Big Lift CB22, Operation, Maintenance And Parts Manual

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BL-CB22-1214 - 04-11-2019 10-1
SECTION 10
ELECTRICAL COMPONENTS
10-1.ELECTRICAL CONTROL PANEL
10-1.1.Maintenance
NOTE: Erratic operation of the truck may be caused
by defective controller components. Before
removing the electrical panel, perform trou-
bleshooting procedures per
SECTION 4 , to
determine corrective action to be taken.
There are no user-serviceable parts inside the control-
ler. No attempt should be made to open the controller.
Opening the controller may damage it and will void the
warranty.
The controller is programmed at the factory specifi-
cally for the truck model on which it is equipped. It is
important to replace the controller with the correct pre-
programmed unit to assure proper performance set-
tings intended for that particular truck. See
Figure 12-
31 or Figure 12-32 for the preprogrammed controller
number.
It is recommended that the controller exterior be
cleaned periodically, and if a Zapi Handset is avail-
able, this periodic cleaning provides a good opportu-
nity to check the controller’s diagnostic history file. It is
also recommended that the controller’s fault detection
circuitry be checked whenever the vehicle is serviced.
10-1.2.Cleaning
1. Turn off the key switch (12, Figure 12-29 or 12,
Figure 12-30 ) and disconnect the batteries.
2. Remove the compartment covers as described in
paragraph
5-3.
3. Remove any dirt or corrosion from the bus bar
area. The controller should be wiped clean with a
moist rag. Allow it to dry before reconnecting the
battery.
4. Make sure the connections to the buss bars are
tight. Use two well insulated wrenches for this
task in order to avoid contacting the buss bars.
10-1.3.Panel Removal.
1. Turn off the key switch (12, Figure 12-29 or 12,
Figure 12-30 ) and disconnect the batteries.
2. Remove the compartment covers as described in
paragraph
5-3.
3. Tag and disconnect all electrical cables which
connect to the control panel (5,
Figure 10-1 ) or (5,
Figure 10-2 )
4. Remove two screws (1), two lock washers (2), two
flat washers (3), horn (4) and control panel (5).
10-1.4.Panel Disassembly.
Refer to Figure 10-3 for location and identity of the
major replacement components mounted on the panel
and remove defective parts.
NOTE: Contactor (10) is not repairable and must be
replaced if defective.
10-1.5.Panel Installation.
1. Install the control panel (5, Figure 10-1 ) or (5, Fig-
ure 10-2 ) and horn (4). Secure with two screws
(1), two lock washers (2) and two flat washers (3).
2. Connect all electrical cables to the control panel
as noted during removal.
3. Install the compartment covers as described in
paragraph
5-3.
4. Reconnect the batteries and turn on the keyswitch
(12,
Figure 12-29 or 12, Figure 12-30 ).
10-2.HORN REPLACEMENT
1. Turn off the key switch (12, Figure 12-29 or 12,
Figure 12-30 ) and disconnect the batteries.
2. Remove the compartment covers as described in
paragraph
5-3.
3. Tag and disconnect all electrical connections from
horn (4,
Figure 10-1 ) or (4, Figure 10-2 ).
4. Remove screws (1), lock washers (2), flat wash-
ers (3) and horn (4).
5. Install horn and secure with screws (1), lock
washers (2), flat washers (3).
6. Install the compartment covers as described in
paragraph
5-3.
7. Reconnect the batteries and turn on the keyswitch
(12,
Figure 12-29 or 12, Figure 12-30 ).