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
, 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
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 (6,
) and dis-
connect the batteries.
2.
Remove the compartment covers as described in
paragraph
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.Panel
Removal.
1.
Turn off the key switch (6,
) and dis-
connect the batteries.
2.
Remove the compartment covers as described in
paragraph
3.
Tag and disconnect all electrical cables which
connect to the control panel (5,
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
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,
) 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
4.
Reconnect the batteries and turn on the keyswitch
(6,
10-2.HORN REPLACEMENT
1.
Turn off the key switch (6,
) and dis-
connect the batteries.
2.
Remove the compartment covers as described in
paragraph
3.
Tag and disconnect all electrical connections from
horn (4,
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
7.
Reconnect the batteries and turn on the keyswitch
(6,
69
Summary of Contents for BGL-22
Page 12: ...NOTES 12...
Page 18: ...NOTES 18...
Page 34: ...NOTES 34...
Page 39: ...Figure 5 4 Cap Assembly R6878 39...
Page 42: ...Figure 6 1 Transmission Motor Brake Assembly R6879 42...
Page 44: ...Figure 7 1 Transmission Motor Brake Assembly R6879 44...
Page 45: ...Figure 7 2 Load Wheels R6882 45...
Page 46: ...NOTES 46...
Page 48: ...Figure 8 2 Elevation System Telescopic R6883 48...
Page 50: ...Figure 8 3 Mast TRIMAST R6884 50...
Page 52: ...NOTES 52...
Page 54: ...Figure 9 1 Hydraulic System R6886 54...
Page 56: ...Figure 9 3 Hydraulic System TRIMAST R6888 56...
Page 58: ...Figure 9 4 Elevation System Telescopic R6883 58...
Page 59: ...Figure 9 5 Lift Cylinder Telescopic R6889 59...
Page 61: ...Figure 9 6 Elevation System TRIMAST R6884 61...
Page 62: ...Figure 9 7 Free Lift Cylinder TRIMAST R6890 62...
Page 64: ...Figure 9 8 Secondary Lift Cylinder TRIMAST R6891 64...
Page 67: ...Figure 9 10 Tilt Cylinder R6893 67...
Page 68: ...NOTES 68...
Page 70: ...Figure 10 1 Electrical System R6478 R6894 70...
Page 71: ...Figure 10 2 Electrical Panel R6478 R6895 71...
Page 73: ...Figure 10 3 Transmission Motor Brake Assembly R6879 73...
Page 74: ...NOTES 74...
Page 75: ...SECTION 11 OPTIONAL EQUIPMENT 75...
Page 76: ...NOTES 76...
Page 78: ...Figure 12 1 Steering System R6876 78...
Page 80: ...Figure 12 2 Control Head R6877 80...
Page 82: ...Figure 12 3 Cap Assembly R6878 82...
Page 85: ...NOTES 85...
Page 86: ...Figure 12 5 Transmission Motor Brake Assembly R6879 86...
Page 89: ...NOTES 89...
Page 90: ...Figure 12 7 Frame R6881 90...
Page 92: ...Figure 12 8 Load Wheels R6882 92...
Page 94: ...Figure 12 9 Elevation System Telescopic R6883 94...
Page 96: ...Figure 12 10 Elevation System TRIMAST R6884 96...
Page 98: ...Figure 12 11 Lift Carriage R6815 98...
Page 101: ...NOTES 101...
Page 102: ...Figure 12 13 Hydraulic System R6665 102...
Page 104: ...Figure 12 14 Pump Motor R6886 104...
Page 107: ...NOTES 107...
Page 108: ...Figure 12 16 Hydraulic System TRIMAST R6888 108...
Page 110: ...Figure 12 17 Tilt Cylinder Mounting R6892 110...
Page 112: ...Figure 12 18 Lift Cylinder Telescopic R6889 112...
Page 114: ...Figure 12 19 Free Lift Cylinder TRIMAST R6890 114...
Page 116: ...Figure 12 20 Secondary Lift Cylinder TRIMAST R6891 116...
Page 118: ...Figure 12 21 Tilt Cylinder R6893 118...
Page 120: ...Figure 12 22 Electrical System R6894 120...
Page 123: ...NOTES 123...
Page 124: ...Figure 12 24 Drive Motor R6630 124...
Page 128: ...NOTES 128...
Page 129: ...129...
