Big Lift CB22-128 User Manual (English)

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Big Lift LLC MANUAL NO. BL-CB22-0612

www.bigjoeforklifts.com 06/13/2012

CB22

SELF-PROPELLED,

COUNTERBALANCED LIFT TRUCK

Operation

Maintenance

Repair Parts List

Table of Contents3
Description5
Introduction5
General Description5
Safety Features5
Name Plate5
Cb22 Lift Truck5
Operation7
General7
Operating Precautions7
Load Center7
Before Operation8
Sample of Operator Check List9
General Control Operation10
Driving and Stopping Procedures10
2-5.1. Stopping10
Forward/Reverse Control10
Pushbutton Switches10
Belly-Button Switch11
Steering Arm Gas Spring11
Lift and Lower Controls11
Tilt Controls11
Loading and Unloading11
Parking11
Brake Actuation11
Planned Maintenance13
General13
Monthly and Quarterly Checks13
Battery Care13
3-3.2. Safety Rules14
3-3.3. Battery Care and Charging14
3-3.4. Battery Cleaning14
3-3.5. Maintenance Free Batteries15
Charging Batteries15
Lubrication16
Lift Chain Maintenance16
Lubrication Diagram17
Troubleshooting19
General19
Steering Arm21
Controller Troubleshooting22
4-2.1. Zapi Handset22
4-2.2. Fault Detection22
4-2.3. Testing Truck Operation22
4-2.4. Settings and Adjustments23
Zapi Handset23
Zapi Handset27
Zapi Handset29
Zapi Controller31
Zapi Controller Connections31
Steering Arm, Control Head and Compartment35
Control Head35
5-1.1. Cap Assembly Removal35
5-1.2. Cap Assembly Installation36
5-1.3. Control Head Removal37
5-1.4. Control Head Installation37
5-1.5. Speed Potentiometer Replacement37
5-1.6. Belly-Button Switch Replacement37
5-1.7. Horn Switch Replacement37
5-1.8. Lift and Lower Switch38
Emergency Reverse Switch Assembly38
Cap Assembly39
5-1.9. Tilt Switch Replacement40
Steering Arm40
5-2.1. Return Spring Replacement40
5-2.2. Steering Arm Removal40
5-2.3. Steering Arm Installation40
Compartment Covers40
5-3.1. Removal40
5-3.2. Installation40
Brake Servicing41
Brakes41
6-1.1. Brake Assembly Replacement41
Transmission, Motor, Brake Assembly42
Transmission, Drive Wheel, Load Wheel43
Drive Wheel43
Transmission43
Load Wheel43
7-3.1. Removal43
7-3.2. Load Wheel Installation43
Transmission, Motor, Brake Assembly44
Load Wheels45
Elevation System Servicing47
General47
Lift Chain Length Adjustment47
8-2.1. Telescopic47
Chain Assembly47
Elevation System (Telescopic)48
8-2.2. Trimast Free Lift Chain49
8-2.3. Trimast Secondary Lift Chain49
Lift Chain Wear Inspection49
Lift Chain Replacement51
8-4.1. Telescopic51
8-4.2. Trimast Free Lift Chain51
8-4.3. Trimast Secondary Lift Chain51
Lift Cylinders51
Hydraulic System Servicing53
Lines and Fittings53
Hydraulic Pump, and Motor Assy53
9-2.1. Removal53
9-2.2. Disassembly and Reassembly53
Hydraulic System54
9-2.3. Installation55
Lift Cylinder (Telescopic)57
9-3.1. Removal57
9-3.2. Repair57
9-3.3. Installation57
Elevation System (Telescopic)58
Lift Cylinder (Telescopic)59
Lift Cylinder (Trimast Free Lift)60
9-4.1. Removal60
9-4.2. Repair60
9-4.3. Installation60
Elevation System (Trimast)61
Lift Cylinder (Trimast Secondary)63
9-5.1. Removal63
9-5.2. Repair63
9-5.3. Installation63
9-5.4. Tilt Cylinders65
Electrical Components69
Electrical Control Panel69
10-1.1.Maintenance69
10-1.2.Cleaning69
10-1.3.Panel Removal69
10-1.4.Panel Disassembly69
10-1.5.Panel Installation69
Horn Replacement69
Pump Motor72
Drive Motor72
10-4.1.Motor Removal72
10-4.2.Motor Installation72
Deadman Switch72
10-5.1.Replacement72
Illustrated Parts Breakdown77
Control Head80
Free Lift Cylinder (Trimast)114

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Big Lift CB22-128 Specifications

General

Brand	Big Lift
Model	CB22-128
Category	Lifting Systems
Language	English

Big Lift CB22-128 User Manual

Table of Contents

Big Lift CB22-128 Specifications