Table Of Contents - Big Joe J1-192 Maintenance 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 INSTALL /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 ASSY. REPLACEMENT ........5-1
6 TRANSMISSION, DRIVE WHEEL,
Load Wheel AND CASTERS..........................6-1
6-1 TRANSMISSION AND DRIVE MOTOR. ....6-1
6-2 LOAD WHEEL. ...........................................6-2
BL-J1-192-0315 - 11-19-2019
Page Section
6-2.1
6-2.2
6-3 DRIVE WHEEL ...........................................6-2
6-4 CASTER. ....................................................6-2
7 ELEVATION SYSTEM SERVICING ...................7-1
7-1 GENERAL...................................................7-1
7-2 LIFT CHAIN LENGTH ADJUSTMENT .......7-1
7-3 LIFT CHAIN WEAR INSPECTION .............7-2
7-4 LIFT CHAIN REPLACEMENT ....................7-2
7-4-.1
7-4.1.1
7-4.1.2
Lift Cylinders. 7
Hydraulic System Servicing 1
Lines And Fittings 1
HYDRAULIC PUMP, MOTOR, AND RESERVOIR
ASSY 1
Removal 1
Disassembly And Reassembly 1
Installation 3
Lift Cylinder (Full Free Lift) 3
Removal 3
Repair 3
Installation 3
LIFT CYLINDER (THREE STAGE MAST SECOND-
ARY) 8
Removal 8
Repair 8
INSTALLATION 9
Electrical Components 1
Electrical Control Panel 1
MAINTENANCE 1
Cleaning 1
Panel Removal. 1
Panel Disassembly. 1
Panel Installation. 1
Horn Replacement. 1
LOWERING BUZZER REPLACEMENT. 3
Level Sensor Buzzer Replacement. 3
LEVEL SENSOR REPLACEMENT. 3
Warning Light Replacement. 3
Battery Replacement. 3
Battery Charger. 3
Removal. 3
INSTALLATION. 3
Platform Cable Replacement.. 4
Three Stage Mast 4
Optional Equipment 1
INDUS TRIAL BATTERY 1
Illustrated Parts Breakdown 1
REMOVAL ..........................................6-2
INSTALLATION ..................................6-2
THREE STAGE MAST........................7-2
MAST LIFTING CHAIN..................7-2
PLATFORM LIFTING CHAIN ........7-2
Page
1