bracket and secure with two 1. Position battery indicator on bracket and secure
screws. with its mounting bracket and nuts.
2. Reconnect harness to buzzer. 2. Reconnect harness to battery indicator.
3. Install compartment covers as described in para- 3. Install compartment covers as described in para-
graph 5-2. graph 5-2.
4. Turn on key switch and emergency disconnect.

10-4 BL-EZ40-0515 - 01-31-2018

 DH_0020

Figure 10-2 Electrical Components (Sheet 2)

BL-EZ40-0515 - 01-31-2018 10-5

10-1.21.Lift Limit Switch Removal. 10-1.22.Lift Limit Switch Installation.
1. Lower forks fully. 1. Position limit switch on bracket and secure with
2. Turn off key switch and emergency disconnect. two screws, lock washers and nuts.

3. Remove the compartment covers as described in 2. Reconnect harness to limit switch.

paragraph 5-2. 3. Install compartment covers as described in para-
4. Tag and disconnect harness from limit switch. graph 5-2.

5. Remove two nuts, screws, lock washers and limit 4. Turn on key switch and emergency disconnect.
switch from bracket.

DH_0017

Figure 10-3 Electric System

10-6 BL-EZ40-0515 - 01-31-2018

10-2.PUMP MOTOR. 1. Turn off key switch and emergency disconnect.
The pump motor is replaceable but not repairable. 2. Remove the compartment covers as described in
Refer to paragraph 9-3. paragraph 5-2.
3. Disconnect wiring from the deadman switch.
10-3.DRIVE MOTOR.
4. Remove the two screws, lock washers and
The drive motor exposed surfaces should be cleaned bracket from bracket.
at least once a month to assure proper cooling of
5. Remove two screws and switch from bracket.
motor. Use an air hose to blow dust off of motor sur-
faces. 6. Position the new switch on bracket and secure
with the two screws.
The drive motor is replaceable but not repairable.
Refer to paragraph 7-3. 7. Position bracket on bracket and secure with two
screws and lock washers.
10-4.DEADMAN SWITCH 8. Install compartment covers as described in para-
graph 5-2.
10-4.1.Replacement
9. Turn on key switch and emergency disconnect.

BL-EZ40-0515 - 01-31-2018 10-7

 NOTES

10-8 BL-EZ40-0515 - 01-31-2018

 SECTION 11
OPTIONAL EQUIPMENT

BL-EZ40-0515 - 01-31-2018 11-1

 NOTES

11-2 BL-EZ40-0515 - 01-31-2018

 SECTION 12
ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the EZ40 Lift Truck.

BL-EZ40-0515 - 01-31-2018 12-1

 DH_0001

Figure 12-1 Steering Arm

12-2 BL-EZ40-0515 - 01-31-2018

 Steering Arm

Qty.
Pos. Part Number Description Notes
Reqd.
1 1120-340000-00-B CONTROL HEAD ASSEMBLY 1

2 1146-330000-30 CONTROL ARM ASSEMBLY 1

3 1120-320000-00 GAS SPRING 1

4 0000-000151-00 SCREW, M8 X 25 1

5 1120-300003-00 SHAFT 1

6 0000-000011-00 BUSHING, 2015 2

7 0000-000386-00 SCREW, M6 X 20 1

8 1120-300005-00 BRACKET 1

9 0000-000429-00 SCREW, M5 X 8 1

10 0000-000030-00 SCREW, M10 X 16 1

11 0000-000159-00 LOCK WASHER, M8 3

12 0000-000063-00 LOCK WASHER, M10 1

13 0000-000490-00 HARNESS CLAMP 1

14 0000-000031-00 SCREW, M5 X 8 1

15 1118-520003-00 WIRE HARNESS 1

16 1118-520005-10 DEADMAN SWITCH ASSEMBLY 1

17 1120-300001-0A BRAKE BRACKET 1

18 1120-300006-00 SPACER 1

19 0000-000009-00 SCREW, M4 X 12 2

20 0000-000122-00 LOCK WASHER, M4 3

21 0000-000377-00 SCREW, M2 X 20 2

22 0000-000378-00 SCREW, M4 X 16 1

23 0000-000702-00 FLAT WASHER, M4 1

24 0000-000491-00 HARNESS CLAMP 1

25 0000-000139-00 NUT, M4 1

26 0000-000109-00 SCREW, M8 X 16 3

27 1220-560001-00 INCHING SWITCH 2

BL-EZ40-0515 - 01-31-2018 12-3

 DH_0002

Figure 12-2 Control Head

12-4 BL-EZ40-0515 - 01-31-2018

 Control Head

Qty.
Pos. Part Number Description Notes
Reqd.
1 1120-342000-00-B CAP ASSEMBLY 1

2 1120-340005-00 TRAVELLING KNOB R 1

3 0000-000038-00 LOCK WASHER Ø3 2

4 0000-000037-00 SCREW M3×12 2

5 0000-000004-00 SCREW M5×12 2

6 0000-000206-00 LOCK WASHER Ø5 4

7 0000-000390-00 FLAT WASHER Ø5 4

8 0000-000088-00 SCREW M4×8 2

9 0000-000122-00 LOCK WASHER Ø4 2

10 0000-000702-00 FLAT WASHER Ø4 2

11 0000-000322-00 SCREW M8×25 2

12 0000-000159-00 LOCK WASHER Ø8 2

13 0000-000176-00 FLAT WASHER Ø8 2

14 1120-340003-00 TRAVELLING KNOB L 1

15 1120-343000-00-B REVERSING SWITCH ASSEMBLY 1

16 0000-000004-00 SCREW M5×12 2

17 0000-000035-00 SCREW M5×20 4

18 1120-340002-00 COVER 1

19 1120-341000-00 GRIPE 1

20 1120-340001-00 POD 1

21 1220-520008-0C ACCELERATOR ASSEMBLY 1

22 0000-000010-00 SCREW M5×6 1

BL-EZ40-0515 - 01-31-2018 12-5

 DH_0004

Figure 12-3 Cap Assembly

12-6 BL-EZ40-0515 - 01-31-2018

 Cap Assembly

Qty.
Pos. Part Number Description Notes
Reqd.
1 1120-342001-00 UPPER COVER 1

2 1120-342203-00 BUTTON FOR LIFTING (R) 1

3 1120-342202-00 BUTTON FOR LOWERING (R) 1

4 1120-342102-00 SPRING 8

5 1120-342201-00 BUTTON BRACKET (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 0000-000039-00 SCREW ST3.5×9.5 6

12 0000-000490-00 HARNESS CLAMP 3

13 1120-342200-00 LIFT AND LOWER BOX (R) ASSEMBLY 1

14 1120-342100-00 LIFT AND LOWER BOX (L) ASSEMBLY 1

15 1220-520006-0C BUTTONS ASSEMBLY 1

16 1220-560002-00 INCHING SWITCH II 5

17 1120-342002-00 HORN BUTTON 1

18 1120-342005-00 PIN 2

19 1120-342003-00 SPRING 2

20 1120-342004-00 BUTTON BRACKET 1

BL-EZ40-0515 - 01-31-2018 12-7

 DH_0005

Figure 12-4 Emergency Reverse Switch Assembly

12-8 BL-EZ40-0515 - 01-31-2018

 Emergency Reverse Switch Assembly

Qty.
Pos. Part Number Description Notes
Reqd.
— 1120-343000-00-B EMERG. REVERSE SWITCH ASSY 1

1 1120-343002-00 EMERGENCY REVERSE BUTTON 1

2 1120-343003-00 SPRING 2

3 1120-342005-00 PIN 2

4 1120-343001-0A BRACKET 1

5 1120-343004-00 PIN 1

6 1220-520005-0C WIRE HARNESS-REVERSING SWITCH 1

7 1220-560002-00 SWITCH 1

BL-EZ40-0515 - 01-31-2018 12-9

 DH_0006

Figure 12-5 Transmission Motor, Brake Mounting

12-10 BL-EZ40-0515 - 01-31-2018

 Transmission Motor, Brake Mounting

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000027-00 SCREW, M6 X 55 3

2 1120-210000-00 BRAKE ASSEMBLY 1

3 1120-220000-00 MOTOR ASSEMBLY 1

4 0000-000154-00 SCREW, M8 X 35 8

5 0000-000159-00 LOCK WASHER, M8 8

6 0000-000176-00 FLAT WASHER, M8 8

7 0000-000155-00 SCREW, M10 X 40 5

8 0000-000063-00 LOCK WASHER, M10 5

9 0000-000007-00 FLAT WASHER, M10 5

10 1120-230000-00 BEARING 1

11 0000-000013-00 GREASE FITTING, M8 1

Used up to serial number

12 4230-210000-10 TRANSMISSION ASSEMBLY 1
E2219364

Used from serial number

12a 1120-240000-30 TRANSMISSION ASSEMBLY 1
E2219365

13 1120-200001-20 DRIVE WHEEL ASSEMBLY 1 Poly Diamond-X Cut

14 0000-000025-00 LOCK WASHER, M12 5

15 0000-000157-00 NUT, M12 X 1.25 5

16 0000-000070-00 SCREW, M10 X 25 2

17 1120-210002-00 BRAKE PLATE 1

18 1120-240014-30 STUDS 5

BL-EZ40-0515 - 01-31-2018 12-11

 DH_0007

Figure 12-6 Transmission - Used up to serial number E2219364

12-12 BL-EZ40-0515 - 01-31-2018

 Transmission - Used up to serial number E2219364

Qty.
Pos. Part Number Description Notes
Reqd.
— 4230-210000-10 TRANSMISSION ASSEMBLY 1

1 1120-240001-30 GEAR CASE 1

2 1120-240002-30 PLUG 1

3 0000-000214-00 O-RING 135 X 3.1 1

4 1120-240003-30 COVER 1

5 0000-000056-00 LOCK WASHER, M6 12

6 0000-000259-00 BOLT, M6 X 16 8

7 1120-240019-30 WASHER A.R. As Required

8 0000-000961-00 BEARING 2

9 1120-240005-30 PLUG 1

10 1120-GB30-10 SPIRAL BEVEL GEAR KIT 1 Includes 2 gears

11 1120-240007-30 WASHER 1

12 1120-240008-30 LOCKING PLATE 1

13 0000-000277-00 BOLT, M8 X 25 3

14 0000-001054-00 BEARING 2

15 4230-GB10-00 GEAR KIT 1 Includes 2 gears

16 0000-000379-00 FLAT WASHER, M14 1

17 0000-001055-00 WASHER, M14 1

18 0000-001056-00 NUT, M14 X 1.5 1

19 0000-000211-00 O-RING, 150 X 3.1 1

20 1120-240010-30 COVER 1

21 1120-240011-30 VENT PLUG 1

22 0000-000055-00 SCREW M6×16 4

23 1120-240017-30 SEAL WASHER, TC80 X 65 X 8 1

24 1120-240013-30 OUTPUT SHAFT 1

BL-EZ40-0515 - 01-31-2018 12-13

 DH_0024

Figure 12-7 Transmission - Used from serial number E2219365

12-14 BL-EZ40-0515 - 01-31-2018

 Transmission - Used from serial number E2219365

Qty.
Pos. Part Number Description Notes
Reqd.
-- 1120-240000-30 TRANSMISSION ASSEMBLY 1

1 1120-240001-30 GEAR CASE 1

2 1120-240002-30 PLUG 1

3 0000-000214-00 O-RING 135×3.1 1

4 1120-240003-30 COVER 1

5 0000-000056-00 LOCK WASHER Ø6 12

6 0000-000259-00 BOLT M6×16 8

7 1120-240019-30 WASHER A.R. As required

8 0000-000961-00 BEARING 2

9 1120-240005-30 PLUG 1

10 11120-GB30-10 SPIRAL BEVEL GEAR KIT 1 Includes 2 gears

11 1120-240007-30 WASHER 1

12 1120-240008-30 LOCKING PLATE 1

13 0000-000277-00 BOLT M8×25 3

14 0000-001054-00 BEARING 2

15 1120-GB30-00 GEAR KIT 1 Includes 2 gears

16 0000-000379-00 FLAT WASHER Ø14 1

17 0000-001055-00 WASHER Ø14 1

18 0000-001056-00 NUT M14×1.5 1

19 0000-000211-00 O-RING 150×3.1 1

20 1120-240010-30 COVER 1

21 1120-240011-30 GAS PLUG 1

22 0000-000055-00 SCREW M6×16 4

23 1120-240017-30 SEAL WASHER TC80×65×8 1

24 1120-240013-30 OUTPUT SHAFT 1

BL-EZ40-0515 - 01-31-2018 12-15

 DH_0008

12-16 BL-EZ40-0515 - 01-31-2018

 Figure 12-7 Compartment Covers

Compartment Covers

Qty.
Pos. Part Number Description Notes
Reqd.
Used up to serial number
1 1118-100001-00-02 COVER - REHRIG BLUE 1
E2316807

Used between serial num-

1a 1118-100001-10-02 COVER - REHRIG BLUE 1
ber E2316808 - 324180205

Used from serial number

1b 1118-100001-00-02 COVER - REHRIG BLUE 1
324180206

Used up to serial number

1c 1118-100001-00-04 COVER - OLD PEPSI BLUE 1
E2316807

Used between serial num-

1d 1118-100001-10-04 COVER - OLD PEPSI BLUE 1
ber E2316808 - 324180206

Used up to serial number

1e 1118-100001-00-06 COVER - NEW PEPSI BLUE 1
E2316807

Used between serial num-

1f 1118-100001-10-06 COVER - NEW PEPSI BLUE 1
ber E2316808 - 324180206

Used from serial number

1g 1118-100001-00-06 COVER - NEW PEPSI BLUE 1
324180206

Used up to serial number

1h 1118-100001-00-05 COVER - M.D. GREEN 1
E2316807

Used between serial num-

1i 1118-100001-10-05 COVER - M.D. GREEN 1
ber E2316808 - 324180206

Used from serial number

1j 1118-100001-00-05 COVER - M.D. GREEN 1
324180206

Used up to serial number

1k 1118-100001-00-07 COVER - COKE RED 1
E2316807

Used between serial num-

1l 1118-100001-10-07 COVER - COKE RED 1
ber E2316808 - 324180206

Used from serial number

1m 1118-100001-00-07 COVER - COKE RED 1
324180206

Used from serial number

1n 1118-100001-00-08 COVER - AB RED 1
324180206

Used up to serial number

2 1118-100002-00-02 UPPER COVER - REHRIG BLUE 1
324180206

Used between serial num-

2a 1118-100002-10-02 UPPER COVER - REHRIG BLUE 1 ber 324180207 and
324190035

Used from serial number

2b 1118-100002-1A-02 UPPER COVER - REHRIG BLUE 1
324190036

BL-EZ40-0515 - 01-31-2018 12-17

 DH_0008

Figure 12-8 Compartment Covers

12-18 BL-EZ40-0515 - 01-31-2018

 Compartment Covers
Qty.
Pos. Part Number Description Notes
Reqd.
Used up to serial number
2c 1118-100002-00-01 UPPER COVER - OLD PEPSI BLUE 1
324180206

Used up to serial number

2d 1118-100002-00-05 UPPER COVER - NEW PEPSI BLUE 1
324180206

Used between serial num-

2e 1118-100002-10-05 UPPER COVER - NEW PEPSI BLUE 1 ber 324180207 and
324190035

Used from serial number

2f 1118-100002-1A-05 UPPER COVER - NEW PEPSI BLUE 1
324190036

Used up to serial number

2g 1118-100002-00-04 UPPER COVER - M.D. GREEN 1
324180206

Used between serial num-

2h 1118-100002-10-04 UPPER COVER - M.D. GREEN 1 ber 324180207 and
324190035

Used from serial number

2i 1118-100002-1A-04 UPPER COVER - M.D. GREEN 1
324190036

Used up to serial number

2j 1118-100002-00-06 UPPER COVER - COKE RED 1
324180206

Used between serial num-

2k 1118-100002-10-06 UPPER COVER - COKE RED 1 ber 324180207 and
324190035

Used from serial number

2l 1118–100002-1A-06 UPPER COVER - COKE RED 1
324190036

Used between serial num-

2m 1118-100002-10-07 UPPER COVER - AB RED 1 ber 324180207 and
324190035

Used from serial number

2n 1118-100002-1A-07 UPPER COVER - AB RED 1
324190036

Used up to serial number

3 1118-100003-00-02 LOWER COVER - REHRIG BLUE 1
324180206

Used between serial num-

3a 1118-100003-10-02 LOWER COVER - REHRIG BLUE 1 ber 324180207 and
324190035

Used from serial number

3b 1118-100003-1A-02 LOWER COVER - REHRIG BLUE 1
324190036

Used up to serial number

3c 1118-100003-00-01 LOWER COVER - OLD PEPSI BLUE 1
324180206

Used up to serial number

3d 1118-100003-00-05 LOWER COVER - NEW PEPSI BLUE 1
324180206

BL-EZ40-0515 - 01-31-2018 12-19

 DH_0008

Figure 12-9 Compartment Covers

12-20 BL-EZ40-0515 - 01-31-2018

 Compartment Covers

Qty.
Pos. Part Number Description Notes
Reqd.
Used between serial num-
3e 1118-100003-10-05 LOWER COVER - NEW PEPSI BLUE 1 ber 324180207 and
324190035

Used from serial number

3f 1118-100003-1A-05 LOWER COVER - NEW PEPSI BLUE 1
324190036

Used up to serial number

3g 1118-100003-00-04 LOWER COVER - M.D. GREEN 1
324180206

Used between serial num-

3h 1118-100003-10-04 LOWER COVER - M.D. GREEN 1 ber 324180207 and
324190035

Used from serial number

3i 1118-100003-1A-04 LOWER COVER - M.D. GREEN 1
324190036

Used up to serial number

3j 1118-100003-00-06 LOWER COVER - COKE RED 1
324180206

Used between serial num-

3k 1118-100003-10-06 LOWER COVER - COKE RED 1 ber 324180207 and
324190035

Used from serial number

3l 1118-100003-1A-06 LOWER COVER - COKE RED 1
324190036

Used between serial num-

3m 1118-100003-10-07 LOWER COVER - AB RED 1 ber 324180207 and
324190035

Used from serial number

3n 1118-100003-1A-07 LOWER COVER - AB RED 1
324190036

Used up to serial number

4 0000-000649-00 SCREW, M8 X 20 6
324190035

Used from serial number

4a 1118-100004-10 SCREW, M8 X 20 6
324190036

Used up to serial number

5 2214-150002-00 WASHER 6
324190035

6 1118-100005-00 CHARGER CAP 1

7 0000-000126-00 SCREW, M6 X 16 2

8 0000-000119-00 SCREW, M5 X 12 2

9 1118-100004-00-02 MIDDLE COVER - REHRIG BLUE 1

9a 1118-100004-00-04 MIDDLE COVER - OLD PEPSI BLUE 1

9b 1118-100004-00-06 MIDDLE COVER - NEW PEPSI BLUE 1

9c 1118-100004-00-05 MIDDLE COVER - M.D. GREEN 1

9d 1118-100004-00-07 MIDDLE COVER - COKE RED 1

9e 1118-100004-00-08 MIDDLE COVER - AB RED 1

BL-EZ40-0515 - 01-31-2018 12-21

 DH_0009

Figure 12-10 Load Backrest - Hinged Version

Load Backrest - Hinged Version

12-22 BL-EZ40-0515 - 01-31-2018

 Qty.
Pos. Part Number Description Notes
Reqd.
— 1118-600000-00 LOAD BACKREST 1

1 0000-000322-00 SCREW, M8 X 25 2

2 0000-000159-00 LOCK WASHER, M8 8

3 1115-630000-K0 LOAD BACKREST 1

4 1115-670000-K0 HANDLE ASEMBLY 1

5 1115-600003-K0 BOLT 8

6 0000-000737-00 BUSHING, M12 X 10 X 16 8

7 0000-000740-00 NUT, M8 16

8 1118-610000-00 LOAD BACKREST FRAME 1

9 0000-000738-00 SCREW, M8 X 30 6

10 1115-622000-K0 UPPER LINK ASSEMBLY 1

11 1115-621000-K0 LOWER LINK ASSEMBLY 1

12 1115-600004-K0 BLOCK 2

13 0000-000321-00 SCREW, M8 X 20 2

14 0000-000739-00 SCREW, M6 X 20 12.9 40

15 0000-000056-00 LOCK WASHER, M6 40

16 0000-000380-00 FLAT WASHER, M6 40

17 1115-650000-K0 LEG R 1

18 1115-640000-K0 HINGE ASSEMBLY 6

19 1115-660000-K0 LEG L 1

20 0000-000109-00 SCREW, M8 X 16 4

21 0000-000176-00 FLAT WASHER, M8 4

22 1115-680000-K0 BASKET FOR EZ30 / EZ40 1 Basket Only

Includes Items 5, 6, 7, 8, 9,
23 1118-610000-00-B LOAD BACKREST FRAME ASSEMBLY 1
10, 11

BL-EZ40-0515 - 01-31-2018 12-23

 DH_0009

Figure 12-10 Load Backrest - Hinged Version - Continued

12-24 BL-EZ40-0515 - 01-31-2018

 Load Backrest - Hinged Version - Continued

Qty.
Pos. Part Number Description Notes
Reqd.
Includes Items 1, 2, 3, 4, 7,
24 1115-630000-K0-B LOADBACKREST ASSEMBLY 1
12, 14

Includes Items 14, 15, 16,

25 1115-640000-K0-B GUIDE RAIL SYSTEM ASSEMBLY 1
17, 18, 19

26 1115-681000-K0 BRACKET 1

27 0000-000030-00 SCREW 1

Includes Items 27, 28, 29,

28 901803 LOAD RESTRAINT KIT EZ30 / EZ40 1
30, 31

29 0000-000054-00 NUT

30 -- BELT BUCKLE Included in Item 28

31 0000-000070-00 SCREW 1

BL-EZ40-0515 - 01-31-2018 12-25

 DH_0026

Figure 12-11 Load Backrest - Fold Down Version

12-26 BL-EZ40-0515 - 01-31-2018

 Load Backrest - Fold Down Version
Qty.
Pos. Part Number Description Notes
Reqd.
Used up to serial number
- 1118-600000-60 LOAD BACKREST ASSEMBLY 2
324190319

Used from serial number

- 1118-600000-6A LOAD BACKREST ASSEMBLY 2
324190320

1 0000-000322-00 SCREW M8×25 2

2 0000-000159-00 LOCKWASHER Ø8 6

Used up to serial number

3 1118-630000-60 LOAD BACKREST 1
324190319

Used from serial number

3a 1118-630000-6A LOAD BACKREST 1
324190320

4 1115-670000-K0 HANDLE ASSEMBLY 1

5 1115-600003-K0 BOLT 10

6 0000-000737-00 BUSHING 12×10×16 12

7 0000-000740-00 NUT M8 22

8 1118-610000-60 LOAD BACKREST FRAME 1

9 0000-000738-00 SCREW M8×30 6

10 1118-622000-60 UPPER LINK 1

11 1118-621000-60 LOWER LINK 1

12 1115-600004-K0 BLOCK 2

Used up to serial number

13 0000-000321-00 SCREW M8×20 2
E2410446

Used from serial number

13a 0000-000110-00 SCREW M8×65 2
E2410447

14 0000-000739-00 SCREW M6×20 4

15 0000-000056-00 LOCKWASHER Ø6 6

16 0000-000380-00 FLATWASHER Ø6 6

Used up to serial number

17 1118-650000-60 LEG R 1
324150254

Used between serial number

17a 1118-691000-60 LEG R 1 324150255 - 325200220 -
See Pos. # 46 for Kit number

Used from serial number

17b 1118-691000-6A LEG R 1 325200221 - See Pos. # 46a
for Kit number

BL-EZ40-0515 - 01-31-2018 12-27

 DH_0026

Figure 12-11 Load Backrest - Fold Down Version - Continued

12-28 BL-EZ40-0515 - 01-31-2018

 Load Backrest - Fold Down Version - Continued
Qty.
Pos. Part Number Description Notes
Reqd.
Used up to serial number
18 0000-001328-00 BUSHING 14×12×16 2
324150254

Used from serial number

18a 0000-001455-00 BUSHING 14×12×12 2
324150255

Used up to serial number

19 1118-660000-60 LEG L 1
324150254

Used between serial number

19a 1118-692000-60 LEG L 1 324150255 - 325200220 - See
Pos. # 46 for Kit number

Used from serial number

19b 1118-692000-6A LEG L 1 325200221 - See Pos. # 46a for Kit
number

20 0000-000700-00 SCREW M 8×16 4

21 0000-000176-00 FLATWASHER Ø8 4

Used up to serial number

22 1118-682000-60 BOX ASSEMBLY 1
326150719

Used from serial number

22a 1118-682000-6A BOX ASSEMBLY 1
326150720

23 1118-610000-60-B LOAD BACKREST FRAME ASSY. 1

Used up to serial number

24 1118-630000-60-B LOAD BACKREST ASSEMBLY 1
324190319

Used from serial number

24a 1118-630000-6A-B LOAD BACKREST ASSEMBLY 1
324190320

25 1118-640000-60 SIDE LINK 2

Used up to serial number

26 1115-681000-K0 BRACKET 1
325200839

Used from serial number

26a 1118-683000-60 BRACKET 1
325200840

27 1118-600003-60 PLATE 2

28 1118-601000-60 PIN 2

29 0000-000259-00 BOLT M6×16 6

30 1118-650010-60 MAGNET 2

31 0000-000028-00 SCREW M 4×10 2

32 1118-600002-60 BOLT 2

BL-EZ40-0515 - 01-31-2018 12-29

 DH_0026

Figure 12-11 Load Backrest - Fold Down Version - Continued

12-30 BL-EZ40-0515 - 01-31-2018

 Load Backrest - Fold Down Version - Continued
Qty.
Pos. Part Number Description Notes
Reqd.
Used between serial number
33 1118-661000-60 SQUARE SPACER 1
E2410447 and 326150783

Used from serial number

33a 1118-661000-6A SQUARE SPACER 1
326150784

Used from serial number

34 1118-600004-60 WASHER 2
324150255

35 0000-000031-00 SCREW M5×8 1

36 0000-000390-00 FLATWASHER Ø5 2 Used from serial number

324190320
37 1118-661001-60 PLATE 1

38 1118-661002-60 MAGNET 1

Used up to serial number

39 0000-000028-00 SCREW M4×10 2
325130270

39a 0000-001549-00 SCREW M4×12 2 Used from serial number

325130271
40 2214-150002-00 WASHER 2

41 1118-100004-10 SCREW M8×20 2

42 1118-684000-60 ROLLER 1
Used from serial number
43 0000-000550-00 NUT 2
326150784
44 1118-685000-60 BRACKET 1

45 0000-000321-00 SCREW M8×20 2

47 901803 LOAD RESTRAINT KIT 1 Incl. Pos. # 41, 42, 43, 44, 45

48 0000-000030-00 SCREW 1

49 0000-000054-00 NUT 1

50 -- BELT BUCKLE 1 Included in Pos. # 41

51 0000-000070-00 SCREW 1

Not in picture: Used between serial

number 324150255 - 325200220 -
-- 1118-BS-60 FOLD DOWN RAIL KIT (NEW DESIGN) 1
Incl. Pos. # 15, 16, 17a, 18, 19a,
28, 29 and 34

Not in picture: Used from serial

-- 1118-BS-6A FOLD DOWN RAIL KIT (NEW DESIGN) 1 number 325200221 - Incl. Pos. #
15, 16, 17b, 18, 19b, 28, 29 and 34

BL-EZ40-0515 - 01-31-2018 12-31

 DH_0010

Figure 12-12 Frame

12-32 BL-EZ40-0515 - 01-31-2018

 Frame

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000386-00 SCREW, M6 X 20 1

2 1118-130005-00 SHAFT 1

3 0000-000650-00 SNAP RING, M25 2

Used up to serial number

4 1118-110000-30 FORK FRAME 1 E2410414 on trucks with
Hinged Load back Rest

Used between serial number

E2410415 and 324180206 on
4a 1118-110000-3A FORK FRAME 1
trucks with Hinged Load back
Rest

Used from serial number

4b 1118-110000-D0 FORK FRAME 1 324180207 on trucks with
Hinged Load back Rest

Used up to serial number

4c 1118-110000-60 FORK FRAME 1 E2410414 on trucks with Fold
Down Load back Rest

Used between serial number

E2410415 and 324180206 on
4d 1118-110000-6A FORK FRAME 1
trucks with Fold Down Load
back Rest

Used from serial number

4e 1118-110000-G0 FORK FRAME 1 324180207 on trucks with Fold
Down Load back Rest

5 1118-130003-00 LINK 1

6 1115-130004-0A SHAFT 2

7 0000-000708-00 PIN, M5 X 35 2

8 0000-000056-00 LOCK WASHER, M6 2

9 1118-130001-00 LONG SHAFT 1 With grease fitting

10 0000-000677-00 BUSHING, 1610F 4

11 1118-130004-00 SHAFT 1

12 0000-000438-00 FLAT WASHER, M12 1

13 0000-000057-00 NUT, M12 1

BL-EZ40-0515 - 01-31-2018 12-33

 DH_0010

Figure 12-13 Frame Continued

12-34 BL-EZ40-0515 - 01-31-2018

 Frame Continued

Qty.
Pos. Part Number Description Notes
Reqd.
Used up to serial number
14 1118-120000-10 BACK FRAME 1
E2410519

Used between serial number

14a 1118-120000-70 BACK FRAME 1
E2410520 - 324180206

Used from serial number

14b 1118-120000-A0-00 BACK FRAME 1
324180207

Used up to serial number

15 1220-132000-0A SHAFT 2
E2216086

Used from serial number

15a 1118-133000-00 SHAFT 2
E2216087

16 0000-000013-00 GREASE FITTING, M8 2

17 1118-100006-00 ANTI-COLLISION BLOCK, L 1

18 1118-100007-00 ANTI-COLLISION BLOCK, R 1

19 1118-140000-00 CASTER ASSEMBLY 2

20 0000-000151-00 SCREW, M8 X 25 6

21 0000-000159-00 LOCK WASHER, M8 6

22 0000-000176-00 FLAT WASHER, M8 10

23 0000-000109-00 SCREW, M8 X 16 4

24 0000-000055-00 SCREW, M6 X 16 2

25 0000-001130-00 BUSHING 2 Used from 07-03-2013

Used between serial number

26 1118-101000-10 PLATE 1
E2316808 - E2410519

Used between serial number

27 0000-000008-00 SCREW M10 X 20 4
E2316808 - E2410519

Used between serial number

28 0000-000063-00 LOCKWASHER Ø10 4
E2316808 - E2410519

Used between serial number

29 0000-000007-00 FLATWASHER Ø10 4
E2316808 - E2410519

BL-EZ40-0515 - 01-31-2018 12-35

 DH_0011

12-36 BL-EZ40-0515 - 01-31-2018

 Figure 12-14 Lift Link Assembly

Lift Link Assembly

Qty.
Pos. Part Number Description Notes
Reqd.
1 1219-141000-20 DOWN LINK 1

2 0000-001034-00 BUSHING 2

3 1219-140001-00 SHAFT 2

4 0000-000101-00 NUT, M22 X 1.5 2

5 1219-142200-00 CONNECTOR 2

6 1118-132000-00 LONG LINK 2

7 0000-000907-00 BUSHING 4

Used up to serial number

8 1115-130005-0B WHEEL BRACKET 2
E2219364

Used from serial number

8a 1115-130005-4A WHEEL BRACKET 2
E2219365

9 0000-000908-00 BUSHING, 2015 4

10 1115-130003-00 WHEEL BRACKET PIVOT SHAFT 2

11 0000-000708-00 PIN, M5 X 35 8

12 1115-130007-40 LOAD WHEEL SHAFT 2

13 1115-133000-40 LOAD WHEEL 2

14 0000-000435-00 FLAT WASHER, M20 4

15 1118-132100-00 LONG ROD 2

16 1115-130008-00 WASHER 4

BL-EZ40-0515 - 01-31-2018 12-37

 DH_0012

12-38 BL-EZ40-0515 - 01-31-2018

 Figure 12-15 Load Wheel

Load Wheel

Qty.
Pos. Part Number Description Notes
Reqd.
— 1115-133000-40 LOAD WHEEL 2

1 0000-000020-00 BEARING 2

LOAD WHEEL
2 1115-133002-40 1

BL-EZ40-0515 - 01-31-2018 12-39

 DH_0013

Figure 12-16 Caster

12-40 BL-EZ40-0515 - 01-31-2018

 Caster

Qty.
Pos. Part Number Description Notes
Reqd.
— 1118-140000-00 CASTER ASSEMBLY 2

1 0000-000985-00 SCREW, M10 X 20 1

2 1118-140003-00 PLATE 1

3 1118-140001-00 CASTER SUPPORT 1

4 0000-000986-00 BEARING, 6307 1

5 1118-140002-00 CASTER SUPPORT 1

6 0000-000168-00 BOLT, M10 X 90 1

7 1120-140003-00 PU BLOCK 1

8 1120-142000-00 WHEEL BRACKET 1

9 0000-000495-00 BOLT, M12 X 85 1

10 1120-143001-00 SHAFT 1

11 0000-000020-00 BEARING 2

12 1120-143003-00 PU WHEEL 1

13 0000-000426-00 NUT, M10 1

14 1120-140004-00 SPRING 1

15 0000-000987-00 SNAP RING 1

16 0000-000057-00 NUT, M12 1

17 0000-000063-00 LOCK WASHER, M10 1

18 0000-000007-00 FLAT WASHER, M10 1

19 0000-000435-00 FLAT WASHER M20 2

20 0000-000060-00 LOCK WASHER, M12 1

21 0000-000373-00 FLAT WASHER, M12 1

22 0000-000004-00 SCREW, M5 X 12 1

BL-EZ40-0515 - 01-31-2018 12-41

 DH_0014

Figure 12-17 Hydraulic System

12-42 BL-EZ40-0515 - 01-31-2018

 Hydraulic System

Qty.
Pos. Part Number Description Notes
Reqd.
1 2706-141400-00 CONNECTOR, M14 X 1.5 1 Used up to 01/14/2014

1a 2401-143500-00 BOLT M14 X 35 1 Used from 01/15/2014

2 0000-000044-00 WASHER, M14 2

Used up to serial number

3 1118-430000-0A HOSE ASSY 1
E2316807

Used between serial number

3a 1118-430000-10 HOSE ASSY 1
E2316808 - E2410519

Used from serial number

3b 1118-430000-0A HOSE ASSY 1
E2410520

4 1118-420000-00 PUMP & MOTOR ASSY 1

5 0000-000321-00 SCREW, M8 X 20 2

6 0000-000159-00 LOCK WASHER, M8 2

7 0000-000176-00 FLAT WASHER, M8 2

8 1118-410000-00 CYLINDER 1

9 0000-000293-00 RETAINING RING, M20 2

10 1118-400001-00 SHAFT 1

11 0000-000210-00 FLAT WASHER, M8 2

12 0000-000705-00 BUSHING 2

BL-EZ40-0515 - 01-31-2018 12-43

 DH_0015

Figure 12-18 Pump & Motor Assy

12-44 BL-EZ40-0515 - 01-31-2018

 Pump & Motor Assy

Qty.
Pos. Part Number Description Notes
Reqd.
— 1118-420000-00 PUMP & MOTOR ASSY 1

1 1115-560001-00 CLAMP 2

2 1118-420002-00 WIRE HARNESS 1

3 1115-560003-00 DC MOTOR, 0.8KW/24V 1

4 1115-560002-00 RELAY, 24V/150A 1

5 1115-560008-00 SCREW, M8 X 8 2

6 1115-560007-00 BALL, 6G20B 4

7 1118-420007-00 VALVE PLATE 1

8 1115-560006-00 SAFETY VALVE 1

9 1115-560005-00 THROTTLE 1

10 1115-560025-00 O-RING, 16.36 X 2.21 1

11 1115-560026-00 SCREW 1

12 1115-560016-00 CHECK VALVE 1

13 1115-560017-00 SOLENOID VALVE 1

14 1118-420014-00 RETURN PIPE 1

15 1115-560010-00 CONNECTING SHAFT 1

16 1115-560011-00 GEAR PUMP 1

17 1115-560012-00 WASHER, M5 2

18 1115-560013-00 SCREW, M5 X 70 2

19 1115-560015-00 OIL FILTER 1

20 1118-420020-00 SUCTION PIPE 1

21 1118-420021-00 O-RING, 69 X 3.5 1

22 1118-420022-00 OIL TANK 1

23 1120-430023-00 O-RING, 11.2 X 2.65 1

24 1115-560024-00 AIR FILTER 1

25 1115-561001-00 BRUSH KIT 2

BL-EZ40-0515 - 01-31-2018 12-45

 DH_0016

Figure 12-19 Lift Cylinder

12-46 BL-EZ40-0515 - 01-31-2018

 Lift Cylinder

Qty.
Pos. Part Number Description Notes
Reqd.
— 1118-410000-00 LIFT CYLINDER 1

— 1118-QSY-0A SEAL KIT 1 Includes Items 2, 3, 7

1 1118-410001-00 PISTON ROD 1

2 0000-000672-00 WIPER RING, M40 X 50 X 5-6.5 1

3 0000-000673-00 O-RING, M45 X 3.1 1

4 1115-410002-0B GLAND NUT 1

5 1118-411000-00 CYLINDER BODY 1

6 1115-410003-0B GUIDE RING 1

7 0000-000512-00 VX-SEAL 1

8 1115-410004-00 BUSHING 1

BL-EZ40-0515 - 01-31-2018 12-47

 DH_0017

Figure 12-20 Electrical System

12-48 BL-EZ40-0515 - 01-31-2018

 Electrical System
Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000030-00 SCREW, M10 X 16 4

2 0000-000063-00 LOCK WASHER, M10 4

3 0000-000007-00 FLAT WASHER, M10 4

4 1118-511000-00 ELECTRICAL MOUNTING PLATE 1 Up to Serial number E2410289

4a 1118-511000-70 ELECTRICAL MOUNTING PLATE 1 From Serial number E2410290

5 0000-000368-00 SCREW, M8 X 12 2

6 2214-150002-00 WASHER 2

7 0000-000108-00 NUT, M6 4 Used up to 04/23/2014

8 1118-540000-00 BOARD 1 Up to Serial number 324170264

8a 1118-540000-70 BOARD 1 From Serial number 324170265

9 0000-000117-00 SCREW, M5 X 10 3

10 0000-000206-00 LOCK WASHER, M5 5

11 0000-000390-00 FLAT WASHER, M5 5

12 0000-001103-00 R HARNESS CLAMP UC-1.5 2

13 0000-001086-00 R HARNESS CLAMP UC-5 2

14 2112-410005-00 RUBBER CUSHION 2 Used up to 10/27/2013

14a 1115-100005-00 RUBBER CUSHION 2 Used from 10/28/2013

15 1118-500002-00 BRACKET 1

16 0000-000004-00 SCREW, M5 X 12 2

17 1120-500006-00 LIFTING LIMIT SWITCH 1

18 1118-520007-10 WIRE HARNESS OF LIMIT SWITCH 1

19 0000-001031-00 SCREW, M4 X 30 2

20 0000-000122-00 LOCK WASHER, M4 2

21 0000-000139-00 NUT, M4 2

22 003231 BATTERY 2 85Ah Battery

22a 1118-560007-00 BATTERY 2 100Ah Battery

23 1118-100011-00 SPACER A.R. As required

24 1118-100010-00 PLATE 2 Used up to 04/23/2014

25 0000-000055-00 SCREW, M6 X 16 4 Used up to 04/23/2014

26 1115-100002-00 SPACER A.R. As required

27 1280-100005-00 FLAT PLUG 1 Up to serial number 324170264

BL-EZ40-0515 - 01-31-2018 12-49

 DH_0018

Figure 12-21 Drive Motor Assembly

12-50 BL-EZ40-0515 - 01-31-2018

 Drive Motor Assembly

Qty.
Pos. Part Number Description Notes
Reqd.
-- 1120-220000-00 MOTOR ASSEMBLY 1

1 0000-000293-00 RETAINING RING, M20 2

2 0000-000226-00 KEY 1

3 1120-220001-00 TERMINAL BLOCK 1

4 0000-000206-00 LOCK WASHER, M5 17

5 0000-000117-00 SCREW, M5 X 10 2

6 0000-000166-00 NUT, M6 6

7 0000-000056-00 LOCK WASHER, M6 6

8 1120-220002-00 BEARING 1

9 0000-000204-00 KEY 1

10 0000-000409-00 O-RING, M63 X 3.55 1

11 0000-000436-00 NUT, M12 X 1.5 1

12 0000-000323-00 SCREW, M5 X 16 14

BL-EZ40-0515 - 01-31-2018 12-51

 DH_0019

Figure 12-22 Electrical Components (Sheet 1)

12-52 BL-EZ40-0515 - 01-31-2018

 Electrical Components (Sheet 1)

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000119-00 SCREW, M5 X 12 2

2 1115-510008-00 EMERGENCY STOP SWITCH 1

3 1118-510002-00 MOUNTING PLATE 1

4 0000-000700-00 SCREW, M8 X 16 4

5 0000-000159-00 LOCK WASHER, M8 4

6 0000-000176-00 FLAT WASHER, M8 4

Used up to serial number

7 1118-510005-00 UPPER MOUNTING PLATE 1
E2316807

Used from serial number

7a 1118-510005-0A UPPER MOUNTING PLATE 1
E2316808

8 0000-000077-00 SCREW, M6 X 12 2

9 0000-000056-00 LOCK WASHER, M6 2

10 0000-000380-00 FLAT WASHER, M6 2

11 1120-540001-00-B FUSE STAND 1

12 1120-540002-00 FUSE, 200A 1

13 0000-000074-00 SCREW, M6 X 20 2

14 0000-000550-00 NUT, M8 2

15 0000-000210-00 FLAT WASHER, M8 2

16 0000-000004-00 SCREW, M5 X 12 7

17 0000-000206-00 LOCK WASHER, M5 4

18 1120-500004-00-30 CONTROLLER AC0 1

19 1120-500005-00 CONTACTOR 1

20 1118-560006-00-02 CHARGER ASSEMBLY 20A 1

BL-EZ40-0515 - 01-31-2018 12-53

 DH_0019

Figure 12-23 Electrical Components (Sheet 1) - Continued

12-54 BL-EZ40-0515 - 01-31-2018

 Electrical Components (Sheet 1) - Continued

Qty.
Pos. Part Number Description Notes
Reqd.
21 1115-500006-10 CHARGER CABLE 1

22 1115-500009-00 CHARGER HOOP 2

23 0000-000031-00 SCREW, M5 X 8 1

24 0000-000390-00 FLAT WASHER, M5 4

25 0000-00546-00 NUT, M5 3

26 1118-510005-10 PLATE II 1 Only used between

Serial number
27 0000-000035-00 SCREW M5×20 2 E2316808 - E2410289

Used from serial number

27a 0000-000004-00 SCREW M5×12 2
E2410290

Used from serial number

28 1220-150005-00 NUT M8 2
E2316808

29 1115-510008-10 SWITCH BUTTON 1

BL-EZ40-0515 - 01-31-2018 12-55

 DH_0020

Figure 12-24 Electrical Components (Sheet 2)

12-56 BL-EZ40-0515 - 01-31-2018

 Electrical Components (Sheet 2)

Qty.
Part Number Description Notes
Reqd.
1 1118-560001-00 TIMING RELAY 1

2 1118-560002-00 TIMING RELAY SET 1 Optional up to serial number

324170264. Standard from
3 1118-510001-00 RELAY BRACKET 1 serial number 324170265

4 0000-000009-00 SCREW, M4 X 12 2

5 000-000031-00 SCREW, M5 X 8 4

6 0000-000206-00 LOCK WASHER, M5 6

7 0000-000390-00 FLAT WASHER, M5 6

8 1118-520006-10 RELAY WIRE HARNESS 1 See note for pos. 1-4

9 1118-510004-00 TIE PLATE 1

10 0000-000004-00 SCREW, M5 X 12 2

11 1118-510003-00 PLATE 1

12 1115-520015-00 BUZZER ASSEMBLY 1

13 0000-000037-00 SCREW, M3 X 12 2

14 0000-000139-00 NUT, M4 2

15 1115-520007-00 FAN ASSEMBLY 1

16 1115-500007-00 FAN GUARD 1

17 0000-000121-00 SCREW, M4 X 35 4

18 0000-000122-00 LOCK WASHER, M4 4

19 0000-000702-00 FLAT WASHER, M4 4

20 1115-520019-0A 2-WAY SWITCH 1

21 1115-500016-00 2-WAY SWITCH KEY 2

22 1115-520013-00 LED WIRE HARNESS 1

23 1115-510009-00 LAMP HOLDER 1

BL-EZ40-0515 - 01-31-2018 12-57

 DH_0020

Figure 12-24 Electrical Components (Sheet 2) - Continued

12-58 BL-EZ40-0515 - 01-31-2018

 Electrical Components (Sheet 2) - Continued

Qty.
Part Number Description Notes
Reqd.
Optional up to serial number
24 1118-522000-00 BRAKE RELEASE BUTTON 1 324170264. Standard from
serial number 324170265

25 1115-520005-0A BDI WIRE HARNESS 1 Without Hourmeter

25a 1115-520005-20 BDI WIRE HARNESS 1 With Hourmeter

Used from serial number

26 0000-000498-00 SCREW M6 X 30 2
324170265

Used from serial number

27 1118-540002-70 PLATE 1
324170265

Without Hourmeter. Set the

BDI dial to the following: M =
28 1115-510006-00 BDI (BATTERY INDICATOR) 1
Industrial Battery, Q =
Maint.Free Battery

With Hourmeter. Set the BDI

dial to the following: M =
28a 1115-510006-20 BDI (BATTERY INDICATOR) 1
Industrial Battery, Q =
Maint.Free Battery

Used between Serial number

29 1118-510004-10 PLATE I 1
E2316808 - E2410289

Used from serial number

30 0000-000108-00 NUT M6 4
324170265

BL-EZ40-0515 - 01-31-2018 12-59

 DH_0021

Figure 12-25 Wiring Harness

12-60 BL-EZ40-0515 - 01-31-2018

 Wiring Harness

Qty.
Pos. Part Number Description Notes
Reqd.
1 1118-520001-00 MASTER WIRE HARNESS 1

2 1120-500010-00 FUSE 10A 1

3 1118-520002-00 SWITCHING WIRE HARNESS 1

4 1118-520004-00 WIRE HARNESS OF PUMP 1

Only used up to serial num-

5 1118-520008-10 SHORT CIRCUIT SWITCH 1
ber 324170264 (Optional)

BL-EZ40-0515 - 01-31-2018 12-61

 DH_0022

Figure 12-26 Wiring Cables

12-62 BL-EZ40-0515 - 01-31-2018

 Wiring Cables

Qty.
Pos. Part Number Description Notes
Reqd.
1 1118-531003-00 CABLE, BATTERY CONNECTOR 1

2 1118-531002-00 CABLE, BATTERY - 1

3 1118-531001-00 CABLE, BATTERY + 1

4 1118-531004-00 F CABLE + 1

5 1118-531006-00 M CABLE + 1

6 1118-531008-00 B CABLE+ 1

7 1118-531007-00 PUMP POWER CABLE + 1

8 1118-531005-00 PUMP POWER CABLE - 1

9 1118-532001-00 DRIVING MOTOR CABLE U 1

10 1118-532002-00 DRIVING MOTOR CABLE V 1

11 1118-532003-00 DRIVING MOTOR CABLE W 1

BL-EZ40-0515 - 01-31-2018 12-63

Big Lift LLC