Big Joe Joey J1-162 Manuals

Manuals and User Guides for Big Joe Joey J1-162. We have 1 Big Joe Joey J1-162 manual available for free PDF download: Maintenance And Repair Parts Manual

Big Joe Joey J1-162 Maintenance And Repair Parts Manual

Big Joe Joey J1-162 Maintenance And Repair Parts Manual (180 pages)

Task Support Vehicle

Brand: Big Joe | Category: Utility Vehicle | Size: 5 MB

Table of Contents

Warning
2
Table of Contents
3
Introduction
5
General Description
5
J1 Elevating Work Platform
5
Data Plate and Warning Decal
6
Installation / Warranty Check List
6
J1 Data Plate
6
2 Planned Maintenance

9
- General
  9
- Monthly and Quarterly Checks
  9
- Frequent Inspections
  9
- Annual Inspections
  9
- Battery Care
  9
- 2-5.2 Safety Rules
  10
- 2-5.3 Maintenance Personnel
  10
- 2-5.4 Battery Care and Charging
  10
- 2-5.5 Battery Cleaning
  10
- 2-5.6 Maintenance Free Batteries
  10
- Charging Batteries
  11
- Replacing Batteries
  11
- 2-7.1 Battery Disposal
  11
- Lubrication
  12
- Lift Chain Maintenance
  12
  - Recommended Lubricants
    12
  - Lubrication Diagram
    13
  - Lubrication Chart
    13
3 Troubleshooting

17
- General
  17
- Troubleshooting Chart
  17
- 3-2.1 Zapi Handset
  20
- 3-2.2 Fault Detection
  20
- 3-2.2.1 General
  20
- 3-2.2.2 Logbook Access
  20
- 3-2.3 Testing Truck Operation
  20
- Controller Troubleshooting
  20
- 3-2.4 Factory Settings
  21
- Parameter Adjustments
  21
4 Steering System

37
- Control Arm
  37
- 4-1.1 Steering Control Removal
  37
- Steer Motor
  38
- 4-1.2 Steering Control Installation
  38
- Compartment Cover
  38
- 4-2.1 Cover Removal
  38
- 4-2.2 Cover Installation
  38
- 4-3.1 Motor Removal
  38
- Drive System
  39
- 4-3.2 Motor Installation
  39
5 Brake Servicing

41
- 5-1.1 Brake Assembly Replacement
  41
- Transmission, Motor & Brake Assembly
  42
6 Drive Unit Assy. , Load Wheel & Casters

45
- Transmission, Drive Wheel, Load Wheel, Casters
  45
- Transmission and Drive Motor
  45
- Load Wheel
  46
- Drive Wheel
  46
- Caster
  46
- 6-2.1 Removal
  46
- 6-2.2 Installation
  46
- Frame
  47
7 Elevation System Servicing

51
- Lift Chain Length Adjustment
  51
- Chain Assembly
  51
- General
  51
- Lift Chain Wear Inspection
  52
- Lift Chain Replacement
  52
- 7-4.1 Telescopic
  52
- Elevation System (Telescopic)
  53
- 7-4.2 Three Stage Mast
  54
- 7-4.2.1 Mast Lifting Chain
  54
- 7-4.2.2 Platform Lifting Chain
  54
- Lift Cylinders
  58
8 Hydraulic System Servicing

59
- Lines and Fittings
  59
- Hydraulic Pump, Motor and
  59
- 8-2.1 Removal
  59
- 8-2.2 Disassembly and Reassembly
  59
- Hydraulic System
  60
- Lift Cylinder (Telescopic)
  61
- Hydraulic Lift (Telescopic)
  61
- 8-2.3 Installation
  61
- 8-3.1 Removal
  61
- 8-3.2 Repair
  61
- 8-3.3 Installation
  63
- Lift Cylinder (Three Stage Mast Full Free Lift)
  63
- 8-4.1 Removal
  63
- 8-4.2 Repair
  64
- 8-4.3 Installation
  64
- Lift Cylinder (Three Stage Mast Secondary)
  68
- 8-5.1 Removal
  68
- 8-5.2 Repair
  68
- 8-5.3 Installation
  69
9 Electrical Components

71
- Electrical Control Panel
  71
- 9-1.1 Maintenance
  71
- 9-1.2 Cleaning
  71
- 9-1.3 Panel Removal
  71
- 9-1.4 Panel Disassembly
  71
- 9-1.5 Panel Installation
  71
- Horn Replacement
  71
- Level Sensor Buzzer Replacement
  73
- Warning Light Replacement
  73
- Battery Replacement
  73
- Battery Charger
  73
- 9-8.1 Removal
  73
- Platform CABLE REPLACEMENT
  75
- 9-8.2 Installation
  75
- 9-9.1 Telescopic
  75
- 9-9.2 Three Stage Mast
  77
10 Optional Equipment

83
- Industrial Battery
  83
11 Illustrated Parts Breakdown

85
- Caster Assembly - Used up to Serial Number 225170105
  91
- Caster Assembly - Used from Serial Number 225170106
  93
- Control Arm (Left)
  105
- Control Arm (Right)
  107
- Hydraulic System - Overview
  109
- Hydraulic Pump Assembly
  111
- Electrical System
  113
- Battery Assembly - Used up to Serial Number S2410170
  115
- Control Panel
  121
- Wiring Harness
  123
- Wiring Cables - Used up to Serial Number S2213285
  125
- Wiring Cables - Used from Serial Number S2213286
  127
- Platform Assembly
  173

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