Big Lift CB22 Bedienungsanleitung

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

WARNING

Do not operate this truck unless you have been autho-

rized and trained to do so, and have read all warnings

and instructions in Operator’s Manual and on this

truck.

Do not operate this truck until you have checked its

condition. Give special attention to tires, horn, battery,

controller, lift system (including forks or attachments,

chains, cables and limit switches), brakes, steering

mechanism, guards and safety devices.

Operate truck only from designated operating position.

Never place any part of your body into the mast struc-

ture or between the mast and the truck. Do not carry

passengers. Keep feet clear of truck and wear foot

protection.

Observe applicable traffic regulations. Yield right of

way to pedestrians. Slow down and sound horn at

cross aisles and wherever vision is obstructed.

Start, stop, travel, steer and brake smoothly. Slow

down for turns and on uneven or slippery surfaces that

could cause truck to slide or overturn. Use special

care when traveling without load as the risk of overturn

may be greater.

Travel with lifting mechanism as low as possible.

Always look in direction of travel. Keep a clear view,

and when load interferes with visibility, travel with load

trailing.

Use special care when operating on ramps travel

slowly, and do not angle or turn. Travel with load

downhill.

Do not overload truck. Check nameplate for capacity

and load center information.

When using forks, space forks as far apart as load will

permit. Before lifting, be sure load is centered, forks

are completely under load, and load is as far back as

possible against load backrest.

Do not handle unstable or loosely stacked loads. Use

special care when handling long, high or wide loads, to

avoid losing the load, striking bystanders, or tipping

the truck.

Do not handle loads which are higher than the load

backrest or load backrest extension unless load is

secured so that no part of it could fall backward.

Elevate forks or other lifting mechanism only to pick up

or stack a load. Watch out for obstructions, especially

overhead.

Do not lift personnel except on a securely attached

specially designed work platform. USE EXTREME

CARE WHEN LIFTING PERSONNEL. Make sure

mast is vertical, place truck controls in neutral and

apply brakes. Lift and lower smoothly. Remain in oper-

ating position or immediate vicinity as long as person-

nel are on the work platform. Never transport

personnel on forks or work platform.

Do not allow anyone to stand or pass under load or lift-

ing mechanism.

When leaving truck, neutralize travel control, fully

lower lifting mechanism and set brake. When leaving

truck unattended, also shut off power.

TABLE OF CONTENTS

BL-CB22-1214 - 04-11-2019 1

Section Page Section Page

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

2-5 DRIVING AND STOPPING PROCEDURES....2-4

2-5.1 STOPPING............................................2-4

. 2-6 BELLY-BUTTON SWITCH...............................2-5

2-7 STEERING ARM GAS SPRING.......................2-5

2-8 LIFT AND LOWER CONTROLS......................2-5

2-9 TILT CONTROLS.............................................2-5

2-10 LOADING AND UNLOADING ..........................2-5

2-11 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

4-2 CONTROLLER TROUBLESHOOTING............4-4

4-2.1 ZAPI HANDSET....................................4-4

4-2.2 FAULT DETECTION.............................4-4

4-2.2.1 GENERAL.............................................4-4

4-2.2.2 LOGBOOK ACCESS.............................4-4

4-2.3 TESTING TRUCK OPERATION...........4-4

4-2.4 SETTINGS AND ADJUSTMENTS........4-5

4-2.4.1 SET OPTIONS......................................4-5

4-2.4.2 ADJUSTMENTS....................................4-9

4-2.4.3 PARAMETER CHANGE......................4-11

5 STEERING ARM, 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................................... 5-4

5-1.9 TILT SWITCH REPLACEMENT........... 5-6

5-2 STEERING ARM ............................................. 5-6

5-2.1 RETURN SPRING REPLACEMENT.... 5-6

5-2.2 STEERING ARM REMOVAL................ 5-6

5-2.3 STEERING ARM INSTALLATION........ 5-6

5-3 COMPARTMENT COVERS............................. 5-6

5-3.1 REMOVAL............................................ 5-6

5-3.2 INSTALLATION.................................... 5-6

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 TRIMAST FREE LIFT CHAIN............... 8-3

8-2.3 TRIMAST 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 TRIMAST FREE LIFT CHAIN............... 8-5

8-4.3 TRIMAST 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 DISASSEMBLY AND REASSEMBLY .. 9-1

9-2.3 INSTALLATION.................................... 9-3

9-3 LIFT CYLINDER (TELESCOPIC).................... 9-5

9-3.1 REMOVAL............................................ 9-5

9-3.2 REPAIR ................................................ 9-5

9-3.3 INSTALLATION.................................... 9-5

9-4 LIFT CYLINDER (TRIMAST FREE LIFT)........ 9-8

9-4.1 REMOVAL............................................ 9-8

9-4.2 REPAIR ................................................ 9-8

9-4.3 INSTALLATION.................................... 9-8

9-5 LIFT CYLINDER (TRIMAST SECONDARY) . 9-11

9-5.1 REMOVAL.......................................... 9-11

9-5.2 REPAIR .............................................. 9-11

9-5.3 INSTALLATION.................................. 9-11

9-5.4 TILT CYLINDERS............................... 9-13

9-5.4.1 REMOVAL.......................................... 9-13

9-5.4.2 REPAIR .............................................. 9-14

9-5.4.3 INSTALLATION.................................. 9-14

TABLE OF CONTENTS Cont.

1-2 BL-CB22-1214 - 04-11-2019

Section Page Section Page

10 ELECTRICAL COMPONENTS................................. 10-1

E 10-1 LECTRICAL 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

10-2 HORN REPLACEMENT ................................ 10-1

10-3 PUMP MOTOR .............................................. 10-5

10-4 DRIVE MOTOR..............................................10-5

10-4.1 MOTOR REMOVAL ............................10-5

10-4.2 MOTOR INSTALLATION ....................10-5

10-5 DEADMAN SWITCH......................................10-5

10-5.1 REPLACEMENT .................................10-5

11 OPTIONAL EQUIPMENT .........................................11-1

12 ILLUSTRATED PARTS BREAKDOWN ....................12-1

BL-CB22-1214 - 04-11-2019 1-1

SECTION 1

DESCRIPTION

1-1. INTRODUCTION.

This publication describes the 24 volt

CB22 lift truck distributed by Big Lift LLC. Included are

operating instructions, planned maintenance instruc-

tions, lubrication procedures, corrective maintenance

procedures and a complete parts list with part location

illustrations.

Users shall comply with all requirements indicated in

applicable OSHA standards and current edition of

A.N.S.I. B56.1 Part II. By following these requirements

and the recommendations contained in this manual,

you will receive many years of dependable service

from your CB22 lift truck.

1-2. GENERAL DESCRIPTION.

The self-propelled CB22 truck, Figure 1-2, lifts and

transports payloads up to 2200 pounds on adjustable

forks.

The forward and reverse motion is controlled by either

of two thumb control knobs mounted on the control

head. Stopping and turning is controlled by the steer-

ing arm. Lift, Lower and Tilt are controlled by pushbut-

tons on the control head. The battery powered lift truck

is quiet and without exhaust fumes.

The reversible AC motor propels the lift truck in for-

ward or reverse direction throughout the available

speed range. The CB22 lift truck can be driven with

forks raised or lowered; however, the speed is

restricted when the platform is raised above a preset

limit.

The model number will be found on the name plate

(Figure 1-1) along with the serial number, lifting capac-

ity, and load center. Figure 1-2 shows the locations of

the truck’s main components and controls.

1-3. SAFETY FEATURES.

The CB22 is designed and engineered to provide max-

imum safety for operator and payload. Some of the

safety features incorporated into the design are:

• Dead-man brake to apply the brake and cut off drive

power when the steering arm is released.

• Belly-button switch to reverse truck should the oper-

ator accidentally pin himself against a wall or

obstruction.

Figure 1-1 Name Plate

• High speed limit switch to restrict speed when lift

carriage is raised above the preset limit.

• All control functions automatically return to “OFF”

when released.

• Externally accessible quick-disconnect battery plug

within operator's reach.

• Separately fused control circuits and power circuits.

• Readily accessible horn button.

• Lift carriage backrest to help stabilize the load.

• Handle to provide a firm hand hold for operator.

• Flow control valve regulates maximum lowering

speed within prescribed limits.

• Relief valve maintains hydraulic pressure within pre-

scribed limits.

• High visibility color scheme of truck provides visual

alert of truck’s presence.

• Battery Indicator.

R6209

1-2 BL-CB22-1214 - 04-11-2019

Figure 1-2. CB22 Lift Truck

R6898

ITEM COMPONENT

1Chassis

2 Cover

3 Drive wheel

4 Cover

5 Control Handle

6 Battery Indicator

7KeySwitch

8 Front cover

9Mast

10 Back Rest

11 Forks

12 Load Wheel

13 Hydraulic pump

14 Battery

15 Battery Disconnect

ITEM COMPONENT

BL-CB22-1214 - 04-11-2019 2-1

SECTION 2

OPERATION

2-1. GENERAL.

This section gives detailed operating instructions for

the CB22 lift truck. The instructions are divided into the

various phases of operations, such as operating lift,

driving, and stopping. Routine precautions are

included for safe operation.

2-2. OPERATING PRECAUTIONS.

WARNING: Improper operation of the lift truck may

result in operator injury, or load and/or lift

truck damage. Observe the following

precautions when operating the CB22 lift

truck.

The following safety precautions must be adhered to

at all times.

• Do not operate this truck unless you have been

trained and authorized to do so.

• All warnings and instructions must be read and

understood before using the equipment.

• Equipment must not be altered in any way.

• Equipment must be inspected by a qualified person

on a regular basis.

• Do not exceed the rated capacity. Overloading may

result in damage to the hydraulic system and struc-

tural components.

• Be certain that the lifting mechanism is operating

smoothly throughout its entire height, both empty

and loaded.

• Be sure that mast is vertical - do not operate on a

side slope.

• Be sure the truck has a firm and level footing.

• Avoid overhead wires and obstructions.

• Check for obstructions when raising or lowering the

lift carriage.

• Do not handle unstable or loosely stacked loads.

Use special care when handling long, high, or wide

loads to avoid tipping, loss of load, or striking

bystanders.

• Center and carry the load as far back as possible

toward the lift carriage back rest. The center-of-grav-

ity of the load must not exceed the load center listed

on the nameplate. See Figure 2-1 for load center

limitations.

• Pick up loads on both forks. Do not pick up on only

one fork.

• When traveling, always lower the load as far as pos-

sible.

Figure 2-1 Load Center

R3814

2-2 BL-CB22-1214 - 04-11-2019

• When stacking pallets in racks and it is necessary to

move the load in a raised position, use caution.

Operate truck smoothly.

• Observe applicable traffic regulations. Yield right of

way to pedestrians. Slow down and sound horn at

cross aisles and wherever vision is obstructed.

• Operate truck only from designated operating posi-

tion. Never place any part of your body between the

mast uprights. Do not carry passengers.

• Do not allow anyone to stand or pass under load or

lifting mechanism.

• When leaving truck, neutralize travel control. Fully

lower lifting mechanism and set brake. When leaving

truck unattended, turn off key switch, remove key

and disconnect battery.

2-3. BEFORE OPERATION

Table 2-1 covers important inspection points on the

CB22 lift truck which should be checked prior to opera-

tion. Depending on use, some trucks may require

additional checks.

Figure 2-2 shows a sample format of an Operator

Checklist, which can be modified as necessary to fit

your operation.

WARNING: Periodic maintenance of this truck by a

QUALIFIED TECHNICIAN is required.

CAUTION: A QUALIFIED SERVICE TECHNICIAN

should check the truck monthly for

proper lubrication, proper fluid levels,

brake maintenance, motor maintenance

and other areas specified in SECTION 3.

WARNING: If the truck is found to be unsafe and in

need of repair, or contributes to an

unsafe condition, report it immediately to

the designated authority. Do not operate

it until it has been restored to a safe

operating condition. Do not make any

unauthorized repairs or adjustments. All

service must be performed by a qualified

maintenance technician.

Table 2-1 Operator Checks

ITEM PROCEDURE

Transmission

and hydraulic

systems.

Check for signs of fluid leakage.

Forks Check for cracks and damage;

and, that they are properly

secured.

Chains, cables

and hoses Check that they are in place,

secured correctly, functioning

properly and free of binding or

damage.

Guards and load

backrest Check that safety guards are in

place, properly secured and not

damaged.

Safety signs Check that warning labels,

nameplate, etc., are in good

condition and legible.

Horn Check that horn sounds when

operated.

Steering Check for binding or looseness in

steering arm when steering.

Travel controls Check that speed controls on

control head operate in all

speed ranges in forward and

reverse and that belly button

switch functions.

Wheels Check drive wheel for cracks or

damage. Move truck to check

load for freedom of rotation.

Hydraulic

controls Check operation of lift, lower and

tilt to their maximum positions.

Brakes Check that brakes actuate when

steering arm is raised to upright

position, and when lowered to

horizontal position.

Deadman/

Parking brake Check that steering arm raises to

upright position when released

and brake applies.

Battery

disconnect Check that battery can be

disconnected and recon-

nected. Check for connector

damage.

Battery charge Check the battery indicator.

High speed limit

switch Allow for enough space to oper-

ate truck in high speed. Elevate

forks approximately two feet,

then test drive truck to check if

high speed is cut out.

ITEM PROCEDURE

BL-CB22-1214 - 04-11-2019 2-3

Figure 2-2 Sample of Operator Check List

R6479

2-4 BL-CB22-1214 - 04-11-2019

2-4. GENERAL CONTROL OPERATION.

The speed control (See Figure 2-3) located on each

side of the control head provides fingertip control for

driving the truck. Rotate the control in the direction you

want to travel. The farther you rotate the control from

the neutral position, the faster the truck will travel.

Figure 2-3. Forward/Reverse Control

The pushbutton switches (See Figure 2-4), located on

the front of the control head activate the lift, lower, tilt

and horn.

Figure 2-4. Pushbutton Switches

2-5. DRIVING AND STOPPING PROCEDURES.

1. Connect the batteries and turn on the key switch.

Grasp the grips of the steering head so that the

speed control can be comfortably operated by

either thumb.

2. Lower the steering arm to a comfortable position

above horizontal to disengage the brake and to

energize the electrical circuits. If the truck is not

moved, the electrical circuits will time out and will

deenergize. See Figure 2-5.

3. To move forward (with load in front), slowly press

the speed control forward. See Figure 2-3. Press

the forward speed control farther to increase

speed.

4. To slow down or stop, release the speed control

and lower or raise the steering arm to the horizon-

tal or vertical position. See Figure 2-5. In those

positions, the brake engages, slowing or stopping

the truck.

5. Procedures for movement in reverse are the

same as in the forward direction except slowly

press the speed control backward. See Figure 2-

2-5.1. Stopping

The brake pattern of the truck depends on the ground

conditions. The driver must take this into account

when operating the truck.

The driver must be looking ahead when traveling. If

there is no hazard, brake moderately to avoid moving

the load.

There are four different ways to stop the truck:

1. Plugging: This electrical braking function con-

sists of rotating the speed control lever in the

opposite direction of travel and then releasing it

when the truck stops. Plugging is a convenient

way to stop the truck during normal operation. If

the control is not released, the truck will acceler-

ate in the opposite direction.

2. Steering arm (See Figure 2-5): The brake is fully

applied by lowering or raising the steering arm.

(See Figure 2-5) All traction control power is shut

off when the brake is engaged. When the steering

arm is in the upright position, the brake acts as a

parking brake. Deadman braking occurs when the

handle is released and spring action raises steer-

ing arm to the upright position.

3. Emergency braking: Press the emergency brake

switch, all electrical functions are cut out and the

truck automatically brakes.

4. Regenerative braking: If the speed control lever is

released, the truck automatically brakes regener-

atively. When the speed is below .5 MPH, the

brake applies

R6617

R6899

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