Table Of Contents - Big Joe Joey J1 Series Maintenance And Repair Parts Manual

Section
1 DESCRIPTION ............................................................1-1
1-1 Introduction ..........................................1-1
1-2 General Description ...........................1-1
1-3 Data Plate And Warning Decal ........1-2
1-4 INSTALLATION / WARRANTY
CHECK LIST.................................................1-2
2 PLANNED MAINTENANCE ........................................2-1
2-1 General.....................................................2-1
2-2 Monthly And Quarterly Checks.....2-1
2-3 Frequent Inspections.........................2-1
2-4 Annual Inspections ..............................2-1
2-5 Battery Care .........................................2-1
2-5.1 General.....................................................2-1
2-5.2 Safety Rules .............................................2-2
2-5.3 Maintenance Personnel............................2-2
2-5.4 Battery Care And Charging ......................2-2
2-5.5 Battery Cleaning .......................................2-2
2-5.6 Maintenance Free Batteries .....................2-2
2-6 Charging Batteries..............................2-3
2-7 Replacing Batteries ............................2-3
2-7.1 Battery Disposal .......................................2-3
2-8 Lubrication..............................................2-4
2-9 Lift Chain Maintenance .......................2-4
3 TROUBLESHOOTING ................................................3-1
3-1 General.....................................................3-1
3-2 Controller Troubleshooting ........3-4
3-2.1 Zapi Handset ............................................3-4
3-2.2 Fault Detection .........................................3-4
3-2.2.1 General.................................................3-4
3-2.2.2 Logbook Access ...................................3-4
3-2.3 Testing Truck Operation ...........................3-4
3-2.4 Factory Settings........................................3-5
4 STEERING SYSTEM ..................................................4-1
4-1 Control Arm ...........................................4-1
4-1.1 Steering Control RemovaL .......................4-1
4-1.2 Steering Control Installation .....................4-2
4-2 Compartment Cover ............................4-2
4-2.1 Cover Removal.........................................4-2
4-2.2 Cover Installation......................................4-2
4-3 Steer Motor............................................4-2
4-3.1 Motor Removal .........................................4-2
4-3.2 Motor Installation ......................................4-3
5 BRAKE SERVICING....................................................5-1
5-1 BRAKES .......................................................5-1
5-1.1 Brake Assembly Replacement .................5-1
6 DRIVE UNIT ASSY. , LOAD WHEEL & CASTERS.....6-1
6-1 Transmission And Drive Motor........6-1
6-2 Load Wheel ..............................................6-2
6-2.1 Removal ...................................................6-2
6-2.2 Installation ................................................6-2
6-3 Drive Wheel .............................................6-2
6-4 Caster .......................................................6-2
7 ELEVATION SYSTEM SERVICING............................7-1
7-1 GENERAL.....................................................7-1
BL-J1-0315 - 11-19-2019

TABLE OF CONTENTS

Page Section
7-2
7-3
7-4
7-4.1
7-4.2
7-4.2.1
7-4.2.2
7-5
8 HYDRAULIC SYSTEM SERVICING........................... 8-1
8-1
8-2
8-2.1
8-2.2
8-2.3
8-3
8-3.1
8-3.2
8-3.3
8-4
8-4.1
8-4.2
8-4.3
8-5
8-5.1
8-5.2
8-5.3
9 ELECTRICAL COMPONENTS ................................... 9-1
9-1
9-1.1
9-1.2
9-1.3
9-1.4
9-1.5
9-2
9-3
9-4
9-5
9-6
9-7
9-8
9-8.1
9-8.2
9-9
9-9.1
9-9.2
10 OPTIONAL EQUIPMENT ......................................... 10-1
10-1
11 ILLUSTRATED PARTS BREAKDOWN .................... 11-1
Lift Chain Length Adjustment ......... 7-1
Lift Chain Wear Inspection ............... 7-2
Lift Chain Replacement...................... 7-2
Telescopic................................................ 7-2
Three Stage Mast .................................... 7-4
Mast Lifting Chain ................................ 7-4
Platform Lifting Chain .......................... 7-4
Lift Cylinders ........................................ 7-8
Lines And Fittings ................................. 8-1
Hydraulic Pump, Motor And
RESERVOIR ASSEMBLY............................ 8-1
Removal................................................... 8-1
Disassembly And Reassembly ................ 8-1
Installation................................................ 8-3
Lift Cylinder (Telescopic)................. 8-3
Removal................................................... 8-3
Repair ...................................................... 8-3
Installation................................................ 8-5
LIFT CYLINDER
(THREE STAGE MAST FULL FREE LIFT).. 8-5
Removal................................................... 8-5
Repair ...................................................... 8-6
Installation................................................ 8-6
LIFT CYLINDER
(THREE STAGE MAST SECONDARY)..... 8-10
Removal................................................. 8-10
Repair .................................................... 8-10
Installation.............................................. 8-11
Electrical Control Panel................ 9-1
Maintenance ............................................ 9-1
Cleaning................................................... 9-1
Panel Removal......................................... 9-1
Panel Disassembly .................................. 9-1
Panel Installation...................................... 9-1
Horn Replacement............................... 9-1
LOWERING BUZZER REPLACEMENT ...... 9-3
LEVEL SENSOR
BUZZER REPLACEMENT ........................... 9-3
LEVEL SENSOR REPLACEMENT .............. 9-3
Warning Light Replacement ............ 9-3
Battery Replacement......................... 9-3
Battery Charger.................................. 9-3
Removal................................................... 9-3
Installation................................................ 9-5
Platform Cable Replacement ......... 9-5
Telescopic................................................ 9-5
Three Stage Mast .................................... 9-7
Industrial Battery ........................... 10-1
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