Blue Giant EPJ-40, Owner'S Manual

Page: 59 / 124

B
G-D40-0131
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-
19 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 key switch (21, Figure 12-20 ) and emer-
gency disconnect (2, Figure 12-19 ).
2. Remove the compartment covers as described in
paragraph
5-2.
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 steering the buss bars.
10-1.3.Controller Removal.
1. Turn off key switch (21, Figure 12-20 ) and emer-
gency disconnect (2, Figure 12-19 ).
2. Remove the compartment covers as described in
paragraph
5-2.
3. Tag and disconnect harness (1, Figure 12-21 )
from controller (18, Figure 10-1 ).
4. Remove four screws (16), lock washers (17) and
remove controller (18).
10-1.4.Controller Installation.
1. Position controller (18, Figure 10-1 ) and the board
and secure with four screws (16) and lock wash-
ers (17).
2. Reconnect harness (1, Figure 12-21 ) to controller
(18, Figure 10-1 ).
3. Install compartment covers as described in para-
graph
5-2.
1. Turn on key switch (21, Figure 12-20 ) and emer-
gency disconnect (2, Figure 12-19 ).
10-1.5.Charger Removal.
1. Turn off key switch (21, Figure 12-20 ) and emer-
gency disconnect (2, Figure 12-19 ).
2. Remove the compartment covers as described in
paragraph
5-2.
3. Tag and disconnect harness (1, Figure 12-21 )
from charger (20, Figure 10-1 ).
4. Tag and disconnect remaining two charger leads
from the pump motor and the fuse.
5. Remove three screws (16, Figure 10-1 ), screw
(23), four lock washers (24), two straps (22) and
charger (20).
10-1.6.Charger Installation.
1. Position charger (20, Figure 10-1 ) on board and
secure with three screws (16, Figure 10-1 ), screw
(23), four lock washers (24) and two straps (22).
2. Reconnect the two charger leads to the pump
motor and the fuse.
3. Reconnect harness (1, Figure 12-21 ) to charger
(20, Figure 10-1 ).
4. Install compartment covers as described in para-
graph
5-2.
5. Turn on key switch (21, Figure 12-20 ) and emer-
gency disconnect (2, Figure 12-19 ).