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Big Joe J1-192 - User Manual

Big Joe J1-192
124 pages
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Big Lift LLC MANUAL NO. BL-J1-192-0315 - 11-19-2019
www.bigjoeforklifts.com PART NO. 901632
J1-192
TASK SUPPORT
VEHICLE
U.S. Patent Nos. D730,614; D733,389; D733,390; D734,589; 9,440,830 B2 and 10,214,402
Maintenance
Repair Parts Manual
NOTE:This vehicle is for indoor and level surface use only.
NOTE:For the most current parts information and service updates,
please refer to the Big Joe Support site at www.bigjoesupport.com

Table of Contents

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Summary

Vehicle Description and Identification

Introduction and General Overview

Overview of the J1 task support vehicle, its capabilities, and manual introduction.

Data Plate and Warning Decals

Location and importance of identification data plates and warning decals on the vehicle.

Installation and Warranty Information

Procedures for initial vehicle setup, installation, and warranty registration process.

Planned Maintenance Procedures

Maintenance Schedule and Checks

Overview of maintenance types, inspection intervals, and general checks.

Battery Care, Safety, and Charging

Essential battery maintenance, safety rules, cleaning, and charging procedures.

Battery Replacement and Disposal

Step-by-step guide for safely replacing vehicle batteries and proper disposal methods.

Lubrication and Lift Chain Maintenance

Recommended lubricants and procedures for inspecting and maintaining lift chains.

Vehicle Troubleshooting Guide

General Troubleshooting and System Issues

Introduction to troubleshooting, covering general issues and system malfunctions.

Controller Diagnostics and Operation Testing

Using Zapi Handset for controller diagnostics, fault detection, and testing truck operations.

Steering System Service

Control Arm and Steer Motor Maintenance

Procedures for steering control arm removal/installation and steer motor replacement.

Compartment Cover Removal and Installation

Instructions for accessing and reassembling the vehicle's compartment covers.

Brake System Maintenance

Brake Assembly Replacement

Step-by-step guide for replacing the drive motor mounted brake assembly.

Drivetrain and Wheel Component Service

Transmission and Drive Motor Service

Procedures for servicing the transmission and drive motor assembly.

Load Wheel and Caster Maintenance

Instructions for removing, installing, and maintaining load wheels and casters.

Elevation System Maintenance

Lift Chain Adjustment and Inspection

Procedures for adjusting lift chain length and inspecting for wear.

Lift Chain Replacement

Detailed steps for replacing mast lifting and platform lifting chains.

Lift Cylinder Information

Note indicating lift cylinder removal and repair are covered in a separate section.

Hydraulic System Maintenance

Hydraulic Lines and Fittings Service

Procedures for maintaining and replacing hydraulic lines and fittings.

Hydraulic Pump, Motor, and Reservoir

Servicing the hydraulic pump, motor, and reservoir assembly, including removal and disassembly.

Lift Cylinder Service (Full Free Lift)

Detailed procedures for removing, repairing, and installing the full free lift cylinder.

Lift Cylinder Service (Three Stage Mast Secondary)

Procedures for servicing the secondary lift cylinder used in three-stage masts.

Electrical Component Service

Electrical Control Panel Service

Maintenance, cleaning, removal, and installation of the electrical control panel.

Component Replacements: Horn, Buzzers, Sensors, Lights, Charger

Procedures for replacing key electrical components like horn, buzzers, sensors, and charger.

Platform Cable Replacement (Three Stage Mast)

Specific instructions for replacing mast harness cables on three-stage mast vehicles.

Optional Equipment Information

Industrial Battery Information

Details on optional industrial batteries and associated chargers.

Illustrated Parts Breakdown

Big Joe J1-192 Specifications

General IconGeneral
BrandBig Joe
ModelJ1-192
CategoryCompact Loader
LanguageEnglish