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Big Lift CB22-128 - User Manual

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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 Contents

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Summary

Section 1: Description

Introduction to CB22 Lift Truck Manual

Outlines the purpose and scope of the manual for the CB22 lift truck.

General Description of CB22 Lift Truck

Provides an overview of the CB22 truck's capabilities, components, and operation.

CB22 Lift Truck Safety Features

Lists key safety features incorporated into the CB22 lift truck design.

Section 2: Operation

General Operating Instructions

Provides general operating instructions for the CB22 lift truck.

Operating Precautions for CB22 Lift Truck

Lists essential safety precautions for operating the CB22 lift truck.

Before Operation Checks

Details pre-operation inspection points for the CB22 lift truck.

General Control Operation Procedures

Explains the operation of speed controls and pushbuttons on the control head.

Driving and Stopping Procedures

Outlines the procedures for driving and stopping the lift truck.

Stopping Methods

Describes the four methods for stopping the truck.

Belly-Button Switch Function

Explains the function of the belly-button switch for safety.

Steering Arm Gas Spring Maintenance

Details the function and potential replacement of the steering arm gas spring.

Lift and Lower Control Operation

Describes how to operate the lift and lower functions using control head buttons.

Tilt Control Operation

Explains how to operate the tilt functions using control head buttons.

Loading and Unloading Procedures

Provides step-by-step instructions for loading and unloading.

Parking Procedure

Outlines the procedure for parking the truck.

Section 3: Planned Maintenance

General Planned Maintenance

Defines planned maintenance and the roles of operator and technician.

Monthly and Quarterly Checks

Details routine inspection and service tasks based on usage.

Battery Care Overview

Covers general battery care, including safety and types.

Battery Safety Rules

Lists essential safety precautions for handling and maintaining batteries.

Battery Care and Charging Procedures

Provides procedures and precautions for charging batteries.

Maintenance-Free Batteries

Describes the characteristics and care of maintenance-free batteries.

Charging Batteries Safely

Outlines the steps for safely charging the truck's batteries.

Lubrication Guide

Refers to tables for recommended lubricants and items requiring lubrication.

Lift Chain Maintenance

Explains how to maintain the lift chains.

Section 4: Troubleshooting

General Troubleshooting Guide

Introduces troubleshooting procedures using a chart.

Controller Troubleshooting

Discusses troubleshooting using the Zapi controller.

Zapi Handset Usage

Describes the functions and use of the Zapi Handset.

Fault Detection and Logbook

Explains how the controller detects and logs faults.

Logbook Access Procedure

Steps to access and view the alarm logbook.

Testing Truck Operation with Handset

How to use the Zapi Handset to test truck functions.

Settings and Adjustments Overview

Overview of settings and adjustments for the controller.

Setting Truck Options via Handset

Procedure for setting various truck operating options via the handset.

Adjusting Controller Parameters

Procedure for changing controller adjustments using the handset.

Section 5: Steering Arm, Control Head, and Compartment

Control Head Servicing

Details servicing procedures for the control head assembly.

Control Head Cap Assembly Removal

Steps to remove the cap assembly from the control head.

Control Head Cap Assembly Installation

Steps to install the cap assembly onto the control head.

Control Head Removal Procedure

Procedures for removing the control head and handle assembly.

Control Head Installation Procedure

Procedures for installing the control head and handle assembly.

Speed Potentiometer Replacement

Detailed steps for replacing the speed potentiometer.

Belly-Button Switch Replacement

Instructions for replacing the belly-button switch.

Horn Switch Replacement

Steps for replacing the horn switch.

Lift and Lower Switch Replacement

Instructions for replacing lift and lower switches.

Tilt Switch Replacement

Steps for replacing tilt switches.

Steering Arm Servicing

Procedures for servicing the steering arm.

Steering Arm Return Spring Replacement

Instructions for replacing the steering arm gas return spring.

Steering Arm Removal

Steps for removing the steering arm assembly.

Steering Arm Installation

Steps for installing the steering arm assembly.

Compartment Cover Removal and Installation

Procedures for removing and installing compartment covers.

Section 6: Brake Servicing

Brake System Overview

General information about the brake system.

Brake Assembly Replacement

Step-by-step guide for replacing the brake assembly.

Section 7: Transmission, Drive Wheel, Load Wheel

Drive Wheel Service

Instructions for removing and installing the drive wheel.

Transmission Service

Procedures for removing and installing the transmission assembly.

Load Wheel Removal

Details for removing the load wheel.

Load Wheel Installation

Details for installing the load wheel.

Section 8: Elevation System Servicing

Elevation System Components

Defines the components of the elevation system.

Lift Chain Length Adjustment

Instructions for adjusting lift chain length.

Telescopic Lift Chain Adjustment

Specific steps for adjusting lift chain length on telescopic masts.

TRIMAST Free Lift Chain Adjustment

Steps to adjust lift chain length for TRIMAST free lift.

TRIMAST Secondary Lift Chain Adjustment

Steps to adjust lift chain length for TRIMAST secondary lift.

Lift Chain Wear Inspection

How to inspect lift chains for wear and determine replacement.

Lift Chain Replacement

Procedures for replacing lift chains.

Telescopic Lift Chain Replacement

Steps for replacing lift chains on telescopic masts.

TRIMAST Free Lift Chain Replacement

Steps for replacing lift chains on TRIMAST free lift.

TRIMAST Secondary Lift Chain Replacement

Steps for replacing lift chains on TRIMAST secondary lift.

Lift Cylinders Service Reference

Notes that lift cylinder repair is covered in Section 9.

Section 9: Hydraulic System Servicing

Hydraulic Lines and Fittings Service

Procedures for servicing hydraulic lines and fittings.

Hydraulic Pump and Motor Assembly Service

Procedures for servicing the hydraulic pump and motor assembly.

Hydraulic Pump and Motor Removal

Steps to remove the hydraulic pump and motor assembly.

Pump and Motor Disassembly;Reassembly

Refers to a figure for pump/motor disassembly.

Hydraulic Pump and Motor Installation

Steps to install the hydraulic pump and motor assembly.

Telescopic Lift Cylinder Service

Procedures for servicing the telescopic lift cylinder.

Telescopic Lift Cylinder Removal

Steps to remove the telescopic lift cylinder.

Telescopic Lift Cylinder Repair

Detailed instructions for repairing the telescopic lift cylinder.

TRIMAST Free Lift Cylinder Service

Procedures for servicing the TRIMAST free lift cylinder.

TRIMAST Free Lift Cylinder Removal

Steps to remove the TRIMAST free lift cylinder.

TRIMAST Free Lift Cylinder Repair

Detailed instructions for repairing the TRIMAST free lift cylinder.

TRIMAST Free Lift Cylinder Installation

Steps to install the TRIMAST free lift cylinder.

TRIMAST Secondary Lift Cylinder Service

Procedures for servicing the TRIMAST secondary lift cylinder.

TRIMAST Secondary Lift Cylinder Removal

Steps to remove the TRIMAST secondary lift cylinder.

TRIMAST Secondary Lift Cylinder Repair

Detailed instructions for repairing the TRIMAST secondary lift cylinder.

TRIMAST Secondary Lift Cylinder Installation

Steps to install the TRIMAST secondary lift cylinder.

Tilt Cylinders Service

Procedures for servicing the tilt cylinders.

Tilt Cylinder Removal

Steps to remove the tilt cylinders.

Tilt Cylinder Repair

Detailed instructions for repairing the tilt cylinders.

Tilt Cylinder Installation

Steps to install the tilt cylinders.

Section 10: Electrical Components

Electrical Control Panel Service

Procedures for maintenance, cleaning, and panel servicing.

Control Panel Maintenance

Discusses maintenance and troubleshooting for the control panel.

Electrical Control Panel Cleaning

Steps for cleaning the electrical control panel.

Electrical Control Panel Removal

Instructions for removing the electrical control panel.

Electrical Control Panel Disassembly

Refers to a figure for panel disassembly and component replacement.

Electrical Control Panel Installation

Steps for installing the electrical control panel.

Horn Replacement Procedure

Instructions for replacing the horn assembly.

Pump Motor Service

Refers to Section 9 for pump motor service.

Drive Motor Service

Explains drive motor cleaning and maintenance.

Drive Motor Removal

Steps to remove the drive motor.

Drive Motor Installation

Steps to install the drive motor.

Deadman Switch Replacement

Procedures for replacing the deadman switch.

Deadman Switch Replacement Steps

Detailed steps for replacing the deadman switch.

Section 11: Optional Equipment

Section 12: Illustrated Parts Breakdown

Big Lift CB22-128 Specifications

General IconGeneral
BrandBig Lift
ModelCB22-128
CategoryLifting Systems
LanguageEnglish