Big Joe Joey J1 Series User manual

OPERATOR’S MANUAL
Big Lift LLC
www.bigjoeforklifts.com
Manual Part No. 901628
05/15/2020
J1
TASK SUPPORT
VEHICLE
U.S. Patent Nos. D730,614; D733,389; D733,390; 9,440,830
and D734,589 Other patents pending
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 protec-
tion 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
service technician.
This vehicle must not be modified
without the manufacturer’s consent.
Components critical to the vehicles
stability such as batteries shall not be
replaced with lighter weight compo-
nents.
Operate vehicle only from designated
platform operating 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 vehicle at full
capacity and lift height. Identify and
avoid holes, drop-offs, bumps and
obstructions.
Before and during all vehicle opera-
tions ensure that adequate clearance
is maintained from overhead obstruc-
tions and energized electrical conduc-
tors 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 plat-
form 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 vicin-
ity. Do not stabilize the platform by
contact with adjacent objects such as
racks or shelving. Do not use the plat-
form as a crane.
Take care to prevent electrical cords,
hoses or other equipment from entan-
gling in platform. Ensure area sur-
rounding the vehicle is free of
personnel and equipment before low-
ering 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.

4
Observe applicable traffic regula-
tions. Yield right of way to pedestri-
ans. Slow down and sound horn at
cross aisles and wherever vision is
obstructed. Avoid hazardous loca-
tions.
Enter and exit platform only through
raised access gates and with the plat-
form fully lowered and vehicle
stopped. When leaving vehicle unat-
tended, remove key to prevent unau-
thorized use.

5
FOREWORD
As an operator, you are responsible
for a vehicle that is useful, powerful,
and can be hazardous if not operated
as described. Observing and adhering
to the safety warnings in this manual
cannot be overemphasized and is
absolutely necessary for your well
being and, for the well being of those
around you.
It is an OSHA requirement that this
manual and parts and service manual
remain with the vehicle at all times as
a handy reference guide to operation.
Detailed maintenance procedures are
found in the parts and service manual,
and are to be performed only by a
qualified service technician. For fur-
ther information on obtaining a com-
plete parts and service manual, see
page 24 of this manual.
The operator who knows his/her vehi-
cle will learn to spot problems as they
develop. This is accomplished by per-
forming the Daily Operator’s Check
list and reporting any problems to the
designated authority.
TABLE OF CONTENTS
SAFETY SYMBOLS ..............................................................................................6
GENERAL DESCRIPTION....................................................................................6
NAME PLATE AND WARNING DECALS.............................................................8
BEFORE OPERATION..........................................................................................9
CONTROLS.........................................................................................................12
INSTRUMENT PANEL ........................................................................................14
OPERATION........................................................................................................16
SAFETY REGULATIONS FOR OPERATION ........................................16
DRIVING PROCEDURES.......................................................................16
STOPPING PROCEDURES ...................................................................17
LIFTING AND LOWERING.....................................................................18
EMERGENCY LOWERING ....................................................................18
PICKING UP A LOAD ............................................................................19
TRANSPORTING LOADS......................................................................19
PLACING LOADS ..................................................................................20
OVERHEAD MAINTENANCE ................................................................20
PARKING................................................................................................20
MOVING A DISABLED VEHICLE ..........................................................20
BATTERY MAINTENANCE.................................................................................21
LUBRICATION ....................................................................................................22
NOTICE - OBTAINING A PARTS AND SERVICE MANUAL..............................23

6
SAFETY SYMBOLS
WARNING and CAUTION are both signal words intended to alert the operator to
the existence and relative degree of a hazard. They are both preceded by a safety
alert symbol consisting of an exclamation mark enclosed by a triangle.
A Warning indicates a hazard which could result in injury or death if proper pre-
cautions are not taken.
A Caution indicates a reminder of routine safety practices.
A prohibition slash (circle with diagonal slash through it) indicates a procedure or
action that should not be performed under any circumstances, as both personal
injury and/or damage to equipment will result.
GENERAL DESCRIPTION
The self-propelled J1 elevating work
platform lifts and transports up to
1,000 pounds capacity including load
and operator. Please see the name
plate Figure 2 for specific capacity
information. The vehicle enables gen-
eral maintenance work and efficient
selection and moving of materials in
any area or at any level of the ware-
house or storeroom. This vehicle is
not for use on mezzanines 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 with-
out special provisions for ventilation.
Users shall comply with all require-
ments indicated in applicable OSHA
standards and the current edition of
A.N.S.I. A92.6. By following these
requirements and the recommenda-
tions contained in this manual, you will
receive many years of dependable
service from your vehicle.
The AC drive motor propels the vehi-
cle in forward or reverse direction.
The vehicle can be driven with the
platform raised or lowered; however
the speed is restricted as the platform
is raised.
On demand power steering makes the
vehicle highly maneuverable and
extremely quiet.
The control arms are used to operate
the work vehicle and provide operator
safety.
The pick tray is used to place and
transport merchandise.
The operator platform contains the
“deadman” footswitch vehicle must be
depressed for the vehicle to operate.
The folding rear tray provides for
transporting up to a 200 pound load.

7
Figure 1 J1 Elevating Work Platform
R6980
ITEM COMPONENT
1 Control arms
2 Pick tray
3 Warning light
4 Cover
5 Control panel
6Casters
7Frame
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

8
NAME PLATE AND WARNING DECALS
Warning decals are located to the left
of the Instrument panel. The name
plate is mounted on the right side of
the Instrument panel.
If the name plate or warning decals
are lost or damaged they should be
replaced immediately. Have your
supervisor or the designated author-
ity contact Big Lift LLC’s Authorized
Dealer for replacement.
The name plate shows the model,
serial number, capacity, lift height,
vehicle weight and minimum battery
weight. See Figure 2.
Figure 2 Name Plate
R6978

9
BEFORE OPERATION
Table 1 covers important inspection
points on vehicles which should be
checked prior to operation. Depending
on use, some vehicles may require
additional checks.
Figure 3 shows a sample format for
an Operator Checklist, which can be
modified as necessary to fit your oper-
ation.
Periodic maintenance of this
vehicle by a QUALIFIED SER-
VICE TECHNICIAN is required.
A QUALIFIED SERVICE TECH-
NICIAN should check the vehi-
cle regularly during preventive
maintenance for proper lubrica-
tion, proper fluid levels, brake
maintenance, motor mainte-
nance and other areas specified
in the parts and service manual
maintenance section.
If the vehicle is found to be unsafe
and in need of repair, or contrib-
utes to an unsafe condition,
report it immediately to the des-
ignated authority. Do not operate
it until it has been restored to a
safe operating condition. Do not
make any unauthorized repairs
or adjustments. All service must
be performed by a QUALIFIED
SERVICE TECHNICIAN using
Big Joe OEM parts.
PREPARING FOR OPERATION
Preparing the vehicle for operation
after delivery or transport:
1. Check that the equipment is com-
plete.
2. Check the hydraulic oil level.
Refer to page 22.
3. Install the battery if necessary.
4. Charge the batteries. Refer to
page 21.
5. Visually inspect the entire vehi-
cle for obvious damage.
DURING INITIAL USE
Operating the vehicle with no load or
under light load conditions for initial
use is recommended. A light load is
30 to 50% of the rated load. During
the first 100 hours of operation
observe the following:
1. Prevent the new battery from
over-discharging.
2. Perform preventive maintenance
services carefully and completely.
3. Avoid sudden stops, starts or
turns.
4. Perform oil changes and lubrica-
tion earlier than specified.
WARNING:
WARNING:
WARNING:

10
Figure 3 Sample of Operator Check List
R7033

11
Table 1 Operator Check List
ITEM PROCEDURE
Transmission and hydraulic
systems
Check for signs of fluid leakage.
Pick tray and rear tray Check for cracks and damage and that it is
properly secured.
Chains, cables and hoses Check that they are in place, properly secured
and not damaged.
Control arms and guard rails Check that vehicle operation is disabled when
arms and guard rails are raised.
Safety warning label and
nameplate
Check that warning labels, nameplate, etc.,
are in good condition and legible.
Horn and flashing lights Check that horn sounds when operated and
flashing lights are operable.
Steering Check for binding or looseness in steering
arm when steering.
Travel controls Check that travel control on right control arm
operates in all speed ranges in forward and
reverse.
Wheels Check drive wheel for cracks or damage.
Move vehicle to check load wheels and cast-
ers for freedom of rotation.
Hydraulic controls Check operation of lift and lower to their maxi-
mum positions.
Emergency power discon-
nect switch
Check that brakes actuate when emergency
power disconnect switch is depressed.
Battery disconnect Check that battery can be disconnected and
reconnected. Check for connector damage.
Speed limit switches Allow for enough space to operate vehicle in
all speeds Test drive the vehicle to check for
speed reductions when elevated. TRIMAST
vehicles have three speed reductions, Tele-
scopic vehicles have two speed reductions.
Platform Operation Check that all controls in the platform operat-
ing compartment are operational.

12
CONTROLS
Figure 4 Controls
R6979
ITEM COMPONENT
1 Lift button
2 Lower button
3 Horn button
4 Keyswitch
5 Travel switch
6 Emergency power discon-
nect switch
7 Steering control
8 Battery disconnect and
charger
9 Emergency lowering button
10 “Deadman” footswitch
11 Instrument panel
ITEM COMPONENT

13
LIFT BUTTON (1, Figure 4)
To raise the platform, push and hold
the LIFT button until desired height is
reached. Guard rails need to be in
lowered position and “deadman”
footswitch needs to be engaged for
travel and lift.
LOWER BUTTON (2, Figure 4)
To lower the platform, push and hold
the LOWER button until the desired
height is reached. Guard rails need to
be in lowered position and foot pedal
needs to be engaged for travel and
lift.
HORN BUTTON (3, Figure 4)
Sounds the horn.
KEYSWITCH (4, Figure 4)
The keyswitch has two positions, ON
and OFF. Remove the key to prevent
unauthorized use.
TRAVEL SWITCH (5, Figure 4)
This switch controls forward, neutral
and reverse travel. Travel direction is
also indicated on the instrument
panel.
EMERGENCY POWER DISCON-
NECT SWITCH (6, Figure 4)
Pushing down the emergency power
disconnect switch disconnects the
main power, deactivates all electrical
functions, causing the vehicle to brake
automatically.
STEERING CONTROL (7, Figure 4)
This control is operated in the conven-
tional manner. Drive wheel direction is
also indicated on the instrument
panel.
BATTERY DISCONNECT (8, Figure
4)
The battery disconnect can be used to
cut off all power to the vehicle. It is
also used to connect the batteries to
the battery charger.
EMERGENCY LOWERING BUTTON
(9, Figure 4)
Press this button to lower the platform
in case of an emergency.
“DEADMAN” SWITCH (10, Figure 4)
Operator must stand on this pedal to
to activate the controls.
INSTRUMENT PANEL (11, Figure 4)
The instrument panel contains the fol-
lowing displays and controls:

14
INSTRUMENT PANEL
Figure 5 Instrument Panel
LOW BATTERY ALARM LED (1, Fig-
ure 5)
This LED lights when the measured
battery voltage is equal or less than
40% nominal battery voltage.
FAULT ALARM LED (2, Figure 5)
When a fault is detected, this LED will
light. The display (7, Figure 5) will dis-
play the warning and fault indication.
Report alarm to the designated
authority and do not use the vehicle
until corrected by a qualified
mechanic.
TEMPERATURE ALARM LED (3,
Figure 5)
When the temperature of the drive
motor is too high, the LED will illumi-
nate. Temporarily stop operation until
the temperature drops and notify an
authorized technician.
DRIVE PEDAL ALARM LED (4, Fig-
ure 5)
When the drive pedal is released, this
LED will illuminate.
BRAKE ALARM LED (5, Figure 5)
This LED will illuminate when the
brake is actuated.
FUNCTION KEYS (6, Figure 5)
Use the left arrow button to adjust the
speed mode. Use the down arrow but-
ton to switch the driving mode.
DISPLAY (7, Figure 5)
The display has the following func-
tions:
R6981

15
Figure 6 Instrument Panel
Battery Indicator (1, Figure 6): The
state of charge is displayed by ten
notches. Each notch represents 10%
of the battery charge. For example,
the illustration shows the battery has
80% charge.
Information Display (2, Figure 6):
Displays the warnings and faults.
Report warnings and faults to the des-
ignated authority and do not use the
vehicle until corrected by a qualified
mechanic.
Speed Display (3, Figure 6): Indi-
cates the vehicle’s speed.
Hour Meter Display (4, Figure 6):
Displays the amount of hours that the
vehicle has been operated
Speed Mode Display (5, Figure 6):
There are four speed ranges available
in both the high speed driving mode
and the crawl speed driving mode.
Use the “left” function key (6, Figure
5) to select the desired mode. “1” indi-
cates the slowest speed while “4” indi-
cates the highest speed.
When the platform rises the
vehicle automatically enters
crawl speed.
Steering Display (6, Figure 6): One
of nine notches will indicate the steer-
ing angle of the drive wheel.
Driving Mode Display (7, Figure 6):
The vehicle can be operated in two
driving modes, normal speed or crawl
speed. Use the “down” function key
(6, Figure 5) to switch the driving
mode. The crawl speed will automati-
cally come on when the operator plat-
form reaches the speed limit switch.
When you are in crawl speed, a “Tur-
tle” (7, Figure 6) shows on the display.
R6982A
CAUTION:
Crawl Speed.

16
OPERATION
SAFETY REGULATIONS FOR
OPERATION
Operator Authorization: The vehicle
may only be used by trained person-
nel, who have been authorized to
operate the vehicle by the supervisor
or the designated authority.
Operator’s Responsibilities: The
operator must be informed of his
duties and responsibilities and be
trained in the operation of the vehicle
and shall be familiar with the opera-
tor’s manual.
Unauthorized Use of Vehicle: The
operator is responsible for the vehicle
during the time it is in use. He/she
shall prevent unauthorized persons
from driving or operating the vehicle. It
is forbidden to carry passengers or to
lift personnel.
Damage and Faults: The supervisor
or the designated authority must be
immediately informed of any damage
or fault codes. Vehicles not safe for
operation must not be used until they
have been repaired.
Repairs: The operator must not carry
out any repairs or alterations to the
vehicle. The operator must never dis-
able or adjust safety mechanisms or
switches.
Hazardous area: A hazardous area is
defined as the area in which a person
is at risk due to vehicle movement, lift-
ing operations, or the load itself. This
also includes areas which can be
reached by falling loads or lowering
equipment.
• Unauthorized persons must be kept
away from hazardous area.
• Where there is danger to personnel,
a warning (the horn) must be
sounded with sufficient notice.
• If unauthorized personnel are still
within the hazardous area the vehi-
cle shall be brought to a halt imme-
diately.
Safety devices and warning signs:
Safety devices, warning signs and
warning instruction shall be strictly
observed.
DRIVING PROCEDURES
The vehicle can be driven with the
platform raised or lowered; however,
the speed is restricted when the plat-
form is raised above a preset limit.
Do not leave the platform cage
floor area while the operator
platform is elevated. Do not
lean out from the outside of a
cage rail. Climbing on the guard
rails and/or trays is strictly pro-
hibited and can lead to severe
injury or death.
Only one person is permitted in
the operator’s compartment at
all time.
WARNING:
WARNING:

17
Proceed as follows to start and stop
the vehicle.
1. Step on the operator platform
with your back against the back
rest.
2. Lower the control arms and guard
rails.
3. Turn on the keyswitch (4, Figure
7) and pull up on the emergency
power disconnect switch (6, Fig-
ure 7).
4. Step on “deadman” footswitch
(10, Figure 7) to activate the elec-
trical controls.
5. Adjust the driving mode (4, Fig-
ure 6) using the “down” key (6,
Figure 5).
6. Select the speed mode (5, Figure
6) using the “left” function key (6,
Figure 5).
7. Use the steering control (7, Fig-
ure 7) to steer the vehicle in the
required direction. Drive wheel
direction is indicated on the
instrument panel.
8. Using your right hand, move the
travel switch (5, Figure 7) to the
desired direction.
The vehicle is equipped with a
level sensor. When the vehicle
is elevated and on a slope
greater than 4.5 degree, the
level sensor sounds an alarm
beeper. The truck is only to be
used indoors on a level surface.
This vehicle is not for use on
mezzanines or balcony areas.
STOPPING PROCEDURES
The brake pattern of the vehicle
depends largely on the ground condi-
tions. The driver must take this into
account when operating the vehicle.
The driver must be looking ahead
when traveling. If there is no hazard,
brake moderately to avoid moving the
load.
The vehicle can brake in three differ-
ent ways;
Coasting Brake: release the drive
pedal (10, Figure 7) and allow the
vehicle to coast to a stop.
Reverse Braking: To stop faster,
slowly move the travel switch (5, Fig-
ure 7) to the opposite direction, this is
also referred to as “plugging”.
NOTE: The vehicle direction may be
reversed while moving. The
control will cycle the motor to
stop and then reverse in a
timed sequence without dan-
ger to the equipment. Exer-
cise caution when doing so,
especially when traveling at
maximum speed.
Emergency Braking: To stop rapidly
when an emergency exists, press the
emergency power disconnect switch
(6, Figure 7).
Except in an emergency, do not
stop suddenly.
WARNING:
WARNING:

18
Figure 7 Operation
LIFTING AND LOWERING
Ensure there are no other peo-
ple standing underneath the
raised platform. Instruct other
people to move out of the haz-
ardous area.
Lifting: Press and hold the lift button
(1, Figure 7) until you reach the
desired height.
Never raise the guard rails
when the vehicle is in an ele-
vated position.
Lowering: Press and hold the lower
button (2, Figure 7) until you reach the
desired height.
Lowering, the vehicle sounds
an intermittent alarm beeper.
EMERGENCY LOWERING
If a condition exists where lowering
without power is necessary, instruct
someone on the ground to push sole-
noid valve button (1, Figure 8) through
hole in the cover (9, Figure 7).
Do not leave the platform cage
floor area while the operator
platform is elevated. Do not
lean out from the outside of a
cage rail. Climbing on the guard
rails and/or trays is strictly pro-
hibited and can lead to severe
injury or death.
R6679
WARNING:
WARNING:
CAUTION:
WARNING:

19
Figure 8 Lowering Control
PICKING UP A LOAD
1. Drive the vehicle carefully up to
the storage location (4, Figure 9).
2. Press the lift button (1) until pick
tray (3) reaches the desired
height.
3. Move the load from storage loca-
tion (4) to tray (3).
4. Press the lower button (2) until
the platform is completely low-
ered.
TRANSPORTING LOADS
1. Always transport load with the
platform completely lowered.
2. Always transport loads on the
pick tray or the rear tray.
3. Always be prepared to brake.
Only stop suddenly in emergency
situations.
4. Reduce speed in tight areas.
Figure 9 Order Picking
R6989
R6985

20
PLACING LOADS
1. Drive the vehicle carefully up to
the storage location (4, Figure 9).
2. Press the lift button (1) until pick
tray (3) reaches the desired
height.
Ensure storage location is suit-
able for storing the load (size
and capacity).
3. Move the load from tray (3) to
storage location (4).
4. Press the lower button (2) until
the platform is completely low-
ered.
OVERHEAD MAINTENANCE
When performing overhead mainte-
nance, please ensure there are no
obstacles, beams or other obstruc-
tions before elevating lift. Always fully
lower the platform before moving to
the next maintenance position.
Ensure a safe work environment
before proceeding with maintenance
and never operate the lift outside.
PARKING
When leaving the vehicle, it must be
securely parked even for a short time.
1. Park the vehicle in its designated
parking area.
Do not park the vehicle on a
slope. The platform must be
completely lowered.
2. Lower the platform completely.
3. Set the emergency power discon-
nect switch to apply the brake.
4. Turn keyswitch to off position.
Remove key for added security.
5. Pull out battery disconnect.
MOVING A DISABLED VEHICLE
Do not attempt to move a disabled
vehicle; notify your supervisor or
proper authority.
WARNING:
WARNING: