Big Joe J1-192 Use and care manual

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

WARNING
Do not operate this vehicle unless you have been
authorized and trained to do so, and have read all
warnings and instructions in Operator’s Manual and on
this vehicle. Read, understand and comply with the
information on the vehicle’s nameplate at all times.
Do not operate this vehicle until you have performed
the daily operation’s check list. Verify and inspect tires,
horn, battery, controller, lift and hydraulic systems,
brakes, steering mechanism and guards. Verify that all
emergency controls, personal protection and safety
devices are in place and functioning correctly and
ensure the vehicle is free of fluid leaks and has no
loose or missing parts. Report any problems to the
designated authority and do not use the vehicle until
they are corrected by a qualified mechanic.
This vehicle must not be modified without the manu-
facturer’s consent. Components critical to the vehicles
stability such as batteries shall not be replaced with
lighter weight components.
Operate vehicle only from designated platform operat-
ing position. Use this vehicle indoors on level surfaces
only. Never operate on ramps and slopes or uneven
floors. This vehicle is not for use on mezzanines or
balcony areas. Before operating, inspect the floor area
it will be used on and be certain it will support the vehi-
cle at full capacity and lift height. Identify and avoid
holes, drop-offs, bumps and obstructions.
Before and during all vehicle operations ensure that
adequate clearance is maintained from overhead
obstructions and energized electrical conductors and
parts.
Before elevating platform be sure guardrail access
gates are in place and lowered. Keep feet on platform
floor at all times while using vehicle, never climb onto
guard rails or platform shelf. Do not use ladders,
planks or other devices to achieve additional height on
platform.
When transferring loads to platform or platform shelf,
do not exceed capacity ratings on vehicle nameplate.
Ensure loads are centered and do not contact any
obstructions in the vehicle’s vicinity. Do not stabilize
the platform by contact with adjacent objects such as
racks or shelving. Do not use the platform as a crane.
Take care to prevent electrical cords, hoses or other
equipment from entangling in platform. Ensure area
surrounding the vehicle is free of personnel and equip-
ment before lowering platform.
Maintain a clear view of the ground while travelling and
a safe distance from obstacles in the vehicle or plat-
form’s path. Ensure personnel in the vicinity are aware
of the vehicle’s movement. Travel at a safe speed for
the conditions the vehicle is operating in.
Observe applicable traffic regulations. Yield right of
way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision is obstructed. Avoid
hazardous locations.
Enter and exit platform only through raised access
gates and with the platform fully lowered and vehicle
stopped. When leaving vehicle unattended, remove
key to prevent unauthorized use.

BL-J1-192-0315 - 11-19-2019 1
Section Page Section Page
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
6-2.1 REMOVAL ..........................................6-2
6-2.2 INSTALLATION ..................................6-2
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 THREE STAGE MAST........................7-2
7-4.1.1 MAST LIFTING CHAIN..................7-2
7-4.1.2 PLATFORM LIFTING CHAIN ........7-2
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
INDUSTRIAL BATTERY 1
ILLUSTRATED PARTS BREAKDOWN 1

1-2 BL-J1-192-0315 - 11-19-2019

BL-J1-192-0315 - 11-19-2019 1-1
SECTION 1
DESCRIPTION
1-1. INTRODUCTION.
This publication describes the 24 volt J1 task support
vehicle by Big Lift LLC. Included are planned mainte-
nance instructions, lubrication procedures, corrective
maintenance procedures and a complete parts list with
part location illustrations.
Users shall comply with all requirements indicated in
applicable OSHA standards and the current edition of
A.N.S.I. A92.6. By following these requirements and
the recommendations contained in this manual, you
will receive many years of dependable service from
your J1 task support vehicle.
1-2. GENERAL DESCRIPTION.
The self-propelled J1 task support vehicle lifts and
transports up to 1,000 pounds capacity including load
and operator. The vehicle enables general mainte-
nance work and efficient selection and moving of
materials in any area or at any level of the warehouse
or storeroom. This vehicle is not for use on mezza-
nines or balcony areas. The design permits one man
to perform all operations of selecting stock, driving
vehicle, and replacing the stock at the designated
place. The battery-powered vehicle is quiet and allows
operation in closed areas without special provisions
for ventilation.
Figure 1-1 J1 Elevating Work Platform
R6980
ITEM COMPONENT
1 Control arms
2 Pick tray
3 Warning light
4 Cover
5 Control panel
6Casters
7 Frame
8 Drive wheel
9 Hydraulic pump and
reservoir
10 Battery retainer
11 Battery
12 “Deadman” footswitch
13 Operator platform
14 Load wheels
15 Side gates
16 Rear tray for additional capacity and
storage
17 Mast
ITEM COMPONENT

1-2 BL-J1-192-0315 - 11-19-2019
The AC motor propels the vehicle in forward or
reverse direction. The vehicle can be driven with the
platform raised or lowered; however the speed is
restricted above 24”.
On demand power steering makes the vehicle highly
maneuverable.
The control arms are used to operate the work vehicle
and provide operator safety.
The pick tray is used to place and transport merchan-
dise, equipment and tools.
The operator platform contains the “deadman”
footswitch which must be depressed for the vehicle to
operate.
The folding rear tray provides for transporting up to a
200 pound load.
1-3. DATA PLATE AND WARNING DECAL.
Warning decals are located to the left of the Instrument
panel. The data plate is mounted on the right side of
the Instrument panel.
If the data plate or warning decals are lost or damaged
they MUST be replaced immediately. Have your
supervisor or the designated authority contact Big Lift
LLC Authorized Dealer for replacement.
The data plate shows the model, serial number,
capacity, lift height, vehicle weight and minimum bat-
tery weight. See Figure 1-2.
1-4. INSTALLATION / WARRANTY CHECK LIST.
The Big Lift, LLC Installation and Warranty Registra-
tion Reports are used to initiate the start of the war-
ranty period to the first original end user.
This report also serves as documentation that all items
on the Installation and Warranty Registration Report
were reviewed and discussed with the end user prior
to taking receipt of the equipment.
This report must be completed and returned to Big Lift,
LLC within fifteen (15) days of receipt of equipment.
(See “page 1-3” for a copy of the form, also available
at www.bigjoesupport.com)
Figure 1-2 J1 Data Plate
R6978

BL-J1-192-0315 - 11-19-2019 1-3
page 1-3

1-4 BL-J1-192-0315 - 11-19-2019
NOTES

BL-J1-192-0315 - 11-19-2019 2-1
SECTION 2
PLANNED MAINTENANCE
2-1. GENERAL.
Planned maintenance consists of periodic visual and
operational checks, inspection, lubrication, and sched-
uled maintenance designed to catch an issue in the
early hours or discover malfunctions and defective
parts. The operator performs the checks in the Opera-
tor’s Manual, and refers any required servicing to a
qualified maintenance technician who performs the
planned maintenance and any required servicing.
2-2. MONTHLY AND QUARTERLY CHECKS.
Table 2-1 is a monthly and quarterly inspection and
service chart based on normal usage of equipment
eight hours per day, five days per week. If the vehicle
is used in excess of forty hours per week, the fre-
quency of inspection and service should be increased
accordingly. These procedures must be performed by
a qualified service technician or your Big Lift LLC Ser-
vice Representative.
2-3. FREQUENT INSPECTIONS.
The owner and user are required by ANSI A92.6 to
ensure frequent inspections of the J1 Task Support
Vehicle occur and are performed in accordance with
the following points: 1. If purchased used unless it's
determined that the frequent and annual inspections
are current. 2. The J1 Task Support Vehicle has been
in service for three (3) months or 150 hours, whichever
comes first. 3. The J1 Task Support Vehicle has been
out of service for a period longer than three (3)
months. inspection is to be performed by a mechanic
that is qualified and authorized to perform service on
the J1 Task Support Vehicle. All service records must
be maintained. (See “Page 2-6” and “Page 2-7” for
copy of inspection sheet, also available at www.bigjoe-
support.com).
2-4. ANNUAL INSPECTIONS.
The owner and user are required by ANSI A92.6 to
ensure annual inspections of the J1 Task Support
Vehicle occur and are performed no later than 13
months from the date of prior annual inspection or
every 700 hundred hours of use, whichever occurs
first. This annual inspection is to be performed by a
mechanic that is qualified and authorized to perform
service on the J1 Task Support Vehicle. All service
records must be maintained. (See “Page 2-6” and
“Page 2-7” for copy of inspection sheet, also available
at www.bigjoesupport.com).
2-5. BATTERY CARE.
2-5.1. General
The vehicle may be equipped with maintenance free
batteries.
The care and maintenance of the battery is very
important to obtain efficient vehicle operation and
maximum battery life.
CAUTION: Gases produced by a battery can be
explosive. Do not smoke, use an open
flame, create an arc or sparks in the
vicinity of the battery. Ventilate an
enclosed area well when charging.
CAUTION: Batteries contain sulfuric acid which may
cause severe burns. Avoid contact with
eyes, skin or clothing. In case of contact,
flush immediately and thoroughly with
clean water. Obtain medical attention
when eyes are affected. A baking soda
solution (one pound to one gallon of
water) applied to spilled acid until bub-
bling stops, neutralizes the acid for safe
Table 2-1 Monthly and Quarterly Inspection and Service Chart
VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check electrical brake for proper operation.
Monthly Inspect wiring for loose connections and damaged insulation.
Monthly Check wheels for wear and damage.
Monthly Check "deadman” footswitch for proper operation.
Monthly Check lift chain tension, lubrication & operation (see paragraph 2-9.)
Quarterly Check lift cylinder for leakage.
Quarterly Test electric steering.
Quarterly Check steering gear for wear and lubricate.
Semi-annually Inspect for chain wear (See SECTION 7)

2-2 BL-J1-192-0315 - 11-19-2019
2-5.2. Safety Rules
• Wear protective clothing, such as rubber apron,
gloves, boots and goggles when performing any
maintenance on batteries. Do not allow electrolyte to
come in contact with eyes, skin, clothing or floor. If
electrolyte comes in contact with eyes, flush immedi-
ately and thoroughly with clean water. Obtain medi-
cal attention immediately. Should electrolyte be
spilled on skin, rinse promptly with clean water and
wash with soap. A baking soda solution (one pound
to one gallon of water) will neutralize acid spilled on
clothing, floor or any other surface. Apply solution
until bubbing stops and rinse with clean water.
• Do not bring any type of flame, spark, etc., near the
battery. Gas formed while the battery is charging, is
highly explosive. This gas remains in cell long after
charging has stopped.
• Do not lay metallic or conductive objects on battery.
Arcing will result.
• Do not touch non-insulated parts of DC output con-
nector or battery terminals to avoid possible electri-
cal shock.
• Disconnect all AC and DC power connections before
servicing battery.
• Do not charge a frozen battery.
• Do not use charger if it has been dropped or other-
wise damaged.
2-5.3. Maintenance Personnel
Batteries may only be charged, serviced or replaced
by trained personnel. This manual and the manufac-
turer’s instructions concerning batteries and charging
stations must be observed when carrying out the work.
2-5.4. Battery Care and Charging
CAUTION: Never smoke or bring open flame near
the battery. Gas formed during charging
is highly explosive and can cause seri-
ous injury.
1. Charge the battery only in areas designated for
that use.
2. Battery terminals should be checked and cleaned
of corrosion regularly. Good battery terminal con-
tact is essential not only for operation, but also for
proper charging of the battery.
3. Make certain battery used meets weight and size
requirements of vehicle. NEVER operate vehicle
with an undersized battery.
2-5.5. Battery Cleaning
Always keep vent plugs tightly in place when cleaning
battery. When properly watered and charged, the bat-
tery will remain clean and dry. All that is necessary is
to brush or blow off any dust or dirt that may accumu-
late on them. However, if electrolyte is spilled or over-
flows from a cell, it should be neutralized with a
solution of baking soda and water, brushing the soda
solution beneath the connectors and removing grime
from the covers. Then rinse the battery with cool water
from a low pressure supply to remove the soda and
loosen dirt. If batteries stay wet consistently, they may
be either overcharged or over filled. This condition
should be investigated and corrected.
2-5.6. MAINTENANCE FREE BATTERIES
Some vehicles may be equipped with maintenance
free batteries. These batteries are completely sealed,
will not require any watering and have a full 80% dis-
charge available.
Sealed Maintenance Free batteries contain a pressure
release valve and under normal operating conditions
do not require any special ventilation.
CAUTION: Do not try to open this battery or remove
the pressure release valve.
Only under severe overcharging, such as connected
to an improperly sized charger, will any significant
amount of gases be released from the battery. Also,
being a valve regulated battery, it never requires
watering.

BL-J1-192-0315 - 11-19-2019 2-3
2-6. CHARGING BATTERIES
Charging requirements will vary depending on depth of
discharge and temperature. Follow safety rules when
placing a battery on charge.
Proceed as follows:
1. Park vehicle at charging station with platform low-
ered and turn the key switch OFF.
2. Apply the emergency disconnect switch.
3. Check the condition of the AC cord and battery
cables. If there are any cuts in the cable, any
exposed wires, loose plugs or connectors, DO
NOT attempt to charge the batteries.
4. Disconnect plug (1, Figure 2-1) from the vehicle
and connect it to charger’s plug (2).
5. Connect cord (3) and charge the battery accord-
ing to Supplement 374 *.
6. Disconnect the charger cord and insert it in its
receptacle on the vehicle.
Figure 2-1 Battery Charging
2-7. REPLACING BATTERIES
Replace only with original OEM batteries or batteries
approved by an authorized Big Lift LLC dealer. Con-
tact your authorized Big Joe dealer for information on
optional batteries and battery chargers.
1. Park vehicle at charging station with platform low-
ered and turn the key switch OFF.
2. Apply the emergency parking brake.
3. Disconnect the battery from the vehicle and place
the battery plug and cable in such a way that they
will not get caught on the vehicle when the battery
is removed.
4. Remove retainer (2, Figure 2-2).
WARNING: Take caution when removing the battery
pack or optional industrial battery from
the vehicle. Battery is located on battery
rollers. Use of a battery stand is recom-
mended when removing the battery.
Only an authorized Big Joe dealer
should be used for battery removal and
installation.
5. Remove battery (1) out the side of the vehicle.
6. Install in reverse order.
WARNING: The weight and dimensions of the bat-
tery have considerable affect on the
operational safety of the vehicle. Battery
equipment may only be replaced with the
agreement of the manufacturer.
Figure 2-2 Battery Replacement
2-7.1. Battery disposal:
Dispose in accordance with national environmental
protection regulations or disposal laws. The manufac-
turer’s disposal instructions must be followed
* Please refer to the Big Joe Support site at www.bigjoesupport.com
R6986
R6987

2-4 BL-J1-192-0315 - 11-19-2019
2-8. LUBRICATION.
Refer to Table 2-2 for the recommended types of
grease and oil. Table 2-3 in conjunction with
Figure 2-3 identifies the items requiring lubrication.
2-9. LIFT CHAIN MAINTENANCE.
Fully raise and lower lift carriage while observing
chains as they move over chain sheaves. Ensure
chain is aligned and tracking properly and all links are
pivoting freely. With lift carriage fully lowered, spray on
a film of Moly Chain Lube. For more information see
SECTION 7
Table 2-2 Recommended Lubricants
(See Table 2-3 for Application)
R6115
No. 1 Grease—Polylub GA352P
No. 2 Hydraulic oil—L-HM46#.

BL-J1-192-0315 - 11-19-2019 2-5
Figure 2-3 Lubrication Diagram
Table 2-3 Lubrication Chart
FIG 3-2
INDEX
NO.
LOCATION METHOD OF
APPLICATION
TYPE
(Table
2-3)
APPLICATION
OF
LUBRICANT
1 Mast Spray No. 1 Full length of channel where rollers
operate.
2 Hydraulic Reservoir Can No. 2 With platform fully lowered, fill res-
ervoir with hydraulic oil to level
on dip stick.
R6988

2-6 BL-J1-192-0315 - 11-19-2019
VERSION G PAGE 1 OF 2
Big Lift LLC.
1060 N. Garfield St.
Lombard, IL 60148
MODEL: SERIAL:
PFC
PFC
Instrument panel is clean and free of debris and dash display is functional.
Operator left side control arm steering wheel functions properly.
Emergency lower button operates properly.
Ensure gate switches disable travel/lift and lower functions and flashing lights on the front and rear of
the vehicle.
HOUR METER:
BATTERY SPEC.: OPTIONS: PREVIOUS INSPECTION:
Platform guard rails are undamaged and gates open / close freely.
Chains are adequately lubricated and are not dry or rusty.
Mast cover plates are in place and securely attached for each section.
Continued on page 2
FREQUENT INSPECTIONS: The owner and user are required by ANSI A92.6 to ensure frequent inspections of the J1 Task Support
Vehicle occur and are performed in accordance with the following points: 1. If purchased used unless it's determined that the
frequent and annual inspections are current. 2. The J1 Task Support Vehicle has been in service for three (3) months or 150
hours, whichever comes first. 3. The J1 Task Support Vehicle has been out of service for a period longer than three (3) months.
inspection is to be performed by a mechanic that is qualified and authorized to perform service on the J1 Task Support Vehicle.
All service records must be maintained.
INSPECTION REQUIREMENTS per ANSI A92.6 (ANNUAL AND FREQUENT)
ANNUAL INSPECTION: The owner and user are required by ANSI A92.6 to ensure annual inspections of the J1 Task Support
Vehicle occur and are performed no later than 13 months from the date of prior annual inspection or every 700 hundred hours of
use, whichever occurs first. This annual inspection is to be performed by a mechanic that is qualified and authorized to perform
service on the J1 Task Support Vehicle. All service records must be maintained.
DEALER INFORMATION OWNER / END USER INFORMATION
COMPANY:
ADDRESS:
www.bigjoesupport.comJ1 - Task Support Vehicle (TSV)
Annual Inspection Report
INSTRUCTIONS: Refer to service/maintenance manuals for specific information regarding inspection procedures and criteria.
Indicate in the appropriate space as each item has been performed. If the item is found to be not acceptable, describe each
discrepancy on an additional page and attach to the form. Immediate action must be taken to correct all discrepancies. The
vehicle shall not be placed in service until all discrepancies have been corrected.
CITY/STATE/ZIP:
COMPANY:
ADDRESS:
CITY/STATE/ZIP:
MAST SIZE:
VEHICLE INFORMATION:
Operator right side control arm functions properly. Horn / travel / lift / lower / accelerator buttons are
functional.
Put a 9
9
in the column that applies: P = Passed Inspection , F = Failed Inspection, C = Corrected
Drive and operate machine to test all functions. Ensure controls operate properly and return to "off" or
neutral when released.
Ensure emergency power disconnect switch deactivates all movement and power and that the deadman
foot switch operate properly.
FUNCTIONS and CONTROLS
Mast sections are free of visual evidence of damage. Mast chains and cables are inspected per the
Service and Maintenance Manual.
OPERATOR PLATFORM ASSEMBLIES
The drive wheel returns to "neutral" (straight forward) when powering up the vehicle and is accurately
depicted on the LCD display.
All nuts, bolts, pins, shafts, covers, bearings and wear pads are checked for proper installation, and do
not have excessive wear, cracks or distortion.
Mast wiring harnesses are properly installed, seated in their pulleys and that there are no frayed or
broken strands.
Mast operates smoothly to full height and descends smoothly. Ensure speed cutbacks occur at
appropriate heights per the maintenance manual.
Page 2-6

BL-J1-192-0315 - 11-19-2019 2-7
VERSION G PAGE 2 OF 2
Big Lift LLC.
1060 N. Garfield St.
Lombard, IL 60148
www.bigjoesupport.com
J1 - Task Support Vehicle (TSV)
Annual Inspection Report
MODEL: SERIAL:
PFC
PFC
PFC
PFC
HYDRAULIC SYSTEM
DEALER: OWNER / END USER:
Ensure stability pads at base of unit (adjacent to caster wheels) are intact, properly secured and have
not sustained any damage
Ensure the electronic brake operates properly.
GENERAL
Ensure paint is in good condition and that there are not any issues with the overall appearance of the
task support vehicle.
Grease and lubricate the mast channel per maintenance manual.
Ensure battery fluid level is correct (if applicable).
Visually inspect motors to ensure there is no damage.
Ensure battery charger scrolls through diagnostics when plugged in.
Ensure all electrical connections are tight, free of frays and corrosion.
Ensure battery meets weight and voltage requirements.
Ensure fluid level is correct in hydraulic tank.
Ensure hydraulic pump is secure and undamaged, operates properly and is free of leaks.
Ensure hydraulic control valve is secure and undamaged, operates properly and is free of leaks.
Ensure hydraulic oil breather/vented cap is clean, hydraulic tank cap is tight and vent is open.
POWER and DRIVE SYSTEM
The undersigned certifies that this machine has been inspected, per each area of inspection, and any and all discrepancies have been
brought to the attention of the Owner / User, and that all discrepancies have been corrected prior to any further use of this machine.
Inspect front and rear load trays for functionality and damage.
MANUALS - DECALS - DATA PLATE
DATE:
OWNER / USER
SIGNATURE:
OWNER / USER
PRINTED NAME: DATE:
DEALER
SIGNATURE:
DEALER
PRINTED NAME:
Ensure ANSI/ SIA A92.6 manual of responsibilities, operations manual and service manual are in weather
resistant pouch on vehicle.
Ensure data plate is in place, secured and legible
Ensure all instruction and safety decals are installed, secure and legible.
ADDITIONAL COMMENTS
Lift cylinder is free of damage, no evidence of leaks and that all hardware is secure and undamaged.
All hydraulic hoses, fittings and components are properly secured and that there is no evidence of leaks.
VEHICLE INFORMATION:
MAST SIZE: HOUR METER:
Ensure optional equipment such as anchor point, tether, full body harness and tow hitch are in good
condition and fully functional (if applicable).
Inspect overall structural condition including welds.
Verify that no unauthorized modifications or additions have been made.
Ensure drive, load and caster wheels are properly installed, secure and do not have excessive wear.
Ensure all five wheels have contact with the floor.
Page 2-7

2-8 BL-J1-192-0315 - 11-19-2019
NOTES

BL-J1-192-0315 - 11-19-2019 3-1
SECTION 3
TROUBLESHOOTING
3-1. GENERAL
Use Table 3-1 as a guide to determine possible
causes of trouble. The table is divided into five main
categories: Vehicle and Hydraulic System Will Not
Operate: Vehicle Does Not Operate Forward or
Reverse: Trouble With Braking: Trouble With Lifting Or
Lowering, and Miscellaneous malfunctions.
Table 3-1 Troubleshooting Chart
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TRAVEL AND HYDRAULIC
SYSTEM WILL NOT OPERATE
a. Battery connector not con-
nected.
Check the battery connector and
connect if necessary.
b. Keyswitch “OFF” or defective. Turn keyswitch “ON” or bypass
keyswitch to determine if it is
malfunctioning.
c. Safety guard rail open. Close safety guard rail.
d. Emergency power disconnect
switch pressed or defective.
Disengage the emergency power
disconnect switch or bypass
switch to determine if it is mal-
functioning.
e. “Deadman” footswitch not
pressed or defective.
Press "deadman" footswitch or
bypass pedal to determine if it is
malfunctioning.
f. Battery charge too low. Check battery charge, charge bat-
tery if necessary.
g. Faulty fuse. Test fuses.
VEHICLE DOES NOT OPERATE
FORWARD OR REVERSE
Vehicle does not travel forward or
reverse. All other functions oper-
ate normally.
a. Check all wiring. A loose con-
nection may be the cause of
malfunction.
Tighten all loose connections
before further troubleshooting.
c. Defective controller. Check for proper operation and
replace if necessary.
d. Defective travel switch. Check and replace switch if defec-
tive.
Vehicle travels forward but not in
reverse.
Defective travel switch. Check and replace switch if defec-
tive.
Vehicle travels reverse but not in
forward.
Defective travel switch. Check and replace switch if defec-
tive.
Vehicle travels forward and in
reverse at lower speeds; will not
travel at high speed.
a. Defective travel switch in con-
trol head.
Check and replace switch if defec-
tive.
b. Operator platform raised above
47 inches.
Lower operator platform below 47
inches.

3-2 BL-J1-192-0315 - 11-19-2019
Table 3-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH LIFTING OR
LOWERING
Oil sprays or flows from the top of
the lift cylinder.
Defective packing in lift cylinder Repair lift cylinder.
Squealing sounds when lifting
Operator’s platform.
a. Oil level too low. Identify oil leak and fill reservoir.
b. Dry channels in mast. Apply grease.
c. Defective mast or Platform roll-
ers
Replace rollers.
Forks do not lift to top. a. Oil level too low. Add oil to reservoir.
b. Load larger than capacity. Refer to I.D.plate for capacity.
Weak, slow or uneven action of
hydraulic system.
a. Defective pump or relief valve. Check pressure. Adjust as
necessary.
b. Worn lift cylinder. Replace cylinder.
c. Load larger than capacity. Refer to I.D.platefor capacity.
d. Defective lift motor relay. Replace relay on pump motor.
e. Battery charge low. Charge battery.
Platform does not lift, pump motor
does not run.
a. Battery is dead or discon-
nected.
Check and recharge if required.
b. Defective wiring. Check and repair as required.
c. Defect in electrical system for
operating pump motor.
Check lift switch in control head,
as well as the relay.
Platform does not lift, motor runs. Defect in hydraulic system. Check the oil level in the reservoir
and the oil lines to the lift cylin-
der, and repair as required. If
normal, check the hydraulic
pump, and relief valve. Repair, or
adjust.
Platform lifts, but will not go down. Defect in hydraulic system Check lowering control switch and
lowering solenoid. Replace as
required.
Load will not hold a. Oil bypassing internally in con-
trol valve
Replace valve assembly.
b. Worn lift cylinder or packing. Repack cylinder.
Platform does not lift to top. Pump
motor runs.
a. Oil level too low. Add oil to reservoir.
b. Load larger than capacity. Refer to nameplate on side of
mast for maximum load capacity.
c. Batteries need charging. Charge batteries.

BL-J1-192-0315 - 11-19-2019 3-3
Table 3-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH LIFTING OR
LOWERING - Continued
Forks drifts down under load when
in a raised position.
Leak in hydraulic system, lift cylin-
der or lowering valve.
Check for leaking fitting in hydrau-
lic line and repair as required.
Repack lift cylinder or replace
valve assembly.
TROUBLE WITH STEERING
a. Faulty fuse. Test fuses.
b. Check all wiring. A loose con-
nection may be the cause of
malfunction.
Tighten all loose connections
before further troubleshooting.
c. Defective potentiometer. Check and replace potentiometer
if defective.
d. Defective controller. Check for proper operation and
replace if necessary.
e. Defective steer motor. Replace if necessary.

3-4 BL-J1-192-0315 - 11-19-2019
3-2. CONTROLLER TROUBLESHOOTING
3-2.1. Zapi Handset
A Zapi Handset is available that is designed specifi-
cally for use with the Zapi controller. It serves multiple
functions of reading diagnostic data, testing truck
operation, setting options, adjustments and parameter
changes of the controller. The Zapi Handset is avail-
able through your Big Lift LLC dealer. If you require
dealer location information, contact Big Lift LLC.
Remove the rubber plug from the CNC connector of
the controller Figure 3-1 and plug in the Zapi Handset
connector.
Figure 3-1 Zapi Controller
3-2.2. Fault Detection.
3-2.2.1. General
The microprocessor in the controller records the last
five Alarms that have occurred. Items remembered rel-
ative to each Alarm are:
• The alarm code
• The times that each alarm occurs consecutively
• The Hour Meter value when the latest event of every
alarm occurred
This function permits a deeper diagnosis of problems
as the recent history can be revisited.
3-2.2.2. Logbook Access
To view the alarm logbook proceed as follows:
1. Connect the Zapi Handset, refer to paragraph 3-
2.1.
2. Press the ENTER button (3, Figure 3-2) to enter
the MAIN MENU.
3. Press the ROLL down button (2) or the ROLL up
button (1) until ALARMS menu appears on the
display.
4. Press the ENTER button (3) to enter the ALARMS
menu.
5. Press the ROLL up button (1) to view the alarms.
Pressing the ROLL down button (2) returns to the
most recent alarm.
If an alarm has not occurred, the display will show
NONE.
6. Press the OUT button (4) to exit the alarms.
The display will ask: “CLEAR LOGBOOK?” Press
the ENTER button (3) for Yes or OUT button (4)
for No.
7. Press the OUT button (4) again to return to Open-
ing Zapi Menu.
3-2.3. Testing Truck Operation.
The Zapi Handset can be used to test certain truck
operations as follows:
1. Connect the Zapi Handset, refer to paragraph 3-
2.1.
2. Press the ENTER button (3, Figure 3-2) to enter
the MAIN MENU.
3. Press the ROLL down button (2) or the ROLL up
button (1) to find the TESTER display.
4. Press the ENTER button (3) to enter the TESTER
function.
The first switch to be tested is shown on the dis-
play.
5. To verify various switch functions, press the ROLL
down button (2) or the ROLL up button (1) to
locate the switch on the display and then operate
that function to verify operation
6. Press the OUT button (6) to exit the tests. The
display will show TESTER.
7. Press the OUT button (6) again to return to Open-
ing Zapi Menu.
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