Big Joe Joey J1-162 - User Manual

Big Lift LLC MANUAL NO. BL-J1-0315 - 11-19-2019
www.bigjoeforklifts.com
J1 SERIES
(J1-86 / J1-126 / J1-162)
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

Summary

J1 Series Maintenance and Repair Manual

Safety Warnings and Operating Precautions

General Vehicle Operation Warnings

Critical safety instructions for operating the vehicle safely and avoiding hazards.

Section 2: Planned Maintenance

Inspection Schedules and Requirements

Guidelines for monthly, quarterly, frequent, and annual inspections as per ANSI A92.6.

Battery Care and Charging Procedures

Comprehensive guidance on battery maintenance, charging, safety rules, and cleaning.

Battery Replacement and Disposal

Lubrication and Lift Chain Maintenance

Section 3: Troubleshooting

General Troubleshooting Guide

Controller Troubleshooting and Diagnostics

Procedures for controller diagnostics, fault detection, and using the Zapi Handset.

Section 5: Brake Servicing

Brake Assembly Replacement Procedure

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

Section 7: Elevation System Servicing

Lift Chain Length Adjustment and Inspection

Procedures for adjusting lift chain length and inspecting for wear.

Lift Chain Replacement Procedures

Three Stage Mast Lift Chain Service

Section 8: Hydraulic System Servicing

Hydraulic Lines, Fittings, and Pump Service

Lift Cylinder Service (Telescopic)

Detailed steps for removing, repairing, and installing telescopic lift cylinders.

Lift Cylinder Service (Three Stage Mast)

Procedures for servicing lift cylinders for three-stage masts, including full free lift types.

Lift Cylinder Service (Three Stage Mast Secondary)

Steps for removing, repairing, and installing secondary lift cylinders for three-stage masts.

Section 9: Electrical Components

Electrical Control Panel and Component Service

Maintenance, cleaning, and replacement procedures for the electrical control panel and its components.

Component Replacements and Battery Service

Platform Cable Replacement Procedures

Big Joe Joey J1-162 Specifications