Big Lift CB22 - User Manual

Big Lift LLC MANUAL NO. BL-CB22-1214 - 04-11-2019
www.bigjoeforklifts.com
CB22
SELF-PROPELLED,
COUNTERBALANCED LIFT TRUCK
Operation
Maintenance
Repair Parts List
NOTE: For the most current parts information and service updates, please refer to the Big Joe
Support site at www.bigjoesupport.com

Summary

Section 1: Description

1-1. Introduction

Provides an overview of the CB22 lift truck and the manual's content, emphasizing compliance with safety standards.

1-2. General Description

Describes the CB22 truck's general features, capabilities like lifting capacity, and power source.

1-3. Safety Features

Lists key safety features incorporated into the CB22 lift truck design for operator and payload protection.

Section 2: Operation

2-1. General Operation

Outlines the scope of the operation section, covering lift, drive, and stop procedures.

2-2. Operating Precautions

Details critical safety precautions to prevent injury and damage during operation.

2-3. Before Operation Checks

Lists essential inspection points to be checked before operating the lift truck.

2-4. Control Operation

Explains the function of speed and pushbutton controls on the control head.

2-5. Driving and Stopping Procedures

Provides step-by-step instructions for driving and safely stopping the lift truck.

Section 3: Planned Maintenance

3-1. General Maintenance

Defines planned maintenance and the roles of the operator and technician.

3-2. Routine Checks Schedule

Outlines a schedule for routine visual checks and services based on usage.

3-3. Battery Care Guidelines

Covers essential guidelines for maintaining batteries to ensure efficient operation and longevity.

3-4. Battery Charging Procedures

Details the procedure and safety rules for charging the truck's batteries.

3-5. Lubrication Recommendations

Provides information on recommended lubricants and their application points.

3-6. Lift Chain Maintenance

Explains how to inspect and maintain the lift chains for proper operation and wear.

Section 4: Troubleshooting

4-1. General Troubleshooting

Introduces the troubleshooting guide and its categorization of common issues.

4-2. Controller Troubleshooting

Details troubleshooting procedures for the Zapi controller using diagnostic data.

4-3. Troubleshooting Braking Issues

Lists common braking malfunctions and their probable causes and corrective actions.

4-4. Troubleshooting Lift;Lower Issues

Addresses issues related to the lift and lower functions, including hydraulic system problems.

4-5. Miscellaneous Troubleshooting

Covers troubleshooting for various other issues not fitting into specific categories.

Section 5: Steering Arm, Control Head, and Compartment

5-1. Control Head Servicing

Discusses the control head assembly, including component removal and replacement.

5-2. Steering Arm Servicing

Covers the servicing and replacement procedures for the steering arm and its components.

5-3. Compartment Cover Removal;Installation

Details the removal and installation process for the truck's compartment covers.

Section 6: Brake Servicing

6-1. Brake Assembly Replacement

Explains the brake system and provides instructions for brake assembly replacement.

Section 7: Transmission, Drive Wheel, Load Wheel

7-1. Drive Wheel Service

Describes the procedure for removing and installing the drive wheel.

7-2. Transmission Service

Outlines the steps for removing and installing the transmission assembly.

7-3. Load Wheel Service

Details the process for removing and installing the load wheel and its bearings.

Section 8: Elevation System Servicing

8-1. Elevation System Overview

Lists the components included in the elevation system.

8-2. Lift Chain Length Adjustment

Provides instructions for adjusting the lift chain length on different mast types.

8-3. Lift Chain Wear Inspection

Explains how to inspect lift chains for wear and determine when replacement is necessary.

8-4. Lift Chain Replacement

Details the procedures for replacing lift chains on various mast configurations.

8-5. Lift Cylinder Information

Notes that lift cylinder removal and repair are covered in Section 9.

Section 9: Hydraulic System Servicing

9-1. Hydraulic Lines and Fittings

Covers procedures for maintaining hydraulic lines and fittings, including leak repair.

9-2. Hydraulic Pump and Motor Assembly

Details the removal, disassembly, reassembly, and installation of the hydraulic pump and motor assembly.

9-3. Telescopic Lift Cylinder Service

Explains the removal, repair, and installation of the telescopic lift cylinder.

9-4. TRIMAST Free Lift Cylinder Service

Details the process for removing, repairing, and installing the TRIMAST free lift cylinder.

9-5. TRIMAST Secondary Lift Cylinder Service

Covers the removal, repair, and installation of the TRIMAST secondary lift cylinder.

9-5.4. Tilt Cylinder Service

Provides instructions for removing, repairing, and installing the tilt cylinders.

Section 10: Electrical Components

10-1. Electrical Control Panel

Discusses maintenance, cleaning, removal, disassembly, and installation of the electrical control panel.

10-2. Horn Replacement

Details the procedure for replacing the horn on the lift truck.

10-4. Drive Motor Service

Explains motor cleaning, removal, and installation procedures.

10-5. Deadman Switch Replacement

Covers the replacement procedure for the deadman switch.

Section 12: Illustrated Parts Breakdown

Figure 12-1 Steering System Parts

Shows an exploded view and parts list for the steering system components.

Figure 12-2 Control Head Parts

Illustrates the control head assembly and its parts, with serial number variations.

Figure 12-7 Transmission, Motor, Brake Assembly Parts

Shows an exploded view and parts list for the transmission, motor, and brake assembly.

Figure 12-13 Elevation System (Telescopic) Parts

Illustrates the telescopic elevation system components and their part numbers.

Figure 12-20 Hydraulic System Parts

Shows an exploded view and parts list for the hydraulic system (up to serial number 324200458).

Figure 12-23 Pump & Motor Parts

Illustrates the pump and motor assembly components (up to serial number 324200458).

Figure 12-28 Lift Cylinder (Telescopic) Parts

Provides an exploded view and parts list for the telescopic lift cylinder.

Figure 12-30 Secondary Lift Cylinder (Three Stage Mast) Parts

Details the components of the secondary lift cylinder for three-stage masts.

Figure 12-32 Tilt Cylinder Parts

Illustrates the tilt cylinder assembly and its parts.

Figure 12-34 Electrical System Parts

Shows the electrical system components and wiring harness up to a specific serial number.

Figure 12-36 Electrical Panel Parts

Details the electrical panel components and their assembly.

Figure 12-43 Battery Pack Assembly Parts

Details the components of the battery pack assembly and related charger.

Big Lift CB22 Specifications

General

Power Source	Electric
Battery Voltage	48 V
Tire Type	Solid
Model	Big Lift CB22
Lift Height	3000 mm (118 in)