IBH ELECTRIC SERIES - bigjoesupport.com

1 Big Joe Manufacturing Company Des Plaines, IL 60018 MANUAL NO. 901351 Revision D 08/03/06 Manual Price $ ELECTRIC SERIESMANUALLY PROPELLEDIN-BETWEEN-HANDLINGLIFT TRUCKS erial Number 341649 and HigherOperationMaintenanceRepair Parts List901351iTABLE OF CONTENTSS ectionPageSectionPage1 DESCRIPTION .. FEATURES.. AND DECALS..1-22 OPERATION .. PRECAUTIONS.. AND CONTROLS.. INSTRUMENT PANEL .. FLOOR LOCK .. PUSH BAR .. OPTIONAL FIFTH WHEEL .. OPTIONAL REMOTE LIFT/LOWER CONTROL .. MOVING, (POSITIONING) AND TURNING .. THE CONVENTIONAL OPERATION.

2 REMOTE OPERATION OF LIFT WITH REMOTE CONTROL AND UNLOADING..2-53 PLANNED MAINTENANCE .. AND QUARTERLY CHECKS.. CARE .. GENERAL .. CHARGER OPERATION (8 AMP) .. CHARGER OPERATION ("SMART" 15 AMP) .. CHAIN TROUBLESHOOTING ..4-15 LIFT SYSTEM .. MAST ASSEMBLY (TELESCOPIC AND FULL FREE LIFT) .. CHAIN WEAR INSPECTION .. CHAINS ADJUSTMENT.. CHAINS TELESCOPIC AND NON-TELESCOPIC .. FULL FREE CYLINDER REMOVAL.. FULL FREE CARRIAGE.. BACKRESTS..5-66 HYDRAULIC SYSTEM OIL RESERVOIR.. OIL FILTER .. CONTROL VALVE.

3 DISASSEMBLY, LIFT CONTROL VALVE .. CONTROL VALVE.. CYLINDER REPAIR.. NON-TELESCOPIC (MODEL 1018).. NON-TELESCOPIC (MODEL 1518, 1524, 2018, 2024, 2524).. TELESCOPIC .. FULL FREE LIFT .. SPEED CONTROL MODULE.. LINES AND 6-126-10. HYDRAULIC PRESSURE ADJUSTMENT.. 6-127 ELECTRICAL SYSTEM SERVICING .. PUMP MOTOR.. HYDRAULIC PUMP MOTOR (MODEL 2524)SERIAL NUMBER 341649 THRU 344124.. HYDRAULIC PUMP MOTOR (MODEL 2524)SERIAL NUMBER 344125 TO 377757.. HYDRAULIC PUMP MOTOR (MODEL 2524)SERIAL NUMBER 377758 AND HIGHER.. HYDRAULIC PUMP MOTOR (MODELS 1018, 1518, 1524, 2018, 2024)SERIAL NUMBER 341649 THRU 375921.

4 HYDRAULIC PUMP MOTOR (MODELS 1018, 1518, 1524, 2018, 2024)SERIAL NUMBER 375922 AND HIGHER.. CHARGER.. 7-28 FRAME AND RELATED PARTS SERVICING .. WHEEL REPLACEMENT.. WHEEL LOCKS.. FLOOR LOCK FLOOR LOCK PLUNGER REPLACEMENT .. FLOOR LOCK HANDLE REPLACEMENT FOR TRUCKS WITH SERIAL NUMBER 345200 AND LOWER.. FLOOR LOCK HANDLE REPLACEMENT FOR TRUCKS WITH SERIAL NUMBER 345201 AND HIGHER .. 8-39 HYDRAULIC SYSTEM CONTROL. (Figure 9-1) .. SPEED CONTROL MODULE.. WHEEL.. 9-2ii901351 TABLE OF CONTENTS - STRADDLE RE-POSITIONING.

5 9-310 ILLUSTRATED PARTS BREAKDOWN .. 10-1 LIST OF ILLUSTRATIONSF igurePageFigurePage1-1 NAME PLATE .. 1-11-2 TYPICAL IBH LIFT TRUCKS .. 1-22-1 LOAD 2-12-2 SAMPLE OF OPERATOR CHECK LIST .. 2-22-3 INSTRUMENT PANEL .. 2-32-4 FLOOR LOCK AND OPTIONAL FIFTH WHEEL .. 2-42-5 OPTIONAL REMOTE LIFT/LOWER 2-53-1 LUBRICATION 3-35-1 INNER MAST AND RAM HEAD (NON-TEL) 5-15-2 INNER MAST AND RAM HEAD (TEL) .. 5-25-3 INNER MAST AND RAM HEAD (TEL) .. 5-35-4 INNER MAST AND RAM HEAD (FULL FREE LIFT) .. 5-45-5 LIFT CARRIAGES AND 5-76-1 HYDRAULIC SYSTEM SCHEMATIC, BATTERY MODELS.

6 6-16-2 HYDRAULIC SYSTEM (TEL & NON TEL).. 6-26-3 HYDRAULIC SYSTEM (FFL) .. 6-36-4 LIFT CONTROL VALVE ASSEMBLY .. 6-46-5 LIFT CONTROL VALVE ADJUSTMENT POSITION .. 6-46-6 LIFT CYLINDER (NON-TEL) (MODEL 1018) .. 6-66-7 LIFT CYLINDER (NON-TEL) (MODEL 1518, 1524, 2018, 2024, 2524) .. 6-76-8 LIFT CYLINDER (TEL).. 6-96-9 LIFT CYLINDER (FFL) .. 6-117-1 ELECTRICAL SYSTEM .. 7-17-2 MODEL 2524 ORIGINAL WIRING .. 7-27-3 MODEL 2524 REWORKED WIRING .. 7-28-1 LOAD WHEELS(MODEL 1018) .. 8-18-2 LOAD WHEELS(MODEL 15158, 1524, 2018, 2024, 2524) .. 8-28-3 WHEEL 8-28-4 CASTER WHEEL WITH AXLE BUSHING.

7 8-28-5 FLOOR LOCK 8-49-1 REMOTE CONTROL .. 9-19-2 LIFT SPEED CONTROL 9-29-3 FIFTH WHEEL IN PLACE .. 9-29-4 FIFTH WHEEL ASSEMBLY .. 9-39-5 ADJUSTABLE STRADDLE .. 9-410-1 INNER MAST AND RAM HEAD (NON-TEL) .. 10-210-2 INNER MAST AND RAM HEAD (TEL) .. 10-410-3 INNER MAST AND RAM HEAD (TEL) .. 10-610-4 INNER MAST AND RAM HEAD (FFL).. 10-810-5 BASE AND FRAME .. 10-1010-6 LIFT CYLINDER ASSEMBLY (NON-TEL)(MODEL 1018) .. 10-1210-7 LIFT CYLINDER ASSEMBLY (NON-TEL)(MODEL 1518, 1524, 2018) .. 10-1410-8 LIFT CYLINDER ASSEMBLY (NON-TEL)(MODEL 2024, 2524) .. 10-1610-9 LIFT CYLINDER ASSEMBLY (TEL)(MODEL 1518, 1524, 2018).

8 10-1810-10 LIFT CYLINDERS (FULL FREE LIFT) .. 10-2010-11 LIFT CONTROL VALVE ASSEMBLY .. 10-2210-12 LIFT SPEED CONTROL 10-2210-13 LIFT CARRIAGE AND FORK .. 10-2410-14 HYDRAULIC SYSTEM (TEL AND NON-TEL) .. 10-2610-15 HYDRAULIC SYSTEM (FFL) .. 10-2810-16 HYDRAULIC PUMP AND MOTOR WITHOUT REMOTE CONTROL(MODEL 2524 ONLY S/N 341649 TO 344124) .. 10-2910-17 HYDRAULIC PUMP AND MOTOR .. 10-3010-18 HYDRAULIC PUMP AND MOTOR .. 10-3110-19 INSTRUMENT PANEL .. 10-3210-20 LOAD WHEELS(MODEL 1018) .. 10-3210-21 LOAD WHEELS(MODEL 1518, 1524, 2018, 2024, 2524) 10-3310-22 CASTER WHEELS.

9 10-3410-23 FLOOR LOCK 10-34901351iiiLIST OF ILLUSTRATIONS - ContinuedFigurePageFigurePage10-24 FIFTH WHEEL ASSEMBLY .. 10-3510-25 ADJUSTABLE 10-3610-26 BATTERY CHARGER, 8 AMP(STANDARD ON MODELS 1018, 1518, 2018) .. 10-3710-27 BATTERY CHARGER, SMART 15 AMP(STANDARD ON MODELS 1524, 2024, 2524)(OPTIONAL ON MODELS 1018, 1518, 2018) .. 10-3710-28 REMOTE 10-38 LIST OF TABLEST ablePageTablePage1-1 DECAL PART NUMBER1-11-2 PAINT PART NUMBER1-12-1 OPERATOR CHECKS2-23-1 INSPECTION AND SERVICE3-13-2 RECOMMENDED LUBRICANTS3-33-3 HYDRAULIC SYSTEM CAPACITIES3-33-4 LUBRICATION CHART.

10 3-34-1 TROUBLESHOOTING CHART ..4-110-1 FORK (ITEM 4)..10-2410-2 LOAD BACKREST, MODEL 2024 & 2524 ..10-25iv901351 OPERATOR INSTRUCTIONSWARNINGDo not operate this truck unless you have been trainedand authorized to do so, and have read all warningsand instructions in operator's manual and on this not operate this truck until you have checked itscondition. Give special attention to wheels, battery, liftsystem (including forks or attachments, chains, cablesand limit switches), floor lock (brake), steering mecha-nism, guards and safety truck only from designated operating place any part of your body into the mast struc-ture or between the mast and the truck.