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Manual
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BL-CB33-01
15 - 03-01
-2018
12-31
FRAME - CONTINUED
Pos.
Part Number
Description
Qty
.
Reqd.
Notes
23
1280-
180001-0A
BLOCK
1
24
0000-000
279-00
BOL
T
, M8 X 35
1
25
2125-100
002-00
BA
TTERY CLIP
1
26
2140-100
001-00
BA
TTERY BLOCK
1
108
110
Table of Contents
Main Page
Table of Contents
3
Sectionpage
3
Description
5
Introduction
5
General Description
5
Safety Features
5
Name Plate
5
Cb33 Lift Truck
6
Operation
7
General
7
Operating Precautions
7
Load Center
7
Before Operation
8
Control Arm
8
Control Head
8
Sample of Operator Check List
9
General Control Operation
10
2-4.1. Control Arm
10
2-4.2. Control Head
10
Driving and Stopping Procedures
10
2-5.1. Stopping
10
Control Arm Gas Spring
11
Loading and Unloading
11
Parking
11
Planned Maintenance
13
General
13
Monthly and Quarterly Checks
13
Battery Care
13
Electrical System
13
3-3.2. Safety Rules
14
3-3.3. Battery Care and Charging
14
3-3.4. Battery Cleaning
14
3-3.5. Maintenance Free Batteries
15
Charging Batteries
15
Lubrication
16
Lift Chain Maintenance
16
Lubrication Diagram
17
Troubleshooting
19
General
19
4-1.1. Controller Troubleshooting
22
4-1.2. Zapi Handset
22
Zapi Handset
22
4-1.3. Fault Detection
22
4-1.4. Testing Truck Operation
22
4-1.5. Settings and Adjustments
22
Steering System, Control Head and Compartment
39
Control Head
39
5-1.1. Cap Assembly Removal
39
5-1.2. Cap Assembly Installation
40
5-1.3. Control Head Removal
41
5-1.4. Control Head Installation
41
5-1.5. Speed Potentiometer Replacement
41
5-1.6. Belly-Button Switch Replacement
41
5-1.7. Horn Switch Replacement
41
5-1.8. Lift and Lower Switch Replacement
41
5-1.9. Tilt Switch Replacement
41
Control Arm
41
5-2.1. Gas Return Spring Replacement
41
5-2.2. Control Arm Removal
42
5-2.3. Control Arm Installation
42
Compartment Covers
42
5-3.1. Removal
42
5-3.2. Installation
42
Steering Control
42
Steering Motor
42
5-5.2. Installation
43
Brake Servicing
45
Brakes
45
6-1.1. Brake Assembly Replacement
45
Drive Assembly
46
Transmission, Drive Wheel, Load Wheel
47
Drive Wheel
47
Transmission
47
Load Wheel
47
7-3.1. Removal
47
7-3.2. Load Wheel Installation
47
Drive Assembly
48
Elevation System Servicing
51
General
51
Lift Chain Length Adjustment
51
8-2.1. Telescopic
51
8-2.2. Three Stage Mast Free Lift Chain
53
8-2.3. Three Stage Mast Secondary Lift Chain
53
Lift Chain Wear Inspection
53
Lift Chain Replacement
55
8-4.1. Telescopic
55
8-4.2. Three Stage Mast Free Lift Chain
55
8-4.3. Three Stage Mast Secondary Lift Chain
55
Lift Cylinders
55
Hydraulic System Servicing
57
Lines and Fittings
57
Hydraulic Pump, and Motor Assy
57
9-2.1. Removal
57
9-2.2. Installation
57
Lift Cylinder (Telescopic)
59
9-3.1. Removal
59
9-3.2. Repair
61
9-3.3. Installation
61
Lift Cylinder (Three Stage Mast Free Lift)
62
9-4.1. Removal
62
9-4.2. Repair
64
9-4.3. Installation
64
Lift Cylinder (Three Stage Mast Secondary)
65
9-5.1. Removal
65
9-5.2. Repair
65
9-5.3. Installation
65
9-5.4. Tilt Cylinders
67
Tilt Cylinder Mounting
67
Electrical Components
71
Electrical Control Panel
71
10-1.1.Maintenance
71
10-1.2.Cleaning
71
10-1.3.Panel Removal
71
10-1.4.Panel Disassembly
71
10-1.5.Panel Installation
71
10-4.1.Motor Removal
74
10-4.2.Motor Installation
74
10-5.1.Replacement
74
Illustrated Parts Breakdown
79
Control Head
87
Drive System
89
Drive Assembly
89
Drive Motor
91
Compartment
105
Frame
107
Load Wheels
111
Elevation System (Telescopic)
113
Elevation System (Telescopic)
115
Elevation System (Three Stage Mast)
117
Elevation System (Three Stage Mast)
119
Lift Carriage (Telescopic)
122
Lift Carriage (Three Stage Mast)
125
Chain Assembly
129
Hydraulic System
131
Tilt System
137
Lift System (Telescopic)
139
Lift System (Three Stage Mast)
143
Lift Cylinder (Telescopic)
147
Free Lift Cylinder (Three Stage Mast)
149
Secondary Lift Cylinder (Three Stage Mast)
151
Secondary Lift Cylinder
151
(Three Stage Mast)
151
Tilt Cylinder
153
Electrical System
160
Electrical Panel
161
Electrical Panel
163
Wire Harness
165
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