Table Of Contents - Big Joe J1-192 Maintenance Repair Parts Manual

Table of Contents

Warning2
Table Of Contents3
Introduction5
General Description5
J1 Elevating Work Platform5
Installation / Warranty Check List6
Data Plate And Warning Decal6
J1 Data Plate6
Planned Maintenance9
Monthly And Quarterly Checks9
Annual Inspections9
Battery Care9
General9
Frequent Inspections9
2-5.2 Safety Rules10
2-5.3 Maintenance Personnel10
2-5.4 Battery Care And Charging10
2-5.5 Battery Cleaning10
2-5.6 Maintenance Free Batteries10
Charging Batteries11
Replacing Batteries11
Battery Replacement11
2-7.1 Battery Disposal11
Lubrication12
Lift Chain Maintenance12
Recommended Lubricants12
Lubrication Diagram13
Lubrication Chart13
Dealer Information14
Owner / End User Information14
Vehicle Information15
Hydraulic System15
Troubleshooting17
Troubleshooting Chart17
Controller Troubleshooting20
3-2.1 Zapi Handset20
3-2.2 Fault Detection20
3-2.2.1 General20
3-2.2.2 Logbook Access20
3-2.3 Testing Truck Operation20
Parameter Adjustments21
3-2.4 Factory Settings21
Troubleshooting Chart (Traction/Lift Controller)22
Steering System37
Control Arm37
4-1.1 Steering Control Removal37
Compartment Cover38
4-1.2 Steering Control Installation38
4-2.1 Cover Removal38
4-2.2 Cover Installation38
Steer Motor38
4-3.1 Motor Removal38
Drive System39
4-3.2 Motor Installation39
Brake Servicing41
Brake Assembly Replacement41
Transmission, Motor & Brake Assembly42
Transmission, Drive Wheel, Load Wheel, Casters43
Load Wheel44
Drive Wheel44
Caster44
6-2.1 Removal44
6-2.2 Installation44
Frame45
Elevation System Servicing47
Lift Chain Length Adjustment47
Chain Assembly47
Lift Chain Wear Inspection48
Lift Chain Replacement48
7-4-.1 Three Stage Mast48
7-4.1.1 Mast Lifting Chain48
7-4.1.2 Platform Lifting Chain48
Elevation System49
Platform Installation51
Lift Cylinders52
Hydraulic System Servicing53
Lines And Fittings53
Hydraulic Pump, Motor, And Reservoir Assy53
Removal53
Disassembly And Reassembly53
Lift Cylinder (Full Free Lift)55
Installation55
Repair55
Hydraulic Lines57
Lift Cylinder (Three Stage Mast Secondary)60
Electrical Components63
Electrical Control Panel63
Horn Replacement63
Maintenance63
Cleaning63
Panel Removal63
Panel Disassembly63
Panel Installation63
Level Sensor Buzzer Replacement65
Warning Light Replacement65
Battery Charger65
Platform Cable Replacement66
Three Stage Mast66
Optional Equipment71
Industrial Battery71
Illustrated Parts Breakdown73
Platform Assembly81
Caster Assembly - Used Up To Serial Number 22517010582
Caster Assembly - Used From Serial Number 22517010684