Big Joe CB33 - Table of Contents; Sectionpage

TABLE OF CONTENTS
BL-CB33-0115 - 03-01-2018 i
Section Page SectionPage
1 DESCRIPTION............................................................1-1
1-1. INTRODUCTION..............................................1-1
1-2. GENERAL DESCRIPTION...............................1-1
1-3. SAFETY FEATURES. ......................................1-1
2 OPERATION ...............................................................2-1
2-1. GENERAL. .......................................................2-1
2-2. OPERATING PRECAUTIONS. ........................2-1
2-3. BEFORE OPERATION.....................................2-2
2-4. GENERAL CONTROL OPERATION................2-4
2-4.1. CONTROL ARM...............................................2-4
2-4.2. CONTROL HEAD.............................................2-4
2-5. DRIVING AND STOPPING PROCEDURES....2-4
2-5.1. STOPPING.......................................................2-4
2-6. CONTROL ARM GAS SPRING........................2-5
2-7. LOADING AND UNLOADING. .........................2-5
2-8. PARKING. ........................................................2-5
3 PLANNED MAINTENANCE ........................................3-1
3-1. GENERAL. .......................................................3-1
3-2. MONTHLY AND QUARTERLY CHECKS. .......3-1
3-3. BATTERY CARE.............................................3-1
3-3.1. GENERAL ........................................................3-1
3-3.2. SAFETY RULES ..............................................3-2
3-3.3. BATTERY CARE AND CHARGING.................3-2
3-3.4. BATTERY CLEANING......................................3-2
3-3.5. MAINTENANCE FREE BATTERIES................3-3
3-4. CHARGING BATTERIES.................................3-3
3-5. LUBRICATION. ................................................3-4
3-6. LIFT CHAIN MAINTENANCE...........................3-4
4 TROUBLESHOOTING ................................................4-1
4-1. GENERAL ........................................................4-1
4-1.1. CONTROLLER TROUBLESHOOTING............4-4
4-1.2. ZAPI HANDSET ...............................................4-4
4-1.3. FAULT DETECTION. .......................................4-4
4-1.4. TESTING TRUCK OPERATION. .....................4-4
4-1.5. SETTINGS AND ADJUSTMENTS ...................4-5
5 STEERING SYSTEM, CONTROL HEAD AND
COMPARTMENT ........................................................5-1
5-1. CONTROL HEAD.............................................5-1
5-1.1. CAP ASSEMBLY REMOVAL...........................5-1
5-1.2. CAP ASSEMBLY INSTALLATION...................5-2
5-1.3. CONTROL HEAD REMOVAL. .........................5-3
5-1.4. CONTROL HEAD INSTALLATION. .................5-3
5-1.5. SPEED POTENTIOMETER REPLACEMENT. 5-3
5-1.6. BELLY-BUTTON SWITCH REPLACEMENT. ..5-3
5-1.7. HORN SWITCH REPLACEMENT....................5-3
5-1.8. LIFT AND LOWER SWITCH
REPLACEMENT...............................................5-3
5-1.9. TILT SWITCH REPLACEMENT.......................5-3
5-2. CONTROL ARM...............................................5-3
5-2.1. GAS RETURN SPRING REPLACEMENT. ......5-3
5-2.2. CONTROL ARM REMOVAL. ...........................5-4
5-2.3. CONTROL ARM INSTALLATION. ...................5-4
5-3. COMPARTMENT COVERS.............................5-4
5-3.1. REMOVAL........................................................5-4
5-3.2. INSTALLATION................................................5-4
5-4. STEERING CONTROL.....................................5-4
5-4.1. REMOVAL. ...................................................... 5-4
5-4.2. INSTALLATION. .............................................. 5-4
5-5. STEERING MOTOR........................................ 5-5
5-5.1. REMOVAL. ...................................................... 5-5
5-5.2. INSTALLATION. .............................................. 5-5
6 BRAKE SERVICING................................................... 6-1
6-1. BRAKES. ......................................................... 6-1
6-1.1. BRAKE ASSEMBLY REPLACEMENT ............ 6-1
7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL .... 7-1
7-1. DRIVE WHEEL................................................ 7-1
7-2. TRANSMISSION. ............................................ 7-1
7-3. LOAD WHEEL. ................................................ 7-1
7-3.1. REMOVAL ....................................................... 7-1
7-3.2. LOAD WHEEL INSTALLATION....................... 7-1
8 ELEVATION SYSTEM SERVICING ........................... 8-1
8-1. GENERAL........................................................ 8-1
8-2. LIFT CHAIN LENGTH ADJUSTMENT............. 8-1
8-2.1. TELESCOPIC.................................................. 8-1
8-2.2. THREE STAGE MAST FREE LIFT CHAIN ..... 8-3
8-2.3. THREE STAGE MAST
SECONDARY LIFT CHAIN ............................. 8-3
8-3. LIFT CHAIN WEAR INSPECTION................... 8-3
8-4. LIFT CHAIN REPLACEMENT. ........................ 8-5
8-4.1. TELESCOPIC.................................................. 8-5
8-4.2. THREE STAGE MAST FREE LIFT CHAIN ..... 8-5
8-4.3. THREE STAGE MAST
SECONDARY LIFT CHAIN ............................. 8-5
8-5. LIFT CYLINDERS............................................ 8-5
9 HYDRAULIC SYSTEM SERVICING........................... 9-1
9-1. LINES AND FITTINGS .................................... 9-1
9-2. HYDRAULIC PUMP, AND MOTOR ASSY ...... 9-1
9-2.1. REMOVAL ....................................................... 9-1
9-2.2. INSTALLATION ............................................... 9-1
9-3. LIFT CYLINDER (TELESCOPIC).................... 9-3
9-3.1. REMOVAL ....................................................... 9-3
9-3.2. REPAIR ........................................................... 9-5
9-3.3. INSTALLATION ............................................... 9-5
9-4. LIFT CYLINDER
(THREE STAGE MAST FREE LIFT)............... 9-6
9-4.1. REMOVAL ....................................................... 9-6
9-4.2. REPAIR ........................................................... 9-8
9-4.3. INSTALLATION ............................................... 9-8
9-5. LIFT CYLINDER
(THREE STAGE MAST SECONDARY) .......... 9-9
9-5.1. REMOVAL ....................................................... 9-9
9-5.2. REPAIR ........................................................... 9-9
9-5.3. INSTALLATION ............................................... 9-9
9-5.4. TILT CYLINDERS.......................................... 9-11
10 ELECTRICAL COMPONENTS................................. 10-1
10-1. ELECTRICAL CONTROL PANEL ................. 10-1
10-1.1.MAINTENANCE...............
.............................. 10-1
10-1.2.CLEANING .................................................... 10-1
10-1.3.PANEL REMOVAL. ....................................... 10-1
10-1.4.PANEL DISASSEMBLY................................. 10-1
10-1.5.PANEL INSTALLATION. ............................... 10-1