cn and cx200 maintenance 91549 mh

ECN - 705972 Print date - November 2010

MaintenanceSection

CX200, CN200Suction Sweeper

&CW200 Washer

Part No 02625/1

Revision Level B

Foreword

Page Issue Levels

Scheduled Maintenance

Hydraulic System

Electrical System

Water System

Wearing Items

Remove and Refit Procedures

Fault Diagnosis

Service Tools

Health & Safety

F

P

14

15

16

17

18

19

20

21

22

ForewordF:2 Page Issue 04

C200 - Maintenance

Chapter - Page Issue Levels

CHAPTER PPage Issue Levels

P:1Page Issue B

C200 - Maintenance

Chapter - Page Issue LevelsP:2

Page Issue Changed Page Issue Changed

Front Sheet B Foreword 1 04

P Chapter - Page Issue LevelsPage Issue Changed Page Issue Changed

P:1 B P:2 B P:3 B P:4 B

14 Chapter - Scheduled MaintenancePage Issue Changed Page Issue Changed

14:1 04 14:2 B 14:3 04 14:4 0414:5 B 14:6 04

15 Chapter - Hydraulic SystemPage Issue Changed Page Issue Changed

15:1 06 15:2 0615:3 06 15:4 0615:5 B 15:6 0615:7 06 15:8 0615:9 06 15:10 0615:11 06 15:12 0615:13 06 15:14 0615:15 06 15:16 0615:17 06 15:18 0615:19 06 15:20 0615:21 06 15:22 0615:23 06 15:24 0615:25 06 15:26 0615:27 06 15:28 0615:29 06 15:30 06

16 Chapter - Electrical SystemPage Issue Changed Page Issue Changed

16:1 B 16:2 0416:3 04 16:4 0416:5 04 16:6 0416:7 06 16:8 0416:9 04 16:10 0516:11 05 16:12 0516:13 05 16:14 0516:15 05 16:16 B 16:17 B 16:18 B 16:19 B 16:20 B 16:21 B 16:22 B

Page Issue B

C200 - Maintenance

Chapter - Page Issue Levels P:3

16 Chapter - Electrical System continued . . .Page Issue Changed Page Issue Changed

16:23 B 16:24 B 16:25 B 16:26 B 16:27 B 16:28 B 16:29 B 16:30 B 16:31 B 16:32 B 16:33 B 16:34 B 16:35 B 16:36 B 16:37 B 16:38 B 16:39 B 16:40 B 16:41 B 16:42 B 16:43 B 16:44 B 16:45 B 16:46 B 16:47 B 16:48 B 16:49 B 16:50 B

17 Chapter - Water SystemPage Issue Changed Page Issue Changed

17:1 04 17:2 0417:3 B 17:4 0417:5 05 17:6 0417:7 04 17:8 04

18 Chapter - Wearing ItemsPage Issue Changed Page Issue Changed

18:1 04 18:2 0418:3 04 18:4 0418:5 04 18:6 04

19 Chapter - Remove & Refit ProceduresPage Issue Changed Page Issue Changed

19:1 05 19:2 0419:3 04 19:4 0419:5 05 19:6 05

20 Chapter - Fault DiagnosisPage Issue Changed Page Issue Changed

20:1 04 20:2 0420:3 04 20:4 0420:5 04 20:6 04

Page Issue B

C200 - Maintenance

Chapter - Page Issue LevelsP:4 Page Issue B

C200 - Maintenance

21 Chapter - Service ToolsPage Issue Changed Page Issue Changed

21:1 04 21:2 04

22 Chapter - Health & SafetyPage Issue Changed Page Issue Changed

22:1 B 22:2 B 22:3 B 22:4 B 22:5 B 22:6 B 22:7 B 22:8 B

Chapter - Scheduled Maintenance

CHAPTER 14Scheduled Maintenance

14:1

Table of Contents

Section Page

Hydraulics 14: 2- Filter Replacement- Cylinder Maintance

Windscreen Washers 14 : 2

Mesh Screens 14 : 3- Hopper Door- Recirculation

Setting Engine Tickover & Maximum Revs 14 : 4

Torque Wrench Settings 14 : 5

Page Issue 04

C200 - Maintenance

Chapter - Scheduled Maintenance Page Issue B14:2

C200 - Maintenance

Maintenance & Adjustment Instructions

Hydraulic Oil Filters

High Pressure Filter

Many parts of the hydraulic circuit are protected by a high pressure,canister type filter. The filter can be unscrewed using a suitablespanner.

Note: Ensure that used filter elements are disposed of in accordancewith applicable environmental regulations.

Hydraulic Cylinder Maintenance

Periodically inspect cylinder rods for damage, blemishes or build up of materials such as tar, cement, paintetc. The rods can be cleaned with fine wire wool and/or spirit which should be done to enhance long life.

Windscreen Washers

The windscreen washer bottle is mountedbehind the front centre console. The bottleshould be kept topped up with water and aproprietary windscreen washer fluid.

The jets for the washers are mounted on thepantograph wiper arm and should be checkedto ensure they do not become blocked. Theycan be cleaned using a fine needle to unblockthe orifice.

For Routine Maintenance Schedules please refer to Chapter 6 of the Operators Guide.

For engine specific maintenance instructions please refer to the VM Engine Instructions Manual (supplied with each engine/vehicle).

The following items are not covered in the Operators Guide.

Page Issue 04 Chapter - Scheduled Maintenance 14:3

C200 - Maintenance

Mesh Screens

Hopper Door

The hopper mesh screens must be clean at all times foroptimum suction performance. Although these screenscan be cleaned in situ by opening hopper door, it ispreferable to remove them for cleaning using a broomand hosepipe. Removal is simply by grabbing thescreen by the handle provided after first removing thelynch pins, and lifting out of the hopper.

Refitting of the hopper mesh screens can be doneeither in the reverse order of removal, or it may befound easier to refit the meshes by fully lifting thehopper and offering up the mesh. The mesh should belifted into the retaining channel and one at a time, thelynch pins should be fitted.

Note: With the meshes removed it is advisable to ensure the ducts in the roof of the hopper are clean andfree from debris.

Meshes should only be removed with the hopper in the lowered position.

Recirculation Screens

Periodically the wedge wire filter stainless steelscreens in the front and the sides of the hopper mayrequire cleaning. There are two drainage channelsprovided in the hopper for the cleaning of the cavitybehind the screen which will tend to build up withfine material. The hopper should be lifted to fullheight and these channels flushed out with a highpressure washer or hosepipe.

Chapter - Scheduled Maintenance Page Issue 0414:4

C200 - Maintenance

Setting Engine Tickover & Maximum Revs

Note: The following procedure is applicable to Euro 3 and Tier III engines only.

1. Start engine and run machine until normal runningtemperature is obtained before setting engine tickover.

2. Disconnect actuator rod.

3. Attach magnetic pick-up of digital tachometer to engineflywheel, if available. Vehicles CANview unit located in thecab will also do this task.

4. Loosen locknut on idle adjustment screw.

5. Using a flat-bladed screwdriver, turn screw until tickover of 900 rpmis obtained.

6. Retighten locknut.

7. Disconnect flywheel sensor.

8. Adjust actuator rod length to obtain 970 rpm. Once correctrpm is obtained reconnect actuator rod and flywheel sensor.

The actucator rod and flywheel sensor will require re-connecting at various intervals if the setup procedure isconducted without the aid of a digital tachometer to checkprogress of adjustment, (this can be done using theCANview unit located in the cab).

9. Tickover should be 970 rpm and maximum revs of 2400 rpm(Euro 3) 2250 rpm (Tier III - CX) or 1800 rpm (Tier III -CN200) , this should be checked by depressing theaccelerator pedal.

Page Issue B Chapter - Scheduled Maintenance 14:5

C200 - Maintenance

Torque Wrench Settings

No. Description Setting

1 Front Axle Suspension Bolts 56 Nm (40 lb/ft)

2 Rear Wheel Motor Bolts 97 Nm (70 lb/ft)

3 Front Axle Suspension Pivot Bolts 550 Nm (400 lb/ft)

4 Steering/Pedal Box Mounting Bolts 28 Nm (20 lb/ft)

5 Rear Suspension Bolts 550 Nm (400 lb/ft)

6 Cab Mounting Bolts 120 Nm (88.5 lb/ft)

7 Tow Hitch Mounting Bolts (Option) 240 Nm (176 lb/ft)

8 Wiper Motor Arm Nut 20 25 Nm (15 18 lb/ft)

9 Engine Lifting Lugs 32.4 Nm (24 lb/ft)

10 Wheel Motor Adaptors 240 Nm (176 lb/ft)

Chapter - Scheduled Maintenance Page Issue 0414:6

C200 - Maintenance

Chapter - Hydraulic System

CHAPTER 15Hydraulic System

15:1

Table of Contents

Section Page

General Description 15 : 2

Hydraulic Circuits

- Sweep System 15 : 3- Transmission - Euro 4 15 : 4- Transmission - Euro 5 15 : 5- Steering System 15 : 6- Expanding Spray Bar (CW200 Only) 15 : 7- Folding Spray Bar (CW200 Only) 15 : 8- Fixed Spray Bar (CW200 Only) 15 : 9- 3rd Brush 15 : 10

Modus Operandi - CX/CN200 15 : 12

Modus Operandi - CW200 15 : 19

Test Point Function Table 15 : 24

To Set/Check Relief Valves 15 : 25

To Check Fan Motor Pressure & Fan Speed 15 : 27

Hydraulic Blocks - Valve & Port Identification 15 : 28

Page Issue 06

C200 - Maintenance

Chapter - Hydraulic System Page Issue 0615:2

C200 - Maintenance

Maintenance Instructions

Please refer to Operators Guide for additional information.

General Description

The hydraulic system is divided into three circuits; one for the sweep system and all its associated functions,the second for the power steering system of the machine, and finally the hydrostatic transmission system.

The sweep system and steering system are driven by a tandem gear pump mounted in line with thehydrostatic transmission pump, all pumps are driven from the engine's flywheel by-way of a torsionallydamped coupling. The prime pump powers the suction fan, brushes (rotation, raise/lower, position), nozzle(raise/lower), water pump, and hopper (raise/lower). The fan, brushes and water pump are all driven byhydraulic motors. The brushes and nozzle are lifted and positioned by hydraulic cylinders. The hopper is alsoraised and lowered using, single stage hydraulic cylinders. Control of these operations is by way of a uniquethree spool, electrically controlled solenoid valve mounted on the RH chassis sidemember.

The secondary pump provides power for the power steering system, (PAS). Steering is effected using adouble acting cylinder integral with the front axle assembly. Control of the steering is done by a specialsteering servo valve, mounted within the steering column.

Filtration for both systems is provided by suction strainers situated within the hydraulic reservoir, together witha replaceable canister type return line filter acting on the PAS circuit, this filter is located towards the rear ofthe drivers cab.

The third hydraulic system is the vehicle transmission system which is driven by an axial piston pumpmounted direct to the engine flywheel housing. This provides oil to the two rear wheel motors. The system isa closed circuit with a separate header tank, the oil is cooled and filtered separately to the other sweepingand steering systems.

The steering circuit and hydrostatic systems both have their pressures factory preset and only suitablyqualified personnel should effect any adjustments. The various pressure settings being shown on the circuitdiagrams.

Page Issue 06 Chapter - Hydraulic System 15:3

C200 - Maintenance

Swee

p Sy

stem

Hyd

raul

ic C

ircui

t(d

raw

ing

refe

renc

e: 7

2246

1 - I

ssue

01)


C200 - MaintenanceTr

ansm

issi

on S

yste

m H

ydra

ulic

Circ

uit

(dra

win

g re

fere

nce:

722

846

- Iss

ue 0

3)

Page Issue B Chapter - Hydraulic System 15:5

C200 - Maintenance

Tran

smis

sion

Sys

tem

Hyd

raul

ic C

ircui

t - E

uro

5(d

raw

ing

refe

renc

e: 7

0092

15 -

Issu

e E

)


C200 - MaintenanceSt

eerin

g Sy

stem

Hyd

raul

ic C

ircui

t(d

raw

ing

refe

renc

e: 7

2225

6 - I

ssue

00)


C200 - Maintenance


C200 - Maintenance

3rd

Bru

sh H

ydra

ulic

Circ

uit

(dra

win

g re

fere

nce:

700

5697

- Is

sue

B)


C200 - Maintenance


C200 - MaintenanceC

AN

view

Sof

twar

e:ve

r.3.6

Issu

e A

1

4/10

/09

CX/

CN

200

Mod

us O

pera

ndi

EC

N: 7

0424

4

She

et 1

of 7

Ope

ratio

n Sw

itch

Num

ber

Func

tion

Valv

e O

pera

tion

(Act

ive

Sole

noid

s)

Not

es

1.

E10

, H2b

& J

2 Tu

rn E

10 to

ON

pos

ition

, pre

ss H

2b to

st

art e

ngin

e, w

hils

t als

o pr

essi

ng J

2 as

sa

fety

inte

rlock

.

Igni

tion

afte

r sta

rting

C

T1b,

CT2

b, C

T3b,

CT1

4, C

T15,

C

T18.

C

T4 &

CT5

@ 1

00%

cur

rent

. A

ll fo

r 6 s

econ

ds.

1a.

Tran

sit m

ode

(forw

ard

gear

) pre

ssur

e ap

plie

d to

bru

sh a

rms

& n

ozzl

e to

pr

even

t dro

ppin

g.

CT1

4 &

CT1

5 =

ON

C

T4 &

CT5

= 1

5%

1b.

H2b

W

ork

Mod

e S

elec

t (in

clud

e m

emor

y of

ope

ratio

n 2

or 3

w

hen

switc

hed

off).

Ena

ble

palm

rest

con

trols

. Eng

ine

spee

d no

w in

crea

sed

to 1

100

RP

M

(min

). W

ith 3

rd b

rush

mou

nted

; CT3

1 =

ON

.

Eng

ine

spee

d sw

itch

(G8

&

G9)

can

now

be

used

to a

lter

engi

ne s

peed

bet

wee

n 11

00

15

00 rp

m.

F


C200 - Maintenance

CA

Nvie

w S

oft

wa

re:

ve

r.3

.6Is

su

e A

2

6/1

0/0

9C

X/C

N2

00

Mo

du

s O

pe

ran

di

EC

N:

70

42

44

Sh

ee

t 2 o

f7

2.

G1

0

LH

Sw

ee

p S

ele

cto

r; r

ota

tes fa

n,

bru

sh

es, w

ate

r sp

rays a

nd

lo

we

rs

sw

ee

p g

ea

r fu

lly.

Aft

er

6 s

econ

ds

reve

rts t

o p

revio

us L

H m

em

ory

se

ttin

gs

for

bru

sh p

ressu

re a

nd b

rush

sp

eed

.

@ 0

secs

CT

4 &

CT

5 =

0%

C

T1a, C

T2a, C

T6,

C

T17, C

T18, C

T21,

C

T29 =

ALL O

N.

C

T7 =

(ra

mps to s

aved

LH

settin

g).

@

1.5

secs

CT

1a &

CT

2a =

OF

F

@ 3

secs

CT

14 =

ON

C

T4 &

CT

5 (

mem

ory

L

H s

ettin

g)

@ 5

secs

Wate

r spra

ys e

na

ble

d B

rush u

n-p

ark

sequence

com

ple

ted

Defa

ult s

weepin

g v

alv

es

C

T14, C

T17, C

T18, C

T21 &

CT

29

rem

ain

on d

uring s

we

ep

ing.

Va

lve

s C

T4

& C

T5

are

se

t to

pre

vio

usly

sa

ve

d b

rush

pre

ssu

res.

Va

lve

CT

7 r

am

ps t

op

revio

usly

sa

ve

d b

rush s

pe

ed

se

ttin

g.

Pre

ss G

10

in

tra

nsit m

od

e fo

r a

uto

matic s

we

ep

ge

ar

de

plo

ym

en

t o

n s

ele

ction

of

wo

rkm

od

e,

H2b

.

3.

G1

2

RH

Sw

ee

p S

ele

cto

r; r

ota

tes fa

n,

bru

sh

es, w

ate

r sp

rays a

nd

lo

we

rs

sw

ee

p g

ea

r fu

lly.

Aft

er

6 s

econ

ds

reve

rts t

o p

revio

us R

H m

em

ory

se

ttin

gs

for

pre

ssu

re a

nd

bru

sh s

pe

ed

.

@ 0

secs

CT

4 &

CT

5 =

0%

C

T1a, C

T2a, C

T6,

C

T17, C

T18, C

T21,

C

T29 =

all

ON

C

T7 =

(ra

mps to s

aved

settin

g)

@ 1

.5 s

ecs

CT

1a &

CT

2a =

OF

F

@ 3

secs

CT

14 =

ON

C

T4 &

CT

5 (

mem

ory

s

ettin

g)

@ 5

secs

Wate

r spra

ys e

na

ble

d B

rush u

n-p

ark

sequence

com

ple

ted

Defa

ult s

weepin

g v

alv

es

CT

14,

CT

17, C

T18, C

T21, C

T29 r

em

ain

on

during s

we

epin

g.

Va

lve

s C

T4

& C

T5

are

se

t to

pre

vio

usly

sa

ve

d b

rush

pre

ssu

res.

Va

lve

CT

7 r

am

ps t

op

revio

usly

sa

ve

d b

rush s

pe

ed

se

ttin

g.

Pre

ss G

12

in

tra

nsit m

od

e fo

r a

uto

matic s

we

ep

ge

ar

de

plo

ym

en

t o

n s

ele

ction

of

wo

rkm

od

e,

H2b

.


C200 - MaintenanceC

AN

view

Sof

twar

e:ve

r.3.6

Issu

e A

1

4/10

/09

CX/

CN

200

Mod

us O

pera

ndi

EC

N: 7

0424

4

She

et 3

of 7

4.

E8

Suc

tion

Fan

Onl

y (W

ande

rhos

e)Fa

n on

ly s

witc

hed

on

CT1

7, C

T18,

C

T21

= O

N

Fan

only

sw

itche

d of

f C

T3b,

CT1

5,

CT1

8 =

ON

for 3

sec

s

Use

sw

itche

s G

1 &

G2

to

rais

e &

low

er n

ozzl

e. W

hen

fan

is s

witc

hed

off,

nozz

le li

fts

auto

mat

ical

ly.

G11

= c

ance

l. 5.

G

11

Sw

eep

OFF

; ca

ncel

s fa

n, b

rush

es,

wat

er s

pray

s an

d re

turn

s sw

eep

gear

to

stow

ed p

ositi

on.

Als

o ca

ncel

s fa

n on

ly m

ode.

Pre

ss G

11 in

tran

sit m

ode

to c

ance

l au

tom

atic

sw

eep

gear

dep

loym

ent.

@ 0

sec

s

CT1

4, C

T15,

CT1

7,

CT1

8, C

T21

= O

N

CT4

& C

T5 =

100

%

CT7

= O

FF

@ 1

sec

s

CT1

b, C

T2b,

CT3

b

= O

N

@ 6

sec

s

CT1

b, C

T2b,

CT3

b,

CT1

4, C

T15,

CT1

7,

CT1

8, C

T21,

CT4

& C

T5=

0%

Wat

er s

pray

s di

sabl

ed fo

r sw

eep

mod

e se

lect

ion.

Slo

w b

rush

es g

radu

ally

. C

urre

nt to

val

ve C

T7 ra

mp

to

zero

%.

Rel

ease

CT7

slo

wly

. (If

fan

only

runn

ing,

this

will

canc

el fu

nctio

n).

6.

E6

Hop

per R

aise

/Low

er

Rai

se H

oppe

r C

T18,

CT2

2 &

CT2

4b =

ON

Lo

wer

Hop

per

CT1

8, C

T22,

CT2

4b =

ON

Neu

tral s

elec

ted,

han

dbra

ke

ON

, Sw

eepi

ng O

FF. D

urin

g ho

pper

rais

e, e

ngin

e in

crea

sed

by 1

00 R

PM

.

7.

G1

(Low

er)

G2

(Rai

se)

Noz

zle

Hop

; Up/

Dow

n Lo

wer

noz

zle

(G1)

C

T6 =

ON

(rem

ains

on)

N

ozzl

e m

anua

l mod

e =

OFF

Rai

se n

ozzl

e (G

2)

Pul

se

CT1

5 =

ON

, CT6

= O

FF,

nozz

le m

anua

l mod

e =

ON

Use

d du

ring

swee

ping

and

fa

n on

ly m

ode.

Pre

ss G

10 o

r G

12 to

can

cel m

anua

l noz

zle

cont

rol,

valv

e C

T6 =

will

ener

gise

.


C200 - Maintenance

CA

Nvi

ewS

oftw

are:

ver.3

.6

Is

sue

A

14/

10/0

9 C

X/C

N20

0 M

odus

Ope

rand

i

EC

N: 7

0424

4

She

et 4

of 7

8.

G3

(Clo

se)

G4

(Ope

n)

Noz

zle

Flap

; Clo

se/O

pen

Pul

se C

T3a

(Ope

n)

Pul

se C

T3b

(Clo

se)

Use

d du

ring

swee

ping

and

fa

n on

ly m

ode.

9.

G16

c G

16d

LH B

rush

Pos

ition

; joy

stic

k le

ft/rig

ht

CT1

a (o

ut)

G16

d C

T1b

(in)

G16

c P

ositi

on b

rush

L

R a

s re

quire

d du

ring

oper

atio

n 2

or

3.

10.

G17

c G

17d

RH

Bru

sh P

ositi

on; j

oyst

ick

left/

right

C

T2a

(out

) G

17c

CT2

b (in

) G

17d

Pos

ition

bru

sh L

R

as

requ

ired,

dur

ing

oper

atio

n 2

or 3

.

11.

G

5

G6

Bru

sh S

peed

Incr

ease

/Dec

reas

e

with

G14

act

ive

(red

LED

on)

3rd B

rush

Spe

ed In

crea

se/D

ecre

ase

CT7

CT3

3 0

10

0%

App

ly c

urre

nt to

CT7

to

cont

rol b

rush

spe

ed.

App

ly c

urre

nt to

CT3

3 to

co

ntro

l bru

sh s

peed

. S

peed

sav

ed to

mem

ory.


C200 - MaintenanceC

AN

view

Sof

twar

e:ve

r.3.6

Issu

e A

1

4/10

/09

CX/

CN

200

Mod

us O

pera

ndi

EC

N: 7

0424

4

She

et 5

of 7

12.

G16

a G

16b

Bru

sh B

alan

ce; P

ress

ure

Left

Han

d B

rush

C

T4

incr

ease

cur

rent

G16

a C

T4

dec

reas

e cu

rrent

G16

b A

pply

cur

rent

to C

T4 to

co

ntro

l bru

sh b

alan

ce. N

o op

erat

ion

for 6

sec

onds

du

ring

un-p

arki

ng s

eque

nce.

(o

pera

tions

2 &

3).

13.

G17

a G

17b

Bru

sh B

alan

ce; P

ress

ure

Rig

ht H

and

Bru

sh

CT5

in

crea

se c

urre

nt G

17a

CT5

d

ecre

ase

curre

nt G

17b

App

ly c

urre

nt to

CT5

to

cont

rol b

rush

bal

ance

. No

oper

atio

n fo

r 6 s

econ

ds

durin

g un

-par

king

seq

uenc

e.

(ope

ratio

ns 2

& 3

).

13a.

H

2a

For r

ever

se tr

avel

li

ft no

zzle

.. C

T15

De-

ener

gize

CT6

W

hen

in o

pera

tion

2 or

3

sele

ct re

vers

e to

lift

nozz

le.

14.

J1

Rev

erse

Lift

; Noz

zle

over

ride

& b

rush

sc

rub

De-

ener

gize

CT1

5, re

-ene

rgiz

e C

T6,

only

whe

n re

vers

e se

lect

ed.

De-

ener

gize

CT4

& C

T5 w

hils

t de

pres

sed

and

cont

inue

for 8

se

cond

s.

Ret

urn

to la

st s

et b

rush

ba

lanc

e pr

essu

re a

fter 8

se

cond

s.

15.

E3

Sup

awas

h C

T18

& K

(rem

ote)

W

ork

mod

e on

ly w

ith o

r w

ithou

t fan

runn

ing,

not

whi

lst

swee

ping

.


C200 - Maintenance

CA

Nvi

ewS

oftw

are:

ver.3

.6

Is

sue

A

14/

10/0

9 C

X/C

N20

0 M

odus

Ope

rand

i

EC

N: 7

0424

4

She

et 6

of 7

16.

G11

W

ith G

14 a

ctiv

e.

CT3

4a &

CT3

4b =

OFF

17.

G13

W

ith G

14

activ

e; p

ress

G13

to e

ngag

e cl

ockw

ise

brus

h ro

tatio

n.

CT3

4a =

OFF

C

T34b

= O

N

18.

G15

W

ith G

14 a

ctiv

e; p

ress

G15

to e

ngag

e an

ti-cl

ockw

ise

brus

h ro

tatio

n.

CT3

4a =

OFF

C

T34b

= O

N

19.

G14

S

elec

t G14

to a

ctiv

ate

3rd b

rush

mod

e.

20.

G16

a +

G16

b 3r

d Bru

sh A

rm

Rai

se &

Low

er.

Dire

ctio

n a

(low

er) C

T41

= O

N

Dire

ctio

n b

(rais

e) C

T40

= O

N


C200 - MaintenanceC

AN

view

Sof

twar

e:ve

r.3.6

Issu

e A

1

4/10

/09

CX/

CN

200

Mod

us O

pera

ndi

EC

N: 7

0424

4

She

et 7

of 7

21.

G17

a +

G17

b 3r

d Bru

sh H

ead

Tilt

Forw

ards

/Bac

kwar

ds.

Dire

ctio

n a

(forw

ards

) CT3

8a=O

N

Dire

ctio

n b

(bac

kwar

ds) C

T38b

)=O

N

22.

G16

c +

G16

d 3r

d Bru

sh A

rm

Sle

w L

eft/R

ight

. D

irect

ion

c (le

ft) C

T35b

= O

N

Dire

ctio

n d

(righ

t) C

T35a

= O

N

23.

G17

c +

G17

d 3r

d Bru

sh H

ead

W

rist A

ngle

C

lock

wis

e / C

ount

ercl

ockw

ise

Dire

ctio

n c

(cw

) CT3

9b =

ON

Dire

ctio

n d

(ccw

) CT3

9a =

ON


C200 - Maintenance


C200 - Maintenance

Test Point Function Table

Test Point Location Function

TP1 Purge Valve Forward

TP2 Purge Valve Reverse

TP3 Transmission Pump Boost

TP4 Rear Valve Block Main System Pressure

TP5 Front Valve Block Brush Control

TP6 Fan Motor Block Input

TP7 Fan Motor Block Output

TP8 Water Valve Bank (Washer) Water Pressure

TP9 3rd Brush Primary Block Pressure Relief


C200 - Maintenance

To Set/Check Main Relief Valve

1. Start engine and raise hopper.

2. Engage workmode, set engine speed to 1500 rpm (sweeper) or 1600rpm (washer).

3. Press Menu button on CANview screen, scroll down to Service Menuand press Enter.

4. Select Set System Pressure and press enter. Follow screen prompts.Only adjust valve pressure once ten seconds has elapsed.

5. Adjust main relief valve (CT16), if necessary, on rear valve block to setpressure to 225 bar (+2). Select Set System Pressure on theCANview screen to recheck valve pressure.

6. Disengage work mode.

To Set/Check Auxiliary (Hopper/Tank) Relief Valve


2. Engage workmode, set engine speed to 1500 rpm (sweeper) or1600 rpm (washer).

3. Press Menu button on CANview screen, scroll down to ServiceMenu and press Enter.

4. Select Set Hopper/Tank Pressure and press enter. Followscreen prompts. Only adjust valve pressure once ten secondshas elapsed.

5. Adjust auxiliary relief valve (CT19), if necessary, on rear valveblock to set pressure to 110 Bar (+1) for a sweeper or 65 Bar(+1) for a washer. Select Set Hopper/Tank Pressure on theCANview screen to recheck valve pressure.



C200 - Maintenance

To Set/Check Brush/Spraybar Relief Valve


2. Engage workmode, set engine speed to 1500 rpm (sweeper) or1600 rpm (washer).

3. Press Menu button on CANview screen, scroll down to ServiceMenu and press Enter.

4. Select Set Brush/Spraybar Pressure and press enter. Followscreen prompts. Only adjust valve pressure once ten seconds haselapsed.

5. Adjust relief valve (CT26), if necessary, on front valve block to set pressure to 60 Bar (+1) for a sweeperor 65 Bar (+1) for a washer. Select Set Brush/Spraybar Pressure on the CANview screen to recheckvalve pressure.


3rd Brush Relief Valve


2. Attach lead from pressure gauge to TP9on 3rd brush primary hydraulic block.

3. Engage workmode, set engine speed to1500 rpm.

4. Pressure reading should be 80 Bar +1.

5. Adjust relief valve (CT32), if necessary, on3rd brush primary hydraulic block to setpressure to 80 Bar +1.



C200 - Maintenance

To Check Fan Motor Pressure & Fan Speed (Sweeper Only)

Fan Motor Pressures

1. Start engine.

2. Attach lead from pressure gauge to input testpoint of fan motor block.

3. Check Fan Motor Input pressure, should bebetween 170 - 190 Bar.

4. Remove lead from input test point and attach tooutput test point

5. Check Fan Motor Output pressure, should bebetween 60 - 80 Bar.

6. Disconnect lead from test point and switch offengine.

Fan Speed

1. Start engine.

2. Attach fan speed sensor, optical tachometer or similar device.

3. Check fan speed, should be between 2600 - 2900 rpm.

4. Switch off engine.


C200 - MaintenanceH

ydra

ulic

Con

trol

Man

idol

d (R

ear

Valv

e B

lock

- Pa

rt N

o. 7

5755

/1)

Valv

e &

Por

t Ide

ntifi

catio

n


C200 - Maintenance

Swee

p C

ontr

ol M

anifo

ld (F

ront

Val

ve B

lock

)P

art N

o. 7

2239

1-1

Valv

e &

Por

t Ide

ntifi

catio

n

Port

WP

Port

BRT

Port

BRP

CT29

CT6

CT1

CT3

CT2

CT26

ReliefValve

60

Bar

CT15/C

T30

C9

TCT8

CT7

CT4

CT5

CT28

CT27

Port

P3

Port

T

CT13

Port

B2

Port

B1

TP5

Port

AT

Port

LLB

Port

BDM

2

Port

RBB

Port

BDM

1

Port

N

Port

LBB

Port

P

Port

LBA

Port

LLA

Port

RBA


C200 - Maintenance

Flow Regulator - Valve & Port Identification(Part No. 70625-1)

3rd Brush Primary Block - Valve & Port Identification(Part No. 7005188)


C200 - Maintenance

3rd

Bru

sh S

econ

dary

Blo

ck -

Valv

e &

Por

t Ide

ntifi

catio

n(P

art N

o. 7

0053

71)


C200 - Maintenance

Chapter - Electrical System

CHAPTER 16Electrical System

16:1

Table of Contents

Section Page

Electrical Circuits 16 : 2

Euro 4/5 Engine Control 16 : 26

Euro 4/5 Cab Loom Location 16 : 28

Euro 4 Chassis Loom Location 16 : 29

Euro 3 J-Plex Input/Outputs 16 : 30



Cable Colour Codes 16 : 50

Page Issue B

C200 - Maintenance

Chapter - Electrical System Page Issue 04

MK

2 M

ain

Cab

Loo

m -

Shee

t 1(d

raw

ing

refe

renc

e: 7

2254

5 - I

ssue

01)

16:2

C200 - Maintenance

Page Issue 04 Chapter - Electrical System 16:3

C200 - Maintenance

MK

2 M

ain

Cab

Loo

m -

Shee

t 2(d

raw

ing

refe

renc

e: 7

2254

5 - I

ssue

01)

Chapter - Electrical System Page Issue 0416:4

C200 - MaintenanceM

K2

Mai

n C

ab L

oom

- Sh

eet 3

(dra

win

g re

fere

nce:

722

545

- Iss

ue 0

1)


C200 - Maintenance

MK

2 M

ain

Cab

Loo

m -

Shee

t 4(d

raw

ing

refe

renc

e: 7

2254

5 - I

ssue

01)


C200 - MaintenanceM

K2

Mai

n C

ab L

oom

- Sh

eet 5

(dra

win

g re

fere

nce:

722

545

- Iss

ue 0

1)


C200 - Maintenance

J-Pl

ex C

hass

is N

ode

(dra

win

g re

fere

nce:

721

477

- Iss

ue A

)


C200 - Maintenance

Main Chassis Loom - Euro 3(drawing reference: 721479 - Issue 04)


C200 - Maintenance


C200 - Maintenance

Main Chassis Loom (MK1) - Euro 4(drawing reference: 722142 - Issue 03)


C200 - Maintenance


C200 - Maintenance

Main Chassis Loom (MK2) - Euro 4 (LED Rear Lights)(drawing reference: 722667 - Issue A)


C200 - Maintenance


C200 - Maintenance

Main Chassis Loom - Tier 3 (LED Rear Lights)(drawing reference: 722805 - Issue A)


C200 - Maintenance

Chapter - Electrical System Page Issue B16:16

C200 - Maintenance

Main Chassis Loom - Euro 5(drawing reference: 7008399 - Issue A)

Page Issue B Chapter - Electrical System 16:17

C200 - Maintenance


C200 - MaintenanceO

verh

ead

Con

sole

(dra

win

g re

fere

nce:

721

545

- Iss

ue 0

9)


C200 - Maintenance

Rea

r C

ab L

oom

- Eu

ro 3

(dra

win

g re

fere

nce:

721

595

- Iss

ue 0

4)


C200 - Maintenance

Rear Cab Loom - Euro 4 & 5(drawing reference: 722340 - Issue A)


C200 - Maintenance


C200 - MaintenanceR

ear

LED

Str

obe

Bea

cons

(dra

win

g re

fere

nce:

722

944

- Iss

ue 0

0)


C200 - Maintenance

Fron

t Fas

cia

Indi

cato

rs

(dra

win

g re

fere

nce:

722

943

- Iss

ue 0

0)


C200 - Maintenance

3rd Brush Circuit(drawing reference: 7006109 - Issue A)


C200 - Maintenance


C200 - Maintenance

Engine Control - CANbus J1939, Euro 4 & 5

CAN stands for Controller Area Network. It represents dedicated wiring that connects the control units of avehicle (ECU), so as to create a structure similar to that of the nervous system. For the C200 Euro 4/5sweepers the J1939 CANbus connects the engine ECU to the MegaJET control unit allowing control ofengine RPM and other engine data to be exchanged.

The system permits the vehicles various on-board electronic systems to instantaneously exchange hugeamounts of data.

It represents a two-way communication system that is widely used in vehicles, mainly due to the reductionin the number of conductors and the amount of interference.

Information travels according to a specific protocol that defines the dialogue mode.

Information synchronisation.

Call and answer modes between the various systems.

Identification and correction of any transmission errors.

CAN Line Setup

The cable used for the engine CAN line fitted onthe vehicle is a twisted pair of cables (B).

It has these characteristics in order to eliminateany electrical disturbance on the signals.

The sheathing (A) is grey in colour.

CAN Line Efficiency Tests

In order to check the state of efficiency of the CAN line on the vehicle, certain measurements must betaken.

In order to take these measurements, connect to pins 6 and 14 of the diagnosis connector and detect thefollowing;

Values to be detected during measurements (VBD)

0 ~60 ~120 0.L.

CAN line short-circuited CAN line OK One resistor broken CAN line interrupted


C200 - Maintenance

List of VDB (Vehicle Data Bus) Control Units

Reference Description

EDC Engine Management Control Unit

CAN Controller Area Network

MJ MegaJET Node

OBD On Board Diagnostics

CN Chassis Node

CV CANview Unit

IN Internal Control Node

AN Arm Rest Node

VDB (Vehicle Data Bus) Communication Line Schematic


C200 - Maintenance

8

14

2

3

6

15

13

4

12

7 5

1

9

16

17

18

Euro 4/5 Cab Looms - Location & Part Number Listing

Standard SweeperIllustrated

Item No. Part No. Description1 720820/1, 2, 3 or 4 Armrest Console Assy2 721533/1 Loom - Rear Cab to Overhead Console3 721544/1 Overhead Console Assembly4 721547/1 Loom - Cab Exterior Lights5 722133/1 Loom - C200 Main Cab LH Drive

722134/1 Loom - C200 Main Cab RH Drive6 721611/1 Loom - Cab Air Con7 721638/1 Loom - Cab Valve Block8 721680/1 Overhead Power Cables9 721681/1 Floor Mounted Power Cables

10 721682/1 Loom - C200 Exterior Air Con11 721687/1 Earth Lead - Chassis to Cab12 722336/1 Loom S/Assy - C200 Rear Cab

722339-1 Loom G/Assy - C200 Rear Cab13 740366/3 Column Switch Assy C200 (Lights & Aux)14 742014/1 Pedal - Brush Balance 15 741797/2 Column Switch Assy C200 (Transmission)16 741913/1 to /6 Armrest G/Assembly17 722931/1 Front Fascia Indicator Loom18 722948/1 Front Fascia Indicator Extension Loom


C200 - Maintenance

Euro 4/5 Chassis Looms - Location & Part Number Listing

StandardSweeper

Illustrated

Item No. Part No. Description

Item No. Part No. Description

19 720285/1 Fork Sensor Assy 31 721675/1 Loom - C200 Rear Door

20 721472/2 Loom - C200 J-Plex Chassis Node

721675/2 Loom - C200 Rear Door - Single

21 722141/1 Loom - C200 Main Chassis (Euro 4)

722479-1 Loom - C200 Rear Door, Euro 4/5

7008370 Loom - Main Chassis (Euro 5) 7012539 Sensor Module - LED Indicators

7008919 Loom - Main Chassis (Tier 3) 32 721686/1 Earth Lead - Engine to Chassis

22 721521/1 Rear Chassis Lights 33 721765/1 Cable Assy - Hopper Beacon23 721527/1 Tail Lamp LED Assy 34 722248/1 Cable Assy - Batery Negative24 722465/1 Alternator Charging Lead 35 722249/1 Cable Assy - Battery Isolator

721760-1 Lead - Dump Valve 36 722294/1 Loom - C200 Weight Load Indicator

25 721576/1 Road Speed Sensor Assy 37 722363/1 Sensor Assy - Hopper Down

26 721620/1 Cable Assy - Battery to Main Fuse (Euro 4)

38 740455/3 Sensor Assy - C200 Weight Load Indicator

7008394 Cable Assembly (Euro 5) 39 740459/1 Float Switch Assembly

27 721621/1 Cable Assy - Main Fuse to Cab 40 722946/1 Rear LED Strobe Beacon Loom

28 721622/2 Cable Assy - Battery to Starter Motor

41 7005624 Harness - 3rd Brush, Chassis Side

29 721630/1 Loom - C200 Supawash 42 7005772 Harness - 3rd Brush, Brush Arm

30 721653/1Loom - C200 Trailer Socket LHD 43 7005848

Harness - 3rd Brush, Supawash & Isolator Valve

721653/2Loom - C200 Trailer Socket RHD

Vehicle Looms - Chassis


C200 - Maintenance

Type Pin No FunctionOuput 1 CV1-1 Heated Windscreen/Mirrors Relay 11

12v Feed CV1-2 CANview +12 Volts Power Supply0v Feed CV1-3 CANview - Ground

Output 2 CV1-4 NOT USED

12v Feed CV1-5 NOT USED

0v Feed CV1-6 NOT USED


CAN-Lo CV1-8 NOT USED

CAN-Hi CV1-9 NOT USED


J-Plex Rx CV1-11 J-Plex Communication Signal Rx

J-Plex Tx CV1-12 J-Plex Communication Signal Tx

Input 1 CV2-1 Side Lights

Input 2 CV2-2 Dip Beam

Input 3 CV2-3 Main Beam

Input 4 CV2-4 Indicator LH

Input 5 CV2-5 NOT USED

Input 6 CV2-6 Fog Light Switch

Input 7 CV2-7 Heated Windscreen Switch


Input 9 CV2-9 Air Con Status Input

Input 10 CV2-10 Indicator RH



Level 1 CV3-1 NOT USED

Tacho 1 CV3-2 NOT USED

Tacho 2 CV3-3 NOT USED


Analogue Out CV3-5 NOT USED

50mA Source CV3-6 NOT USED


Analogue In 1 CV3-8 NOT USED

5v Source CV3-9 NOT USED


Analogue In 2 CV3-11 NOT USED

0v Source CV3-12 NOT USED

J-Plex CANview Connections (CV)

28/02/2008

C200 Euro 3

Con

nec

tor

3 -

12

Way

Con

nec

tor

1 -

12

Way

Con

nec

tor

2 -

12

Way

Issue 01


C200 - Maintenance

Outputs

Type Pin No FunctionRelay 1 N/C A1 NOT USED

Relay 2 N/C A2 NOT USED

Low Side A3 Fan Only Switch - Indication LED

Low Side A4 NOT USED

High Side A5 Valve CT1a

High Side A6 Valve CT1b

High Side A7 Valve CT2a

High Side A8 Valve CT2b

High Side A9 Valve CT3a - Nozzle Flap Open (option)

High Side A10 Valve CT3b - Nozzle Flap Close (option)



Relay 1 Com A13

Relay 2 Com A14 NOT USED


High Side A16 Valve CT6




High Side A20 Washer - WS2, LH Spraybar

PWM 1 A21 NOT USED

PWM 2 A22 Proportional Valve CT4 - Brush Balance LH (Signal)

PWM 1 Rtn A23 NOT USED

PWM 2 Rtn A24 Proportional Valve CT4 - Brush Balance LH (Return)

Relay 1 N/O A25

Relay 2 N/O A26 NOT USED

High Side A27 Washer - WS3, Centre Spraybar

High Side A28 Washer - WS4, RH Spraybar

High Side A29 Washer - WS5, RH Flusher Jet

High Side A30 Valve K - Supawash & Washer WS1, LH Flusher Jet

High Side A31 Water Pump - Lost water (via relay)

High Side A32 Brush Worklights

PWM 3 A33 Proportional Valve CT5 - Brush Balance RH (Signal)

PWM 4 A34 Proportional Valve CT7 - Brush Speed (Signal)

PWM 3 Rtn A35 Proportional Valve CT5 - Brush Balance RH (Return)

PWM 4 Rtn A36 Proportional Valve CT7 - Brush Speed (Return)

C200 Euro 3

J-Plex Internal Node Connections (IN)

PLU

G A

- I

npu

t/O

utp

ut

Con

nec

tor

36

Way

28/02/2008

Issue 01


C200 - Maintenance

Inputs

Type Pin No FunctionDigital 1 B1 Hopper Lower

Digital 2 B2 Hopper Raise

Digital 3 B3 Water Pump Spray Switch - Sweep Mode

Digital 4 B4 Water Pump Spray Switch - Continuous

Digital 5 B5 Brush Balance Foot Pedal

Digital 6 B6 Supawash Switch

Digital 7 B7 Fan Only Switch

Digital 8 B8 Handbrake Switch

Digital 9 B9 Brake Fluid Low Pressure (option)

Digital 10 B10 NOT USED















Analogue Out B25 NOT USED

Analogue 1 B26 NOT USED



0V Output B29 NOT USED








C200 Euro 3


PLU

G B

- I

npu

t/O

utp

ut

Con

nec

tor

36

Way

28/02/2008

Issue 01


C200 - Maintenance

Type Pin No FunctionPower A1 Chassis Node - 12 Volts Power Supply

Rx - IN A2 J-Plex Communication Signal IN - Rx

Rx - OUT A3 J-Plex Communication Signal OUT - Rx

Tx - IN A4 J-Plex Communication Signal IN - Tx

Tx - OUT A5 J-Plex Communication Signal OUT - Tx

Ground A6 Chassis Node - Ground

Output B1 Valve CT17 - Signal

Ground B11 Valve CT17 - Ground







Output B5 Valve CT24-A - Signal

Ground B15 Valve CT24-A - Ground

Input B6 Hydraulic Oil Low Level Switch - Signal

Ground B16 Hydraulic Oil Low Level Switch - Ground

PWM 1 B7 Reversing/Hopper Bleeper - Signal

PWM 1 Rtn B17 Reversing/Hopper Bleeper - Ground

PWM 2 B8 BIG Mouth Bleeper - Signal (option - no wires)

PWM 2 Rtn B18 BIG Mouth Bleeper - Ground (option - no wires)

Analogue Input +ve B9 Hydraulic Oil Temperature Switch/Sensor (option - no wires)

Analogue Input -ve B19 Hydraulic Oil Temperature Switch/Sensor (option - no wires)

Freq. Input B10 Weight Load Indicator - Sensor Switch

Ground B20 Weight Load Indicator - Sensor Ground

Output B21 Valve CT24-B - Signal

Ground B31 Valve CT24-B - Ground

Input B22 Hopper Not Down sensor - Signal

Ground B32 Hopper Not Down sensor - Ground

Input B23 Rear Door Open sensor - Signal

Ground B33 Rear Door Open sensor - Ground

Input B24 Float Switch Low - Recirc/Washer Tank - Signal

Ground B34 Float Switch Low - Recirc/Washer Tank - Ground

Input B25 Float Switch High - Recirc/Washer Tank - Signal

Ground B35 Float Switch High - Recirc/Washer Tank - Ground

Input B26 Water Tank Low Level Switch (option)

Ground B36 Water Tank Low Level Switch - Ground (option)

PWM 3 B27 NOT USED

PWM 3 Rtn B37 NOT USED

Output/Feed B28 Weight Load Indicator - Sensor supply

Ground B38 NOT USED

Node Address B29 NODE ADDRESS LINK

Node Address B39 NODE ADDRESS LINK

Output/Feed B30 NOT USED

Ground B40 NOT USED

C200 Euro 3

J-Plex Chassis Node Connections (CN)

28/02/2008

Inpu

t/O

utp

ut

Con

nec

tor

40

Way

Pow

er &

Com

ms

Con

nec

tor

6 W

ay

Issue 01


C200 - Maintenance

Type Pin No Function12V Supply A1 12 Volt Power Supply (System)

12V Supply A2 12 Volt Power Supply (Fail Safe)

CAN HI A3 Communication Signal - HI

CAN LO A4 Communication Signal - LO

Earth A5 Earth

Earth A6 Earth

High Side Ouput B1 Drive Pump - Safety Valve

High Side Output B2 Engine Cranking Relay

High Side Output - 3A B3 Transmission Dump Valve

High Side Output - 5A B4 Esos valve

High Side Output - 5A B5 Excess Fuel valve

High Side Output - 7A B6 Reversing Lights

High Side Output - 6A B7 LH Brake Lights

High Side Output - 6A B8 RH Brake Lights

High Side Output - 7A B9 Rear Fog Lights

High Side Output - 5A B10 NOT USED

Analogue Input B11 Drive Foot Pedal - Signal

- Input (Freq.) B12 Engine Speed Sensor - Signal

Transmit - OUT B13 J-Plex Communication Signal - Tx

0V Ref B14 Drive Foot Pedal - 0V Ref


PWM 1 & 2 Rtn B16 Drive Pump - F & R Returns

PWM 1 Out B17 Drive Pump - Forward Valve

PWM 2 Out B18 Drive Pump - Reverse Valve

PWM 3 Out B19 NOT USED

H - Bridge + B20 Engine Fuel Actuator - H Bridge

+ Input B21 Drive Foot Pedal - IVS

- Input (Freq.) B22 Road Speed Sensor - Signal

Receive - IN B23 J-Plex Communication Signal - Rx

0V Ref B24 Engine Fuel Actuator - 0V

5V Ref B25 Engine Fuel Actuator - 5V Ref


Analogue Input B27 Engine Fuel Actuator - Position

Analogue Input B28 Fuel Level Sender (10-180? )

Analogue Input B29 Engine Water Temperature (600-30? )

H - Bridge - B30 Engine Fuel Actuator - H Bridge

- Input B31 Cold Start Temperature Switch

- Input B32 Brake System Low Level Switch

- Input B33 Transmission Oil Low Level

- Input B34 Engine Oil Low Pressure Switch

- Input B35 Engine Cranking/Workmode Button

- Input B36 Forward Signal

- Input B37 Reverse Signal

- Input B38 Brake Pedal Input

+ input B39 Glow Plugs On/Off

+ input B40 Alternator D+ Terminal

C200 Euro 3

MegaJET Node Connections (MJ)

28/02/2008

Inpu

t/O

utp

ut

Con

nec

tor

40

Way

Pow

er &

Com

ms

Con

nec

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Issue 01


C200 - Maintenance

Type Pin No FunctionSupply A1 12-24V DC SupplyEarth A2 Earth

Comms A3 J-Plex TxComms A4 J-Plex Rx

Input B1 Brush Speed - IncreaseOutput B2 Backlight LED #1Output B3 Backlight LED #2Input B4 Brush Speed - DecreaseInput B5 Third Brush Head - Twist ACW

Output B6 Backlight LED #3Input B7 Main Sweep Switch - Left

Output B8 Backlight LED #4Output B9 Backlight LED #5Input B10 Third Brush - On/Off

Output B11 Status LED - Third BrushInput B12 Main Sweep Switch - Park

Output B13 Backlight LED #6Output B14 Backlight LED #7Input B15 Cruise Control - On/Off

Output B16 Status LED - Cruise ControlOutput B17 Backlight LED #8Input B18 Third Brush Head - Twist CW

Output B19 Backlight LED #9Input B20 Main Sweep Switch - RightInput B21 Engine Speed - Decrease

Output B22 Backlight LED #10Output B23 Backlight LED #11Input B24 Engine Speed - Increase

Common B25 Common

Input C1 Btm, Fwd - Nozzle - LowerInput C2 Btm, Bwd - Nozzle - RaiseInput C3 Top, Bwd - Nozzle Flap - OpenInput C4 Top, Fwd - Nozzle Flap - Close

Common C5 Common

Input D1 Top, Fwd - Nozzle Flap - CloseInput D2 Top, Bwd - Nozzle Flap - OpenInput D3 Btm, Bwd - Nozzle - RaiseInput D4 Btm, Fwd - Nozzle - Lower

Common D5 Common

Input E1 Brush Slew LeftInput E2 Brush Slew RightInput E3 Brush Balance IncreaseInput E4 Brush Balance Decrease

Common E5 Common

Input F1 Brush Slew LeftInput F2 Brush Slew RightInput F3 Brush Balance IncreaseInput F4 Brush Balance Decrease

Common F5 Common

C200 Euro 3

Arm Rest Node Connections (AN)M

ain

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Issue 01

28/02/2008LH

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Chapter - Electrical System16:36

C200 - Maintenance

Page Issue B

Type Pin No FunctionOuput 1 CV1-1 Relay - Heated Windscreen & Mirrors

12v Feed CV1-2 CANview +12 Volts Power Supply

0v Feed CV1-3 CANview - Ground

Output 2 CV1-4 NOT USED12v Feed CV1-5 NOT USED0v Feed CV1-6 NOT USEDOutput 3 CV1-7 NOT USEDCAN-Lo CV1-8 NOT USEDCAN-Hi CV1-9 NOT USED

Output 4 CV1-10 NOT USEDJ-Plex Rx CV1-11 J-Plex Communication Signal Rx






Input 5 CV2-5 NOT USEDInput 6 CV2-6 Fog Light Switch


Input 8 CV2-8 NOT USEDInput 9 CV2-9 NOT USED


Input 11 CV2-11 Indicator Trailer


Level 1 CV3-1 NOT USEDTacho 1 CV3-2 NOT USEDTacho 2 CV3-3 NOT USEDLevel 2 CV3-4 NOT USED

Analogue Out CV3-5 NOT USED50mA Source CV3-6 NOT USED

Level 3 CV3-7 NOT USEDAnalogue In 1 CV3-8 NOT USED

5v Source CV3-9 NOT USEDLevel 4 CV3-10 NOT USED

Analogue In 2 CV3-11 NOT USED0v Source CV3-12 NOT USED


29/09/2009

C200 Euro 4/Tier 3

Con

nec

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Con

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Way

Con

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12

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Issue 02


C200 - Maintenance

Outputs

Type Pin No FunctionRelay 1 - N/C (87a) A1 NOT USED

Relay 2 - N/C (87a) A2 NOT USED

Low Side Output A3 Fan Only Switch - Indication Lamp

High Side Output A4 CT34a - 3rd Brush Rotation (CW)

High Side Output A5 Valve CT1a

High Side Output A6 Valve CT1b



High Side Output A9 Valve CT3a - Nozzle Flap Open (option)

High Side Output A10 Valve CT3b - Nozzle Flap Close (option)

Low Side Output A11 Water Pump - Lost water (via relay)

High Side Output A12 CT34b - 3rd Brush Rotation (CCW)

Relay 1 Common (30) A13 NOT USED

Relay 2 Common (30) A14 NOT USED

High Side Output A15 Brush Worklights (via relay)

High Side Output A16 Valve CT6

High Side Output A17 CT35a - 3rd Brush Slew Left



High Side Output A20 WS2 - Washer / CT35b - 3rd Brush Slew Right

PWM 1 - Proportional Output A21 CT33 - 3rd Brush Speed (Signal)

PWM 2 - Proportional Output A22 Proportional Valve CT4 - Brush Balance LH (Signal)

PWM 1 Return A23 CT33 - 3rd Brush Speed (Return)

PWM 2 Return A24 Proportional Valve CT4 - Brush Balance LH (Return)

Relay 1 - N/O (87) A25 CT39a - 3rd Brush Twist CCW

Relay 2 - N/O (87) A26 CT39b - 3rd Brush Twist CW

High Side Output A27 WS3 - Washer / CT31 - 3rd Brush

High Side Output A28 WS4 - Washer / CT38a - 3rd Brush Tilt Fwd

High Side Output A29 WS5 - Washer / CT38b - 3rd Brush Tilt Back

High Side Output A30 Valve K - Supawash & Washer WS1, LH Flusher Jet

High Side Output A31 CT40 - 3rd Brush Raise

High Side Output A32 CT41 - 3rd Brush Lower





C200 Euro 4/Tier 3


PLU

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29/09/2009

Issue 02


C200 - Maintenance

Inputs

Type Pin No Function Low Side Input (-ve) B1 Hopper Lower

Low Side Input (-ve) B2 Hopper Raise

Low Side Input (-ve) B3 Water Pump Spray Switch - Sweep Mode

Low Side Input (-ve) B4 Water Pump Spray Switch - Continuous

Low Side Input (-ve) B5 Brush Balance Foot Pedal

Low Side Input (-ve) B6 Supawash Switch

Low Side Input (-ve) B7 Fan Only Switch

Low Side Input (-ve) B8 Handbrake Switch

Low Side Input (-ve) B9 Brake Fluid Low Pressure (option)

Low Side Input (-ve) B10 Third Brush Arm - Link

Low Side Input (-ve) B11 NOT USED














Analogue - Output B25 NOT USED

Analogue Input #1 B26 NOT USED










Low Side Input (-ve) B36 Outputs A11 & A15 Enable - Link

C200 Euro 4/Tier 3


PLU

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Con

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29/09/2009

Issue 02


C200 - Maintenance

Type Pin No FunctionSupply A1 12-24V DC Supply

Earth A2 Earth

Comms Tx A3 J-Plex Communication Signal - Transmit

Comms Rx A4 J-Plex Communication Signal - Receive

Input B1 Brush Speed - Increase

Output B2 Backlight LED #1


Input B4 Brush Speed - Decrease

Input B5 Third Brush Head - Twist ACW


Input B7 Main Sweep Switch - Left



Input B10 Third Brush - On/Off

Output B11 Status LED - Third Brush

Input B12 Main Sweep Switch - Park



Input B15 Cruise Control - On/Off

Output B16 Status LED - Cruise Control


Input B18 Third Brush Head - Twist CW


Input B20 Main Sweep Switch - Right

Input B21 Engine Speed - Decrease



Input B24 Engine Speed - Increase

Common B25 Common

Input C1 Btm, Fwd - Nozzle - Lower

Input C2 Btm, Bwd - Nozzle - Raise

Input C3 Top, Bwd - Nozzle Flap - Open

Input C4 Top, Fwd - Nozzle Flap - Close

Common C5 Common

Input D1 Top, Fwd - Nozzle Flap - Close

Input D2 Top, Bwd - Nozzle Flap - Open

Input D3 Btm, Bwd - Nozzle - Raise

Input D4 Btm, Fwd - Nozzle - Lower

Common D5 Common

Input E1 Brush Slew Left

Input E2 Brush Slew Right

Input E3 Brush Balance Increase

Input E4 Brush Balance Decrease

Common E5 Common

Input F1 Brush Slew Left

Input F2 Brush Slew Right

Input F3 Brush Balance Increase

Input F4 Brush Balance Decrease

Common F5 Common

C200 Euro 4/Tier 3

Arm Rest Node Connections (AN)

Mai

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RH

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Issue 02

29/09/2009LH

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RH

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05


C200 - Maintenance


Comms Rx A2 J-Plex Communication Signal - Receive IN

Comms Rx A3 J-Plex Communication Signal - Receive OUT

Comms Tx A4 J-Plex Communication Signal - Transmit IN

Comms Tx A5 J-Plex Communication Signal - Transmit OUT












Input B6 Hydraulic Oil Low Level Switch - Signal Ground B16 Hydraulic Oil Low Level Switch - GroundPWM 1 B7 Reversing/Hopper Bleeper - Signal


PWM 2 B8 BIG Mouth Bleeper - Signal (option - no wires)PWM 2 Rtn B18 BIG Mouth Bleeper - Ground (option - no wires)

Analogue Input +ve B9 Hydraulic Oil Temperature Switch/Sensor (option - no wires)Analogue Input -ve B19 Hydraulic Oil Temperature Switch/Sensor (option - no wires)

Freq. Input B10 Weight Load Indicator Sensor - Signal

Ground B20 Weight Load Indicator Sensor - Ground



Input B22 Hopper Down sensor - Signal










PWM 3 B27 NOT USEDPWM 3 Rtn B37 NOT USED

Output/Power B28 Proximity Sensors - Power Supply output

Ground B38 NOT USEDOutput/Power B29 NOT USED

Ground B39 NOT USEDAnalogue Input 2 B30 Node Address #1 (open circuit)

Ground B40 Node Address #1 (open circuit)

C200 Euro 4/Tier 3


29/09/2009

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Issue 02


C200 - Maintenance



CAN HI A3 Engine CAN bus (J1939) - Hi

CAN LO A4 Engine CAN bus (J1939) - Lo

Earth A5 Earth

Earth A6 Earth












- Input (Freq.) B12 NOT USED








H - Bridge + B20 NOT USED




0V Ref B24 NOT USED

5V Ref B25 NOT USED


Analogue Input B27 NOT USED

Analogue Input B28 Fuel Level Sender (10-180)


H - Bridge - B30 NOT USED

- Input B31 Air Filter Service Switch



- Input B34 Fuel Pre-Filter Water Sensor





+ input B39 NOT USED


C200 Euro 4


29/09/2009

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Issue 02


C200 - Maintenance



CAN HI A3 NOT USED

CAN LO A4 NOT USED

Earth A5 Earth

Earth A6 Earth












- Input (Freq.) B12 Engine Speed Sensor - Signal








H - Bridge + B20 Engine Fuel Actuator - H Bridge




0V Ref B24 Engine Fuel Actuator - 0V

5V Ref B25 Engine Fuel Actuator - 5V Ref


Analogue Input B27 Engine Fuel Actuator - Position


Analogue Input B29 Engine Water Temperature (600-30)

H - Bridge - B30 Engine Fuel Actuator - H Bridge




- Input B34 Engine Oil Low Pressure Switch





+ input B39 Glow Plugs On/Off


C200 Tier 3


29/09/2009

I npu

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Issue 02


C200 - Maintenance

Type Pin No FunctionOuput 1 CV1-1 Relay - Heated Windscreen & Mirrors

12v Feed CV1-2 CANview +12 Volts Power Supply

0v Feed CV1-3 CANview - Ground

Output 2 CV1-4 NOT USED12v Feed CV1-5 NOT USED0v Feed CV1-6 NOT USEDOutput 3 CV1-7 NOT USEDCAN-Lo CV1-8 NOT USEDCAN-Hi CV1-9 NOT USED

Output 4 CV1-10 NOT USEDJ-Plex Rx CV1-11 J-Plex Communication Signal Rx






Input 5 CV2-5 NOT USEDInput 6 CV2-6 Fog Light Switch


Input 8 CV2-8 NOT USEDInput 9 CV2-9 NOT USED


Input 11 CV2-11 Indicator Trailer


Level 1 CV3-1 NOT USEDTacho 1 CV3-2 NOT USEDTacho 2 CV3-3 NOT USEDLevel 2 CV3-4 NOT USED

Analogue Out CV3-5 NOT USED50mA Source CV3-6 NOT USED

Level 3 CV3-7 NOT USEDAnalogue In 1 CV3-8 NOT USED

5v Source CV3-9 NOT USEDLevel 4 CV3-10 NOT USED

Analogue In 2 CV3-11 NOT USED0v Source CV3-12 NOT USED


29/09/2009

C200 Euro 5/Tier 3

Con

nec

tor

3 -

12

Way

Con

nec

tor

1 -

12

Way

Con

nec

tor

2 -

12

Way

Issue 02


C200 - Maintenance

Outputs

Type Pin No Functionspare A1 NOT USED

spare A2 NOT USED

Low Side Output A3 Fan Only Switch - Indication Lamp

High Side Output A4 CT34a - 3rd Brush Rotation (CW)





High Side Output A9 Valve CT3a - Nozzle Flap Open (option)

High Side Output A10 Valve CT3b - Nozzle Flap Close (option)

Low Side Output A11 Water Pump - Lost water (via relay)

High Side Output A12 CT34b - 3rd Brush Rotation (CCW)

spare A13 NOT USED

spare A14 NOT USED

High Side Output A15 Brush Worklights (via relay)


High Side Output A17 CT35a - 3rd Brush Slew Left



High Side Output A20 WS2 - Washer / CT35b - 3rd Brush Slew Right

PWM 1 - Proportional Output A21 CT33 - 3rd Brush Speed (Signal)

PWM 2 - Proportional Output A22 Proportional Valve CT4 - Brush Balance LH (Signal)

PWM 1 Return A23 CT33 - 3rd Brush Speed (Return)

PWM 2 Return A24 Proportional Valve CT4 - Brush Balance LH (Return)

High Side Output A25 CT39a - 3rd Brush Twist CCW

High Side Output A26 CT39b - 3rd Brush Twist CW

High Side Output A27 WS3 - Washer / CT31 - 3rd Brush

High Side Output A28 WS4 - Washer / CT38a - 3rd Brush Tilt Fwd

High Side Output A29 WS5 - Washer / CT38b - 3rd Brush Tilt Back

High Side Output A30 Valve K - Supawash & Washer WS1, LH Flusher Jet

High Side Output A31 CT40 - 3rd Brush Raise

High Side Output A32 CT41 - 3rd Brush Lower





C200 Euro 5/Tier 3


PLU

G A

- I

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t/O

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Con

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36

Way

29/09/2009

Issue 02


C200 - Maintenance

Inputs

Type Pin No Function Low Side Input (-ve) B1 Hopper Lower

Low Side Input (-ve) B2 Hopper Raise

Low Side Input (-ve) B3 Water Pump Spray Switch - Sweep Mode

Low Side Input (-ve) B4 Water Pump Spray Switch - Continuous

Low Side Input (-ve) B5 Brush Balance Foot Pedal

Low Side Input (-ve) B6 Supawash Switch

Low Side Input (-ve) B7 Fan Only Switch

Low Side Input (-ve) B8 Handbrake Switch

Low Side Input (-ve) B9 Brake Fluid Low Pressure (option)

Low Side Input (-ve) B10 Third Brush Arm - Link















Analogue - Output B25 NOT USED











Low Side Input (-ve) B36 Outputs A11 & A15 Enable - Link

C200 Euro 5/Tier 3


PLU

G B

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t/O

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29/09/2009

Issue 02

Chapter - Electrical System16:46

C200 - Maintenance

Page Issue B

Type Pin No FunctionSupply A1 12-24V DC Supply

Earth A2 Earth

Comms Tx A3 J-Plex Communication Signal - Transmit

Comms Rx A4 J-Plex Communication Signal - Receive

Input B1 Brush Speed - Increase



Input B4 Brush Speed - Decrease

Input B5 Third Brush Head - Twist ACW


Input B7 Main Sweep Switch - Left



Input B10 Third Brush - On/Off

Output B11 Status LED - Third Brush

Input B12 Main Sweep Switch - Park



Input B15 Cruise Control - On/Off

Output B16 Status LED - Cruise Control


Input B18 Third Brush Head - Twist CW


Input B20 Main Sweep Switch - Right

Input B21 Engine Speed - Decrease



Input B24 Engine Speed - Increase

Common B25 Common

Input C1 Btm, Fwd - Nozzle - Lower

Input C2 Btm, Bwd - Nozzle - Raise

Input C3 Top, Bwd - Nozzle Flap - Open

Input C4 Top, Fwd - Nozzle Flap - Close

Common C5 Common

Input D1 Top, Fwd - Nozzle Flap - Close

Input D2 Top, Bwd - Nozzle Flap - Open

Input D3 Btm, Bwd - Nozzle - Raise

Input D4 Btm, Fwd - Nozzle - Lower

Common D5 Common

Input E1 Brush Slew Left

Input E2 Brush Slew Right

Input E3 Brush Balance Increase

Input E4 Brush Balance Decrease

Common E5 Common

Input F1 Brush Slew Left

Input F2 Brush Slew Right

Input F3 Brush Balance Increase

Input F4 Brush Balance Decrease

Common F5 Common

C200 Euro 5/Tier 3

Arm Rest Node Connections (AN)

Mai

n K

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d -

Con

nec

tor

02

Pow

er &

Co m

ms

Co n

nec

t or

01

RH

Th

um

b -

Con

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03

LH T

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onn

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4

Issue 02

29/09/2009LH

Joy

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k -

Con

nec

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06

RH

Joy

stic

k -

Con

nec

tor

05


C200 - Maintenance


Comms Rx A2 J-Plex Communication Signal - Receive IN

Comms Rx A3 J-Plex Communication Signal - Receive OUT

Comms Tx A4 J-Plex Communication Signal - Transmit IN

Comms Tx A5 J-Plex Communication Signal - Transmit OUT












Input B6 Hydraulic Oil Low Level Switch - Signal Ground B16 Hydraulic Oil Low Level Switch - GroundPWM 1 B7 Reversing/Hopper Bleeper - Signal


PWM 2 B8 BIG Mouth Bleeper - Signal (option - no wires)PWM 2 Rtn B18 BIG Mouth Bleeper - Ground (option - no wires)

Analogue Input +ve B9 Hydraulic Oil Temperature Switch/Sensor (option - no wires)Analogue Input -ve B19 Hydraulic Oil Temperature Switch/Sensor (option - no wires)

Freq. Input B10 Weight Load Indicator Sensor - Signal

Ground B20 Weight Load Indicator Sensor - Ground



Input B22 Hopper Down sensor - Signal










PWM 3 B27 NOT USEDPWM 3 Rtn B37 NOT USED

Output/Power B28 Proximity Sensors - Power Supply output

Ground B38 NOT USEDOutput/Power B29 NOT USED

Ground B39 NOT USEDAnalogue Input 2 B30 Node Address #1 (open circuit)

Ground B40 Node Address #1 (open circuit)

C200 Euro 5/Tier 3


29/09/2009

Inp

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Issue 02


C200 - Maintenance



CAN HI A3 Engine CAN bus (J1939) - Hi

CAN LO A4 Engine CAN bus (J1939) - Lo

Earth A5 Earth

Earth A6 Earth


High Side Output B2 Engine Cranking Signal to Engine ECU










- Input (Freq.) B12 NOT USED








H - Bridge + B20 NOT USED




0V Ref B24 NOT USED

5V Ref B25 NOT USED





H - Bridge - B30 NOT USED




- Input B34 NOT USED





+ input B39 NOT USED


C200 Euro 5


29/09/2009

I npu

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Way

Pow

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Issue 02


C200 - Maintenance



CAN HI A3 NOT USED

CAN LO A4 NOT USED

Earth A5 Earth

Earth A6 Earth






High Side Output - 7A B6 Re

cn and cx200 maintenance 91549 mh

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