CN and CX200 Maintenance 91549 MH

Maintenance
Section
Foreword
Page Issue Levels
Scheduled Maintenance
14
Hydraulic System
15
Electrical System
16
Water System
17
Wearing Items
18
Remove and Refit Procedures
19
Fault Diagnosis
20
Service Tools
21
Health & Safety
22
CX200, CN200
Suction Sweeper
&
CW200 Washer
Part No 02625/1
Revision Level B
ECN - 705972
Print date - November 2010
C200 - Maintenance
F:2
Foreword
Page Issue 04
C200 - Maintenance
CHAPTER
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C200 - Maintenance
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Page Issue B
C200 - Maintenance
CHAPTER
14
Scheduled Maintenance
Table of Contents
Page Issue 04
Section
Page
Hydraulics
- Filter Replacement
- Cylinder Maintance
14: 2
Windscreen Washers
14 : 2
Mesh Screens
- Hopper Door
- Recirculation
14 : 3
Setting Engine Tickover & Maximum Revs
14 : 4
Torque Wrench Settings
14 : 5
14:1
C200 - Maintenance
Maintenance & Adjustment Instructions

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.
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 suitable
spanner.
Note: Ensure that used filter elements are disposed of in accordance
with applicable environmental regulations.
Hydraulic Cylinder Maintenance

Periodically inspect cylinder rods for damage, blemishes or build up of materials such as tar, cement, paint
etc. 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 mounted
behind the front centre console. The bottle
should be kept topped up with water and a
proprietary windscreen washer fluid.
The jets for the washers are mounted on the
pantograph wiper arm and should be checked
to ensure they do not become blocked. They
can be cleaned using a fine needle to unblock
the orifice.
14:2
Page Issue B
C200 - Maintenance
Mesh Screens
Hopper Door
The hopper mesh screens must be clean at all times for
optimum suction performance. Although these screens
can be cleaned in situ by opening hopper door, it is
preferable to remove them for cleaning using a broom
and hosepipe. Removal is simply by grabbing the
screen by the handle provided after first removing the
lynch pins, and lifting out of the hopper.
Refitting of the hopper mesh screens can be done
either in the reverse order of removal, or it may be
found easier to refit the meshes by fully lifting the
hopper and offering up the mesh. The mesh should be
lifted into the retaining channel and one at a time, the
lynch pins should be fitted.
Note: With the meshes removed it is advisable to ensure the ducts in the roof of the hopper are clean and
free from debris.
Meshes should only be removed with the hopper in the lowered position.
Recirculation Screens
Periodically the wedge wire filter stainless steel
screens in the front and the sides of the hopper may
require cleaning. There are two drainage channels
provided in the hopper for the cleaning of the cavity
behind the screen which will tend to build up with
fine material. The hopper should be lifted to full
height and these channels flushed out with a high
pressure washer or hosepipe.
Page Issue 04
14:3
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 running

temperature is obtained before setting engine tickover.
2.
Disconnect actuator rod.
3.
Attach magnetic pick-up of digital tachometer to engine

flywheel, if available. Vehicles CANview unit located in the
cab will also do this task.
4. Loosen locknut on idle adjustment screw.

5. Using a flat-bladed screwdriver, turn screw until tickover of 900 rpm
is obtained.
6. Retighten locknut.
7. Disconnect flywheel sensor.
8. Adjust actuator rod length to obtain 970 rpm. Once correct

rpm is obtained reconnect actuator rod and flywheel sensor.
The actucator rod and flywheel sensor will require reconnecting at various intervals if the setup procedure is
conducted without the aid of a digital tachometer to check
progress of adjustment, (this can be done using the
CANview 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 the
accelerator pedal.
14:4
Page Issue 04
C200 - Maintenance
Torque Wrench Settings
No.
Page Issue B
Description
Setting
Front Axle Suspension Bolts
56 Nm
(40 lb/ft)
Rear Wheel Motor Bolts
97 Nm
(70 lb/ft)
Front Axle Suspension Pivot Bolts
550 Nm
(400 lb/ft)
Steering/Pedal Box Mounting Bolts
28 Nm
(20 lb/ft)
Rear Suspension Bolts
550 Nm
(400 lb/ft)
Cab Mounting Bolts
120 Nm
(88.5 lb/ft)
Tow Hitch Mounting Bolts (Option)
240 Nm
(176 lb/ft)
Wiper Motor Arm Nut
Engine Lifting Lugs
32.4 Nm
(24 lb/ft)
10
Wheel Motor Adaptors
240 Nm
(176 lb/ft)
20 25 Nm
(15 18 lb/ft)
14:5
C200 - Maintenance
14:6
Page Issue 04
C200 - Maintenance
15
CHAPTER
Hydraulic System
Table of Contents
Section
Page
General Description
15 : 2
Hydraulic Circuits
Page Issue 06
- Sweep System
- Transmission - Euro 4
- Transmission - Euro 5
- Steering System
- Expanding Spray Bar (CW200 Only)
- Folding Spray Bar (CW200 Only)
- Fixed Spray Bar (CW200 Only)
- 3rd Brush
15
15
15
15
15
15
15
15
:
:
:
:
:
:
:
:
3
4
5
6
7
8
9
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
15:1
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 the
hydrostatic transmission pump, all pumps are driven from the engine's flywheel by-way of a torsionally
damped 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 by
hydraulic motors. The brushes and nozzle are lifted and positioned by hydraulic cylinders. The hopper is also
raised and lowered using, single stage hydraulic cylinders. Control of these operations is by way of a unique
three 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 a
double acting cylinder integral with the front axle assembly. Control of the steering is done by a special
steering servo valve, mounted within the steering column.
Filtration for both systems is provided by suction strainers situated within the hydraulic reservoir, together with
a replaceable canister type return line filter acting on the PAS circuit, this filter is located towards the rear of
the drivers cab.
The third hydraulic system is the vehicle transmission system which is driven by an axial piston pump
mounted direct to the engine flywheel housing. This provides oil to the two rear wheel motors. The system is
a closed circuit with a separate header tank, the oil is cooled and filtered separately to the other sweeping
and steering systems.
The steering circuit and hydrostatic systems both have their pressures factory preset and only suitably
qualified personnel should effect any adjustments. The various pressure settings being shown on the circuit
diagrams.
15:2
Page Issue 06
(drawing reference: 722461 - Issue 01)
Sweep System Hydraulic Circuit
C200 - Maintenance
Page Issue 06
15:3
Transmission System Hydraulic Circuit
C200 - Maintenance
15:4
Page Issue 06
(drawing reference: 7009215 - Issue E)
Transmission System Hydraulic Circuit - Euro 5
C200 - Maintenance
Page Issue B
15:5
Steering System Hydraulic Circuit
C200 - Maintenance
15:6
Page Issue 06
C200 - Maintenance
Page Issue 06
15:7
C200 - Maintenance
15:8
Page Issue 06
C200 - Maintenance
Page Issue 06
15:9
15:10

(drawing reference: 7005697 - Issue B)
3rd Brush Hydraulic Circuit
C200 - Maintenance
Page Issue 06
C200 - Maintenance
Page Issue 06
15:11
15:12
H2b
ECN: 704244
1b.
1a.
Work Mode Select

(include memory of operation 2 or 3
when switched off).
Transit mode (forward gear) pressure

applied to brush arms & nozzle to
prevent dropping.
Turn E10 to ON position, press H2b to

start engine, whilst also pressing J2 as
safety interlock.
1.
E10, H2b & J2
Function
Enable palm rest controls. Engine

speed now increased to 1100 RPM
(min).
With 3rd brush mounted; CT31 = ON.
CT14 & CT15 = ON

CT4 & CT5 = 15%
Valve Operation
(Active Solenoids)
Ignition after starting
CT1b, CT2b, CT3b, CT14, CT15,
CT18.
CT4 & CT5 @ 100% current.
All for 6 seconds.
CX/CN200 Modus Operandi
Operation Switch Number
CANview Software: ver.3.6
Sheet 1 of 7
Engine speed switch (G8 &

G9) can now be used to alter
engine speed between 1100
1500 rpm.
Notes
Issue A 14/10/09
C200 - Maintenance
Page Issue 06
Page Issue 06
G12
3.
ECN: 704244
G10
2.
RH Sweep Selector; rotates fan,

brushes, water sprays and lowers
sweep gear fully. After 6 seconds
reverts to previous RH memory settings
for pressure and brush speed.
LH Sweep Selector; rotates fan,

brushes, water sprays and lowers
sweep gear fully. After 6 seconds
reverts to previous LH memory settings
for brush pressure and brush speed.
@ 0 secs CT4 & CT5 = 0%

CT1a, CT2a, CT6,
CT17, CT18, CT21,
CT29 = all ON
CT7 = (ramps to saved
setting)
@ 1.5 secs CT1a & CT2a = OFF
@ 3 secs CT14 = ON
CT4 & CT5 (memory
setting)
@ 5 secs Water sprays enabled
Brush un-park sequence
completed
Default sweeping valves CT14,
CT17, CT18, CT21, CT29 remain on
during sweeping.
@ 0 secs CT4 & CT5 = 0%

CT1a, CT2a, CT6,
CT17, CT18, CT21,
CT29 = ALL ON.
CT7 = (ramps to saved
LH setting).
@ 1.5 secs CT1a & CT2a = OFF
@ 3 secs CT14 = ON
CT4 & CT5 (memory
LH setting)
@ 5 secs Water sprays enabled
Brush un-park sequence
completed
Default sweeping valves
CT14, CT17, CT18, CT21 & CT29
remain on during sweeping.
Sheet 2 of 7
Press G12 in transit mode for

automatic sweep gear
deployment on selection of
workmode, H2b.
Valve CT7 ramps to

previously saved brush speed
setting.
Valves CT4 & CT5 are set to

previously saved brush
pressures.
Press G10 in transit mode for

automatic sweep gear
deployment on selection of
workmode, H2b.
Valve CT7 ramps to

previously saved brush speed
setting.
Valves CT4 & CT5 are set to

previously saved brush
pressures.
Issue A 26/10/09
C200 - Maintenance
15:13
15:14
G11
E6
5.
6.
ECN: 704244
7.
E8
4.
G2 (Raise)
G1 (Lower)
Nozzle Hop; Up/Down
Hopper Raise/Lower
Press G11 in transit mode to cancel

automatic sweep gear deployment.
Also cancels fan only mode.
Sweep OFF; cancels fan, brushes,

water sprays and returns sweep gear to
stowed position.
Suction Fan Only (Wanderhose)
Raise nozzle (G2)

Pulse CT15 = ON, CT6 = OFF,
nozzle manual mode = ON
Lower nozzle (G1)

CT6 = ON (remains on)
Nozzle manual mode = OFF
Raise Hopper
CT18, CT22 & CT24b = ON
Lower Hopper
CT18, CT22, CT24b = ON
@ 0 secs CT14, CT15, CT17,

CT18, CT21 = ON
CT4 & CT5 = 100%
CT7 = OFF
@ 1 secs CT1b, CT2b, CT3b
= ON
@ 6 secs CT1b, CT2b, CT3b,
CT14, CT15, CT17,
CT18, CT21, CT4 & CT5
= 0%
Water sprays disabled for sweep mode
selection.
Fan only switched on CT17, CT18,

CT21 = ON
Fan only switched off CT3b, CT15,
CT18 = ON for 3 secs
Sheet 3 of 7
Used during sweeping and

fan only mode. Press G10 or
G12 to cancel manual nozzle
control, valve CT6 = will
energise.
Neutral selected, handbrake

ON, Sweeping OFF. During
hopper raise, engine
increased by 100 RPM.
Use switches G1 & G2 to

raise & lower nozzle. When
fan is switched off, nozzle lifts
automatically.
G11 = cancel.
Slow brushes gradually.
Current to valve CT7 ramp to
zero %.
Release CT7 slowly.
(If fan only running, this will
cancel function).
Issue A 14/10/09
C200 - Maintenance
Page Issue 06
Page Issue 06
ECN: 704244
G6
G5
G17c
G17d
10.
11.
G16c
G16d
G4 (Open)
G3 (Close)
9.
8.
3rd Brush Speed Increase/Decrease
with G14 active (red LED on)
Brush Speed Increase/Decrease
RH Brush Position; joystick left/right
LH Brush Position; joystick left/right
Nozzle Flap; Close/Open
CT33 0 100%
CT7
CT2a (out) G17c

CT2b (in) G17d
CT1a (out) G16d

CT1b (in) G16c
Pulse CT3a (Open)

Pulse CT3b (Close)
Sheet 4 of 7
Apply current to CT33 to

control brush speed.
Speed saved to memory.

control brush speed.
Position brush L R as
required, during operation 2
or 3.
Position brush L R as
required during operation 2 or
3.
Used during sweeping and

fan only mode.
Issue A 14/10/09
C200 - Maintenance
15:15
15:16
G17a
G17b
H2a
J1
E3
13.
13a.
14.
15.
ECN: 704244
G16a
G16b
12.
Supawash
Reverse Lift; Nozzle override & brush

scrub
For reverse travel lift nozzle..
Brush Balance; Pressure

Right Hand Brush
Brush Balance; Pressure

Left Hand Brush
CT18 & K (remote)
De-energize CT15, re-energize CT6,

only when reverse selected.
De-energize CT4 & CT5 whilst
depressed and continue for 8
seconds.
CT15
De-energize CT6
CT5 increase current G17a

CT5 decrease current G17b
CT4 increase current G16a

CT4 decrease current G16b
Sheet 5 of 7
Work mode only with or

without fan running, not whilst
sweeping.
Return to last set brush

balance pressure after 8
seconds.
When in operation 2 or 3
select reverse to lift nozzle.

control brush balance. No
operation for 6 seconds
during un-parking sequence.
(operations 2 & 3).

control brush balance. No
operation for 6 seconds
during un-parking sequence.
(operations 2 & 3).
Issue A 14/10/09
C200 - Maintenance
Page Issue 06
Page Issue 06
G15
G14
18.
19.
ECN: 704244
G16a + G16b
G13
17.
20.
G11
16.
3rd Brush Arm Raise & Lower.
Select G14 to activate 3rd brush mode.
With G14 active; press G15 to engage

anti-clockwise brush rotation.
With G 14 active; press G13 to engage

clockwise brush rotation.
With G14 active.
Direction b (raise) CT40 = ON
Direction a (lower) CT41 = ON
CT34a = OFF
CT34b = ON
CT34a = OFF
CT34b = ON
CT34a & CT34b = OFF
Sheet 6 of 7
Issue A 14/10/09
C200 - Maintenance
15:17
15:18
G16c + G16d
G17c + G17d
22.
23.
ECN: 704244
G17a + G17b
21.
3rd Brush Head Wrist Angle

Clockwise / Counterclockwise
3rd Brush Arm Slew Left/Right.
3rd Brush Head

Tilt Forwards/Backwards.
Direction d (ccw) CT39a = ON
Direction c (cw) CT39b = ON
Direction d (right) CT35a = ON
Direction c (left) CT35b = ON
Direction b (backwards) CT38b)=ON
Direction a (forwards) CT38a=ON
Sheet 7 of 7
Issue A 14/10/09
C200 - Maintenance
Page Issue 06
C200 - Maintenance
Page Issue 06
15:19
C200 - Maintenance
15:20
Page Issue 06
C200 - Maintenance
Page Issue 06
15:21
C200 - Maintenance
15:22
Page Issue 06
C200 - Maintenance
Page Issue 06
15:23
C200 - Maintenance
Test Point Function Table
Test Point
15:24
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
Page Issue 06
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 1600

rpm (washer).
3.
Press Menu button on CANview screen, scroll down to Service Menu

and 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 set
pressure to 225 bar (+2). Select Set System Pressure on the
CANview screen to recheck valve pressure.
6.
Disengage work mode.
To Set/Check Auxiliary (Hopper/Tank) Relief Valve
Page Issue 06
1.
2.
Engage workmode, set engine speed to 1500 rpm (sweeper) or

1600 rpm (washer).
3.
Press Menu button on CANview screen, scroll down to Service

Menu and press Enter.
4.
Select Set Hopper/Tank Pressure and press enter. Follow

screen prompts. Only adjust valve pressure once ten seconds
has elapsed.
5.
Adjust auxiliary relief valve (CT19), if necessary, on rear valve

block to set pressure to 110 Bar (+1) for a sweeper or 65 Bar
(+1) for a washer. Select Set Hopper/Tank Pressure on the
CANview screen to recheck valve pressure.
6.
15:25
C200 - Maintenance
To Set/Check Brush/Spraybar Relief Valve

1.
2.
Engage workmode, set engine speed to 1500 rpm (sweeper) or

1600 rpm (washer).
3.
Press Menu button on CANview screen, scroll down to Service

Menu and press Enter.
4.
Select Set Brush/Spraybar Pressure and press enter. Follow

screen prompts. Only adjust valve pressure once ten seconds has
elapsed.
5.
Adjust relief valve (CT26), if necessary, on front valve block to set pressure to 60 Bar (+1) for a sweeper
or 65 Bar (+1) for a washer. Select Set Brush/Spraybar Pressure on the CANview screen to recheck
valve pressure.
6.
3rd Brush Relief Valve

1.
2.
Attach lead from pressure gauge to TP9

on 3rd brush primary hydraulic block.
3.
Engage workmode, set engine speed to

1500 rpm.
4.
Pressure reading should be 80 Bar +1.
5.
Adjust relief valve (CT32), if necessary, on

3rd brush primary hydraulic block to set
pressure to 80 Bar +1.
6.
15:26
Page Issue 06
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 test

point of fan motor block.
3.
Check Fan Motor Input pressure, should be

between 170 - 190 Bar.
4.
Remove lead from input test point and attach to

output test point
5.
Check Fan Motor Output pressure, should be

between 60 - 80 Bar.
6.
Disconnect lead from test point and switch off

engine.
Fan Speed
Page Issue 06
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.
15:27
Valve & Port Identification
Hydraulic Control Manidold (Rear Valve Block - Part No. 75755/1)
C200 - Maintenance
15:28
Page Issue 06
Page Issue 06
CT7
CT4
CT5
CT8
Port
BRP
CT29
CT15/CT30
CT6 CT3 CT1
Port
BRT
CT2
CT9
Port
WP
CT26
Relief Valve
60 Bar
Port
Port
RBB BDM1
Port
N
Port
LBB
Port
LBA
Port
P
Port
P3
CT13
Port
LLA
CT28
Port
RBA
Port
BDM2
Port
T
Port
LLB
CT27
Port
AT
Port
B2
Port
B1
TP5
Valve & Port Identification
Sweep Control Manifold (Front Valve Block)

Part No. 722391-1
C200 - Maintenance
15:29
C200 - Maintenance
Flow Regulator - Valve & Port Identification

(Part No. 70625-1)
3rd Brush Primary Block - Valve & Port Identification

(Part No. 7005188)
15:30
Page Issue 06
3rd Brush Secondary Block - Valve & Port Identification

(Part No. 7005371)
C200 - Maintenance
Page Issue 06
15:31
C200 - Maintenance
15:32
Page Issue 06
C200 - Maintenance
CHAPTER
16
Electrical System
Table of Contents
Page Issue B
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
16 : 36
16 : 43
Cable Colour Codes
16 : 50
16:1
MK2 Main Cab Loom - Sheet 1

C200 - Maintenance
16:2
Page Issue 04

C200 - Maintenance
Page Issue 04
16:3

C200 - Maintenance
16:4
Page Issue 04

C200 - Maintenance
Page Issue 04
16:5

C200 - Maintenance
16:6
Page Issue 04
J-Plex Chassis Node
(drawing reference: 721477 - Issue A)
C200 - Maintenance
Page Issue 06
16:7
C200 - Maintenance
Main Chassis Loom - Euro 3

16:8
Page Issue 04
C200 - Maintenance
Page Issue 04
16:9
C200 - Maintenance
Main Chassis Loom (MK1) - Euro 4

16:10
Page Issue 05
C200 - Maintenance
Page Issue 05
16:11
C200 - Maintenance
Main Chassis Loom (MK2) - Euro 4

(LED Rear Lights)
16:12
Page Issue 05
C200 - Maintenance
Page Issue 05
16:13
C200 - Maintenance
Main Chassis Loom - Tier 3

(LED Rear Lights)
16:14
Page Issue 05
C200 - Maintenance
Page Issue 05
16:15
C200 - Maintenance
Main Chassis Loom - Euro 5

16:16
Page Issue B
C200 - Maintenance
Page Issue B
16:17
Overhead Console
C200 - Maintenance
16:18
Page Issue B
Rear Cab Loom - Euro 3
C200 - Maintenance
Page Issue B
16:19
C200 - Maintenance
Rear Cab Loom - Euro 4 & 5

16:20
Page Issue B
C200 - Maintenance
Page Issue B
16:21
Rear LED Strobe Beacons
C200 - Maintenance
16:22
Page Issue B
Front Fascia Indicators
C200 - Maintenance
Page Issue B
16:23
C200 - Maintenance
3rd Brush Circuit

16:24
Page Issue B
C200 - Maintenance
Page Issue B
16:25
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 a
vehicle (ECU), so as to create a structure similar to that of the nervous system. For the C200 Euro 4/5
sweepers the J1939 CANbus connects the engine ECU to the MegaJET control unit allowing control of
engine RPM and other engine data to be exchanged.
The system permits the vehicles various on-board electronic systems to instantaneously exchange huge
amounts of data.
It represents a two-way communication system that is widely used in vehicles, mainly due to the reduction
in 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 on
the vehicle is a twisted pair of cables (B).
It has these characteristics in order to eliminate
any 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 be
taken.
In order to take these measurements, connect to pins 6 and 14 of the diagnosis connector and detect the
following;
Values to be detected during measurements (VBD)
0
CAN line short-circuited
16:26
~60
~120
0.L.
CAN line OK
One resistor broken
CAN line interrupted
Page Issue B
C200 - Maintenance
VDB (Vehicle Data Bus) Communication Line Schematic
List of VDB (Vehicle Data Bus) Control Units

Reference
EDC
Engine Management Control Unit
CAN
Controller Area Network
MJ
OBD
Page Issue B
Description
MegaJET Node
On Board Diagnostics
CN
Chassis Node
CV
CANview Unit
IN
Internal Control Node
AN
Arm Rest Node
16:27
C200 - Maintenance
Euro 4/5 Cab Looms - Location & Part Number Listing
2
8
12
6
1
16
15
14
5
9
13
18
17
Standard Sweeper
Illustrated
Item No.
16:28
Part No.
Description
720820/1, 2, 3 or 4
Armrest Console Assy
721533/1
Loom - Rear Cab to Overhead Console
721544/1
Overhead Console Assembly
721547/1
Loom - Cab Exterior Lights
722133/1
Loom - C200 Main Cab LH Drive
722134/1
Loom - C200 Main Cab RH Drive
721611/1
Loom - Cab Air Con
721638/1
Loom - Cab Valve Block
721680/1
Overhead Power Cables
721681/1
Floor Mounted Power Cables
10
721682/1
Loom - C200 Exterior Air Con
11
721687/1
Earth Lead - Chassis to Cab
12
722336/1
Loom S/Assy - C200 Rear Cab
722339-1
Loom G/Assy - C200 Rear Cab
13
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/Assembly
17
722931/1
Front Fascia Indicator Loom
18
722948/1
Front Fascia Indicator Extension Loom
Page Issue B
C200 - Maintenance
Euro 4/5 Chassis Looms Location & Part Number Listing
Standard
Sweeper
Illustrated
Vehicle Looms - Chassis

Item
No.
19
20
21
Part No.
Description
720285/1 Fork Sensor Assy

Loom - C200 J-Plex Chassis
721472/2
Node
Loom - C200 Main Chassis
722141/1
(Euro 4)
7008370
Loom - Main Chassis (Euro 5)
7008919
Loom - Main Chassis (Tier 3)
Item
No.
31
Part No.
Description
721675/1 Loom - C200 Rear Door

Loom - C200 Rear Door 721675/2
Single
Loom - C200 Rear Door, Euro
722479-1
4/5
Sensor Module - LED
7012539
Indicators
32
721686/1 Earth Lead - Engine to Chassis
721521/1 Rear Chassis Lights

721527/1 Tail Lamp LED Assy
722465/1 Alternator Charging Lead
33
34
35
721760-1 Lead - Dump Valve
36
721576/1 Road Speed Sensor Assy

Cable Assy - Battery to Main
721620/1
Fuse (Euro 4)
7008394 Cable Assembly (Euro 5)
37
39
721765/1 Cable Assy - Hopper Beacon

722248/1 Cable Assy - Batery Negative
722249/1 Cable Assy - Battery Isolator
Loom - C200 Weight Load
722294/1
Indicator
722363/1 Sensor Assy - Hopper Down
Sensor Assy - C200 Weight
740455/3
Load Indicator
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
29
721630/1 Loom - C200 Supawash
42
7005772
30
721653/1
43
7005848
22
23
24
25
26
Page Issue B
Loom - C200 Trailer Socket

LHD
Loom - C200 Trailer Socket
721653/2
RHD
38
Harness - 3rd Brush, Chassis

Side
Harness - 3rd Brush, Brush
Arm
Harness - 3rd Brush,
Supawash & Isolator Valve
16:29
C200 - Maintenance
J-Plex CANview Connections (CV)
Connector 3 - 12 Way
C200 Euro 3
16:30
Type
Pin No
Function
Ouput 1
CV1-1
Heated Windscreen/Mirrors Relay 11
12v Feed
CV1-2
0v Feed
CV1-3
CANview +12 Volts Power Supply

CANview - Ground
Output 2
CV1-4
NOT USED
12v Feed
CV1-5
NOT USED
0v Feed
CV1-6
NOT USED
Output 3
CV1-7
NOT USED
CAN-Lo
CV1-8
NOT USED
CAN-Hi
CV1-9
NOT USED
Output 4
CV1-10
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 8
CV2-8
NOT USED
Input 9
CV2-9
Air Con Status Input
Input 10
CV2-10
Indicator RH
Input 11
CV2-11
NOT USED
Input 12
CV2-12
NOT USED
Level 1
CV3-1
NOT USED
Tacho 1
CV3-2
NOT USED
Tacho 2
CV3-3
NOT USED
Level 2
CV3-4
NOT USED
Analogue Out
CV3-5
NOT USED
50mA Source
CV3-6
NOT USED
Level 3
CV3-7
NOT USED
Analogue In 1
CV3-8
NOT USED
5v Source
CV3-9
NOT USED
Level 4
CV3-10
NOT USED
Analogue In 2
CV3-11
NOT USED
Issue 01
0v Source
CV3-12
NOT USED
28/02/2008
Page Issue B
C200 - Maintenance
J-Plex Internal Node Connections (IN)
PLUG A - Input/Output Connector 36 Way
Outputs
Page Issue B
C200 Euro 3
Type
Pin No
Function
Relay 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)
Low Side
A11
NOT USED
Low Side
A12
NOT USED
Relay 1 Com
A13
Relay 2 Com
A14
NOT USED
NOT USED
Low Side
A15
High Side
A16
Valve CT6
High Side
A17
Valve CT14
High Side
A18
Valve CT15
High Side
A19
Valve CT29
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)
Issue 01
PWM 4 Rtn
A36
Proportional Valve CT7 - Brush Speed (Return)
28/02/2008
16:31
C200 - Maintenance
PLUG B - Input/Output Connector 36 Way
Inputs
Type
Pin No
Function
Digital 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
Digital 11
B11
NOT USED
Digital 12
B12
NOT USED
Digital 13
B13
NOT USED
Digital 14
B14
NOT USED
Digital 15
B15
NOT USED
Digital 16
B16
NOT USED
Digital 17
B17
NOT USED
Digital 18
B18
NOT USED
Digital 19
B19
NOT USED
Digital 20
B20
NOT USED
Digital 21
B21
NOT USED
Digital 22
B22
NOT USED
Digital 23
B23
NOT USED
Digital 24
B24
NOT USED
Analogue Out
B25
NOT USED
Analogue 1
B26
NOT USED
Analogue 2
B27
NOT USED
Analogue 3
B28
NOT USED
0V Output
B29
NOT USED
5V Output
B30
NOT USED
Digital 25
B31
NOT USED
Digital 26
B32
NOT USED
Digital 27
B33
NOT USED
Digital 28
B34
NOT USED
Digital 29
B35
NOT USED
Issue 01
B36
NOT USED
28/02/2008
Digital 30
16:32
C200 Euro 3
Page Issue B
C200 - Maintenance
J-Plex Chassis Node Connections (CN)

C200 Euro 3
Input/Output Connector 40 Way
Power & Comms

Connector 6 Way
Type
Page Issue B
Pin No
Function
Power
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
B2
Valve CT18 - Signal
Ground
B12
Valve CT18 - Ground
Output
B3
Valve CT21 - Signal
Ground
B13
Valve CT21 - Ground
Output
B4
Valve CT22 - Signal
Ground
B14
Valve CT22 - 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
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)
NOT USED
PWM 3
B27
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
Issue 01
Ground
B40
NOT USED
28/02/2008
16:33
C200 - Maintenance
MegaJET Node Connections (MJ)
Power & Comms

Connector 6
Way
C200 Euro 3
16:34
Type
Pin No
Function
12V 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
Drive Pump - Safety Valve
High Side Ouput
B1
High Side Output
B2
Engine Cranking Relay
High Side Output - 3A
B3
Transmission Dump Valve
B4
Esos valve
B5
Excess Fuel valve
B6
Reversing Lights
B7
LH Brake Lights
B8
RH Brake Lights
B9
Rear Fog Lights
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
5V Ref
B15
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
PWM 3 Rtn
B26
NOT USED
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
- 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
Issue 01
+ input
B40
Alternator D+ Terminal
28/02/2008
Page Issue B
C200 - Maintenance
Arm Rest Node Connections (AN)
LH Joystick Connector 06
RH Joystick Connector 05
LH Thumb Connector 04
RH Thumb Connector 03
Main Keypad - Connector 02
Power &
Comms
Connector
01
C200 Euro 3
Page Issue B
Type
Pin No
Function
Supply
A1
12-24V DC Supply
Earth
A2
Earth
Comms
A3
J-Plex Tx
Comms
A4
J-Plex Rx
Input
B1
Brush Speed - Increase
Output
B2
Backlight LED #1
Output
B3
Backlight LED #2
Input
B4
Brush Speed - Decrease

Third Brush Head - Twist ACW
Input
B5
Output
B6
Backlight LED #3
Input
B7
Main Sweep Switch - Left
Output
B8
Backlight LED #4
Output
B9
Backlight LED #5
Input
B10
Third Brush - On/Off
Output
B11
Status LED - Third Brush
Input
B12
Main Sweep Switch - Park
Output
B13
Backlight LED #6
Output
B14
Backlight LED #7
Input
B15
Cruise Control - On/Off
Output
B16
Status LED - Cruise Control
Output
B17
Backlight LED #8
Input
B18
Third Brush Head - Twist CW
Output
B19
Backlight LED #9
Input
B20
Main Sweep Switch - Right
Input
B21
Engine Speed - Decrease
Output
B22
Backlight LED #10
Output
B23
Backlight LED #11
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
Input
D2
Input
D3
Input
D4
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
Input
F4
Issue 01
Common
F5
Common
28/02/2008
16:35
C200 - Maintenance
C200 Euro 4/Tier 3
16:36
Type
Pin No
Ouput 1
CV1-1
Relay - Heated Windscreen & Mirrors
Function
12v Feed
CV1-2
0v Feed
CV1-3
CANview - Ground
Output 2
CV1-4
NOT USED
12v Feed
CV1-5
NOT USED
0v Feed
CV1-6
NOT USED
Output 3
CV1-7
NOT USED
CAN-Lo
CV1-8
NOT USED
CAN-Hi
CV1-9
NOT USED
Output 4
CV1-10
J-Plex Rx
CV1-11
J-Plex Tx
CV1-12
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
Input 6
CV2-6
Fog Light Switch
Input 7
CV2-7
Input 8
CV2-8
NOT USED
Input 9
CV2-9
NOT USED
Input 10
CV2-10
Indicator RH
Input 11
CV2-11
Indicator Trailer
Input 12
CV2-12
NOT USED
NOT USED
NOT USED
Level 1
CV3-1
NOT USED
Tacho 1
CV3-2
NOT USED
Tacho 2
CV3-3
NOT USED
Level 2
CV3-4
NOT USED
Analogue Out
CV3-5
NOT USED
50mA Source
CV3-6
NOT USED
Level 3
CV3-7
NOT USED
Analogue In 1
CV3-8
NOT USED
5v Source
CV3-9
NOT USED
Level 4
CV3-10
NOT USED
Analogue In 2
CV3-11
NOT USED
Issue 02
0v Source
CV3-12
NOT USED
29/09/2009
Page Issue B
C200 - Maintenance

Outputs
C200 Euro 4/Tier 3
Page Issue B
Type
Pin No
Function
Relay 1 - N/C (87a)
A1
NOT USED
Relay 2 - N/C (87a)
A2
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
A7
Valve CT2a
High Side Output
A8
Valve CT2b
High Side Output
A9
High Side Output
A10
Low Side Output
A11
High Side Output
A12
CT34b - 3rd Brush Rotation (CCW)
NOT USED
NOT USED
Relay 1 Common (30)
A13
Relay 2 Common (30)
A14
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
A18
Valve CT15
High Side Output
A19
Valve CT29
High Side Output
A20
WS2 - Washer / CT35b - 3rd Brush Slew Right
PWM 1 - Proportional Output
A21
CT33 - 3rd Brush Speed (Signal)
A22
PWM 1 Return
A23
CT33 - 3rd Brush Speed (Return)
PWM 2 Return
A24
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
High Side Output
A31
CT40 - 3rd Brush Raise
High Side Output
A32
CT41 - 3rd Brush Lower
PWM 3
A33
PWM 4
A34
PWM 3 Rtn
A35
PWM 4 Rtn
A36
NOT USED
Issue 02
29/09/2009
16:37
C200 - Maintenance

Inputs
C200 Euro 4/Tier 3
16:38
Type
Pin No
Low Side Input (-ve)
B1
Hopper Lower
Function
B2
Hopper Raise
B3
B4
B5
B6
Supawash Switch
B7
Fan Only Switch
B8
Handbrake Switch
B9
B10
B11
NOT USED
B12
NOT USED
B13
NOT USED
B14
NOT USED
B15
NOT USED
B16
NOT USED
B17
NOT USED
B18
NOT USED
B19
NOT USED
B20
NOT USED
B21
NOT USED
B22
NOT USED
B23
NOT USED
B24
NOT USED
Analogue - Output
B25
NOT USED
Analogue Input #1
B26
NOT USED
Analogue Input #2
B27
NOT USED
Analogue Input #3
B28
NOT USED
0V Output
B29
NOT USED
Third Brush Arm - Link
5V Output
B30
NOT USED
B31
NOT USED
B32
NOT USED
B33
NOT USED
B34
NOT USED
B35
B36
NOT USED
Outputs A11 & A15 Enable - Link
Issue 02
29/09/2009
Page Issue B
C200 - Maintenance
Power &
Comms
Connector 01
C200 Euro 4/Tier 3
Page Issue B
Type
Pin No
Function
Supply
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
Output
B2
Backlight LED #1
Output
B3
Backlight LED #2
Input
B4
Input
B5
Output
B6
Backlight LED #3
Input
B7
Output
B8
Backlight LED #4
Output
B9
Backlight LED #5
Input
B10
Output
B11
Input
B12
Output
B13
Backlight LED #6
Output
B14
Backlight LED #7
Input
B15
Output
B16
Output
B17
Backlight LED #8
Input
B18
Output
B19
Backlight LED #9
Input
B20
Input
B21
Output
B22
Backlight LED #10
Output
B23
Backlight LED #11
Input
B24
Common
B25
Common
Input
C1
Input
C2
Input
C3
Input
C4
Common
C5
Common
Input
D1
Input
D2
Input
D3
Input
D4
Common
D5
Common
Input
E1
Brush Slew Left
Input
E2
Brush Slew Right
Input
E3
Input
E4
Common
E5
Common
Input
F1
Brush Slew Left
Input
F2
Brush Slew Right
Input
F3
Input
F4
Common
F5
Common
Issue 02
29/09/2009
16:39
C200 - Maintenance
Power & Comms

Connector 6 Way
C200 Euro 4/Tier 3
16:40
Type
Pin No
Power
A1
Function
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
Ground
A6
Output
B1
Valve CT17 - Signal
Ground
B11
Valve CT17 - Ground
Output
B2
Valve CT18 - Signal
Ground
B12
Valve CT18 - Ground
Output
B3
Valve CT21 - Signal
Ground
B13
Valve CT21 - Ground
Output
B4
Valve CT22 - Signal
Ground
B14
Valve CT22 - Ground
Output
B5
Ground
B15
Input
B6
Ground
B16
PWM 1
B7
PWM 1 Rtn
B17
PWM 2
B8
PWM 2 Rtn
B18
Analogue Input +ve
B9
Analogue Input -ve
B19
Freq. Input
B10
Weight Load Indicator Sensor - Signal
Ground
B20
Weight Load Indicator Sensor - Ground
Output
B21
Ground
B31
Input
B22
Hopper Down sensor - Signal
Ground
B32
Input
B23
Ground
B33
Input
B24
Ground
B34
Input
B25
Ground
B35
Input
B26
Ground
B36
PWM 3
B27
PWM 3 Rtn
B37
Output/Power
B28
NOT USED
NOT USED
Proximity Sensors - Power Supply output
Ground
B38
NOT USED
Output/Power
B29
NOT USED
Ground
B39
Analogue Input 2
B30
Node Address #1 (open circuit)
Issue 02
Ground
B40
29/09/2009
NOT USED
Page Issue B
C200 - Maintenance
Power & Comms

Connector 6 Way
C200 Euro 4
Page Issue B
Type
Pin No
12V Supply
A1
Function
12V Supply
A2
CAN HI
A3
Engine CAN bus (J1939) - Hi
CAN LO
A4
Engine CAN bus (J1939) - Lo
Earth
A5
Earth
Earth
A6
Earth
High Side Ouput
B1
High Side Output
B2
B3
B4
B5
B6
Reversing Lights
B7
LH Brake Lights
B8
RH Brake Lights
B9
Rear Fog Lights
B10
Analogue Input
B11
NOT USED
NOT USED
NOT USED
- Input (Freq.)
B12
Transmit - OUT
B13
0V Ref
B14
5V Ref
B15
PWM 1 & 2 Rtn
B16
PWM 1 Out
B17
PWM 2 Out
B18
PWM 3 Out
B19
NOT USED
NOT USED
H - Bridge +
B20
+ Input
B21
- Input (Freq.)
B22
Receive - IN
B23
0V Ref
B24
NOT USED
5V Ref
B25
NOT USED
PWM 3 Rtn
B26
NOT USED
Analogue Input
B27
Analogue Input
B28
NOT USED
NOT USED
Fuel Level Sender (10-180)
Analogue Input
B29
H - Bridge -
B30
- Input
B31
Air Filter Service Switch
- Input
B32
- Input
B33
- Input
B34
Fuel Pre-Filter Water Sensor
- Input
B35
- Input
B36
Forward Signal
- Input
B37
Reverse Signal
- Input
B38
Brake Pedal Input
+ input
B39
+ input
B40
NOT USED
NOT USED
NOT USED
Issue 02
29/09/2009
16:41
C200 - Maintenance
Power & Comms

Connector 6 Way
C200 Tier 3
16:42
Type
Pin No
12V Supply
A1
Function
12V Supply
A2
CAN HI
A3
NOT USED
CAN LO
A4
Earth
A5
Earth
Earth
A6
Earth
NOT USED
High Side Ouput
B1
High Side Output
B2
B3
B4
Esos valve
B5
B6
Reversing Lights
B7
LH Brake Lights
B8
RH Brake Lights
B9
Rear Fog Lights
B10
Analogue Input
B11
- Input (Freq.)
B12
Transmit - OUT
B13
0V Ref
B14
5V Ref
B15
PWM 1 & 2 Rtn
B16
PWM 1 Out
B17
PWM 2 Out
B18
PWM 3 Out
B19
NOT USED
H - Bridge +
B20
+ Input
B21
- Input (Freq.)
B22
Receive - IN
B23
0V Ref
B24

NOT USED
NOT USED
5V Ref
B25
PWM 3 Rtn
B26
Analogue Input
B27
Analogue Input
B28
Analogue Input
B29
Engine Water Temperature (600-30)
H - Bridge -
B30
- Input
B31
- Input
B32
- Input
B33
- Input
B34
- Input
B35
- Input
B36
Forward Signal
- Input
B37
Reverse Signal
NOT USED
- Input
B38
Brake Pedal Input
+ input
B39
Glow Plugs On/Off
+ input
B40
Issue 02
29/09/2009
Page Issue B
C200 - Maintenance
C200 Euro 5/Tier 3
Type
Pin No
Ouput 1
CV1-1
Relay - Heated Windscreen & Mirrors
12v Feed
CV1-2
0v Feed
CV1-3
CANview - Ground
Output 2
CV1-4
NOT USED
12v Feed
CV1-5
NOT USED
0v Feed
CV1-6
NOT USED
Output 3
CV1-7
NOT USED
CAN-Lo
CV1-8
NOT USED
CAN-Hi
CV1-9
NOT USED
Output 4
CV1-10
J-Plex Rx
CV1-11
J-Plex Tx
CV1-12
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
Input 6
CV2-6
Fog Light Switch
Input 7
CV2-7
Input 8
CV2-8
Input 9
CV2-9
Input 10
CV2-10
Indicator RH
Input 11
CV2-11
Indicator Trailer
Input 12
CV2-12
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
Level 1
CV3-1
NOT USED
Tacho 1
CV3-2
NOT USED
Tacho 2
CV3-3
NOT USED
Level 2
CV3-4
NOT USED
Analogue Out
CV3-5
NOT USED
50mA Source
CV3-6
NOT USED
Level 3
CV3-7
NOT USED
Analogue In 1
CV3-8
NOT USED
5v Source
CV3-9
NOT USED
Level 4
CV3-10
NOT USED
Analogue In 2
CV3-11
NOT USED
Issue 02
CV3-12
NOT USED
29/09/2009
0v Source
Page Issue B
Function
16:43
C200 - Maintenance

Outputs
C200 Euro 5/Tier 3
16:44
Type
Pin No
Function
spare
A1
NOT USED
spare
A2
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
A7
Valve CT2a
High Side Output
A8
Valve CT2b
High Side Output
A9
High Side Output
A10
Low Side Output
A11
High Side Output
A12
CT34b - 3rd Brush Rotation (CCW)
spare
A13
spare
A14
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
A18
Valve CT15
High Side Output
A19
Valve CT29
High Side Output
A20
WS2 - Washer / CT35b - 3rd Brush Slew Right
A21
CT33 - 3rd Brush Speed (Signal)
A22
PWM 1 Return
A23
CT33 - 3rd Brush Speed (Return)
PWM 2 Return
A24
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
High Side Output
A31
CT40 - 3rd Brush Raise
High Side Output
A32
CT41 - 3rd Brush Lower
PWM 3
A33
PWM 4
A34
PWM 3 Rtn
A35
PWM 4 Rtn
A36
NOT USED
NOT USED
NOT USED
Issue 02
29/09/2009
Page Issue B
C200 - Maintenance

Inputs
C200 Euro 5/Tier 3
Page Issue B
Type
Pin No
Function
B1
Hopper Lower
B2
Hopper Raise
B3
B4
B5
B6
Supawash Switch
B7
Fan Only Switch
B8
Handbrake Switch
B9
B10
B11
NOT USED
B12
NOT USED
B13
NOT USED
B14
NOT USED
B15
NOT USED
B16
NOT USED
B17
NOT USED
B18
NOT USED
B19
NOT USED
B20
NOT USED
B21
NOT USED
B22
NOT USED
B23
NOT USED
B24
NOT USED
Analogue - Output
B25
NOT USED
Analogue Input #1
B26
NOT USED
Analogue Input #2
B27
NOT USED
Analogue Input #3
B28
NOT USED
0V Output
B29
NOT USED
5V Output
B30
NOT USED
B31
NOT USED
B32
NOT USED
B33
NOT USED
B34
NOT USED
B35
B36
Third Brush Arm - Link
NOT USED
Outputs A11 & A15 Enable - Link
Issue 02
29/09/2009
16:45
C200 - Maintenance
Power &
Comms
Connector 01
C200 Euro 5/Tier 3
16:46
Type
Pin No
Supply
A1
12-24V DC Supply
Function
Earth
A2
Earth
Comms Tx
A3
J-Plex Communication Signal - Transmit
Comms Rx
A4
J-Plex Communication Signal - Receive
Input
B1
Output
B2
Backlight LED #1
Output
B3
Backlight LED #2
Input
B4
Input
B5
Output
B6
Backlight LED #3
Input
B7
Output
B8
Backlight LED #4
Output
B9
Backlight LED #5
Input
B10
Output
B11
Input
B12
Output
B13
Backlight LED #6
Output
B14
Backlight LED #7
Input
B15
Output
B16
Output
B17
Backlight LED #8
Input
B18
Output
B19
Backlight LED #9
Input
B20
Input
B21
Output
B22
Backlight LED #10
Output
B23
Backlight LED #11
Input
B24
Common
B25
Common
Input
C1
Input
C2
Input
C3
Input
C4
Common
C5
Common
Input
D1
Input
D2
Input
D3
Input
D4
Common
D5
Common
Input
E1
Brush Slew Left
Input
E2
Brush Slew Right
Input
E3
Input
E4
Common
E5
Common
Input
F1
Brush Slew Left
Input
F2
Brush Slew Right
Input
F3
Input
F4
Common
F5
Common
Issue 02
29/09/2009
Page Issue B
C200 - Maintenance

C200 Euro 5/Tier 3
Power & Comms

Connector 6 Way
Type
Page Issue B
Pin No
Function
Power
A1
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
Ground
A6
Output
B1
Valve CT17 - Signal
Ground
B11
Valve CT17 - Ground
Output
B2
Valve CT18 - Signal
Ground
B12
Valve CT18 - Ground
Output
B3
Valve CT21 - Signal
Ground
B13
Valve CT21 - Ground
Output
B4
Valve CT22 - Signal
Ground
B14
Valve CT22 - Ground
Output
B5
Ground
B15
Input
B6
Ground
B16
PWM 1
B7
PWM 1 Rtn
B17
PWM 2
B8
PWM 2 Rtn
B18
Analogue Input +ve
B9
Analogue Input -ve
B19
Freq. Input
B10
Weight Load Indicator Sensor - Signal
Ground
B20
Weight Load Indicator Sensor - Ground
Output
B21
Ground
B31
Input
B22
Hopper Down sensor - Signal
Ground
B32
Input
B23
Ground
B33
Input
B24
Ground
B34
Input
B25
Ground
B35
Input
B26
Ground
B36
PWM 3
B27
PWM 3 Rtn
B37
Output/Power
B28
NOT USED
NOT USED
Proximity Sensors - Power Supply output
Ground
B38
NOT USED
Output/Power
B29
NOT USED
Ground
B39
Analogue Input 2
B30
Issue 02
Ground
B40
29/09/2009
NOT USED
16:47
C200 - Maintenance
Power & Comms

Connector 6 Way
C200 Euro 5
16:48
Type
Pin No
12V Supply
A1
Function
12V Supply
A2
CAN HI
A3
Engine CAN bus (J1939) - Hi
CAN LO
A4
Engine CAN bus (J1939) - Lo
Earth
A5
Earth
Earth
A6
Earth
High Side Ouput
B1
High Side Output
B2
Engine Cranking Signal to Engine ECU
B3
B4
B5
B6
Reversing Lights
B7
LH Brake Lights
B8
RH Brake Lights
B9
Rear Fog Lights
B10
Analogue Input
B11
NOT USED
NOT USED
NOT USED
NOT USED
- Input (Freq.)
B12
Transmit - OUT
B13
0V Ref
B14
5V Ref
B15
PWM 1 & 2 Rtn
B16
PWM 1 Out
B17
PWM 2 Out
B18
PWM 3 Out
B19
H - Bridge +
B20
+ Input
B21
- Input (Freq.)
B22
Receive - IN
B23
0V Ref
B24
NOT USED
5V Ref
B25
NOT USED
PWM 3 Rtn
B26
NOT USED
Analogue Input
B27
Analogue Input
B28
NOT USED
NOT USED
NOT USED
NOT USED
Analogue Input
B29
H - Bridge -
B30
- Input
B31
- Input
B32
- Input
B33
- Input
B34
- Input
B35
- Input
B36
Forward Signal
- Input
B37
Reverse Signal
- Input
B38
Brake Pedal Input
+ input
B39
+ input
B40
NOT USED
NOT USED
NOT USED
Issue 02
29/09/2009
Page Issue B
C200 - Maintenance
Power & Comms

Connector 6 Way
C200 Tier 3
Page Issue B
Type
Pin No
12V Supply
A1
Function
12V Supply
A2
CAN HI
A3
NOT USED
CAN LO
A4
Earth
A5
Earth
Earth
A6
Earth
NOT USED
High Side Ouput
B1
High Side Output
B2
B3

Esos valve
B4
B5
B6
Reversing Lights
B7
LH Brake Lights
B8
RH Brake Lights
B9
Rear Fog Lights
B10
Analogue Input
B11
NOT USED
NOT USED
- Input (Freq.)
B12
Transmit - OUT
B13
0V Ref
B14
5V Ref
B15
PWM 1 & 2 Rtn
B16
PWM 1 Out
B17
PWM 2 Out
B18
PWM 3 Out
B19
NOT USED
H - Bridge +
B20
+ Input
B21
- Input (Freq.)
B22
Receive - IN
B23
0V Ref
B24
5V Ref
B25
PWM 3 Rtn
B26
Analogue Input
B27
Analogue Input
B28
Analogue Input
B29
Engine Water Temperature (600-30)
H - Bridge -
B30
- Input
B31
- Input
B32
- Input
B33
- Input
B34
- Input
B35
- Input
B36
Forward Signal
- Input
B37
Reverse Signal
- Input
B38
Brake Pedal Input
+ input
B39
Glow Plugs On/Off
+ input
B40
NOT USED
Issue 02
29/09/2009
16:49
C200 - Maintenance
Cable Colour Codes
B
B/U
B/N
B/G
B/P
B/R
B/S
B/S/R
B/W
B/W/G
B/Y
=
=
=
=
=
=
=
=
=
=
=
Black
Black
Black
Black
Black
Black
Black
Black
Black
Black
Black
U
U/N/K
U/G
U/T
U/R
U/W
U/Y
=
=
=
=
=
=
=
Blue
Blue with Brown and Pink Tracers
Blue with Green Tracer
Blue with Orange Tracer
Blue with Red Tracer
Blue with White Tracer
Blue with Yellow Tracer
with Blue Tracer

with Brown Tracer
with Green Tracer
with Purple Tracer
with Red Tracer
with Slate Tracer
with Slate and Red Tracers
with White Tracer
with White and Green Tracers
with Yellow Tracer
N
N/B
N/K
N/Y
=
=
=
=
Brown
Brown with Black Tracer
Brown with Pink Tracer
Brown with Yellow Tracer
G
G/B
G/U
G/K
G/P
G/R
G/S
G/W
G/Y
=
=
=
=
=
=
=
=
=
Green
Green with Black Tracer
Green with Blue Tracer
Green with Pink Tracer
Green with Purple Tracer
Green with Red Tracer
Green with Slate Tracer
Green with White Tracer
Green with Yellow Tracer
W/G
W/P
W/R
= White with Green Tracer

= White with Purple Tracer
= White with Red Tracer
16:50
L-G
L-G/B
L-G/K
L-G/K/S
=
=
=
=
Light
Light
Light
Light
P
P/B
P/W
P/Y
=
=
=
=
Purple
Purple with Black Tracer
Purple with White Tracer
Purple with Yellow Tracer
R
R/B
= Red
= Red with Black Tracer
R/N
R/G
= Red with Brown Tracer

= Red with Green Tracer
R/W
R/Y
= Red with White Tracer

= Red with Yellow Tracer
Green
Green with Black Tracer
Green with Pink Tracer
Green with Pink and Slate Tracers
= Slate
W
W/B
W/U
W/N
=
=
=
=
White
White with Black Tracer
White with Blue Tracer
White with Brown Tracer
Y
Y/B
Y/N
Y/T
Y/K
Y/W
=
=
=
=
=
=
Yellow
Yellow with Black Tracer
Yellow with Brown Tracer
Yellow with Orange Tracer
Yellow with Pink Tracer
Yellow with White Tracer
Page Issue B
C200 - Maintenance
17
CHAPTER
Water System
Table of Contents
Page Issue 04
Section
Page
Lost Water System
17 : 2
Recirculation System
17 : 3
To Set Water Flow Rate
17 : 4
To Set/Check Pump Pressure (HP Jetting Option)
17 : 4
Lost Water Spray Circuit
15 : 5
Expanding Spray Bar Water Hose Circuit
17 : 6
Fixed Spray Bar Water Hose Circuit
17 : 7
Folding Spray Bar Water Hose Circuit
17 : 8
17:1
C200 - Maintenance
Maintenance & Adjustment Instructions

(refer to Operators Guide for Additional Information)
The water system comprises of two circuits:
1. Lost Water System
A. Dust suppression for sweeping.
B. High Pressure Washer.
2. Recirculation Water System
Lost Water System

Filter
The filter may be cleaned and inspected by removing the nine
bolts retaining the suction tube assembly.
Retaining
Screws
Water
Filter
Pump
Located under the RH seat, it is controlled by an intergral electrical
motor. Normal operating pressure is 3 - 4 Bar.
Spray Jets
In order to prevent the water spray jets from blocking, small
strainers are fitted behind each jet. If for some reason the jets
do become blocked, the strainers and jets can be removed by
loosening the nut retaining each jet and cleaning in water.
17:2
Page Issue 04
C200 - Maintenance
Supawash
Supawash is operated using the centre panel mounted rocker switch, ensuring first that, the machine is in
neutral and at tickover. Running the engine any faster whilst using the Supawash equipment may cause
permanent damage to the motor.
Recirculation System
Removal
The recirculation pump is located in the
recirculation tank. To remove this the hopper
must be raised and the hinged ram props put
into position. Remove the recirculation water
tank cover and disconnect the water hoses from
the pump and the two hydraulic pipes. Keep the
hydraulic pipes above the tank level to prevent
oil from siphoning from the hydraulic tank or,
connect the two pipes together with a 3/8
straight connector. The pump may then be
unbolted from the side of the recirculation tank
and removed.
Refitting
Water Hose
Connections
Tank
Cover
Hydraulic Hose
Connections
Recirculation
Pump
Pump Securing Nuts

and Spacers
The refitting of the recirculation pump is effected

in the reverse of removal. Ensure the pump is
piped correctly before using the machine.
Flow Regulator Water Pump/Brush Motors

A flow regulator is provided at the rear of the machine to divide the oil from the fan motor to drive the
recirculating water pump and brush motors. This is set during the test procedure (see chapter 14) and will
only require resetting if replaced. Under no other circumstances should this be tampered with; otherwise
damage to the water pump may occur.
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C200 - Maintenance
To Set Water Flow Rate

1.
Ensure recirculation water tank and lost water tanks are

filled.
2.
Start engine and engage work mode.
3.
Activate green sweep button on arm rest controller, allow

machine to settle.
4.
With hopper in raised position observe the flow of water

falling into the suction tube . Water must be flowing down
the centre of the main suction tube.
5.
Remove cap from flow regulator to access centre screw.
5.
Adjust centre screw of flow regulator by undoing lock nut

and winding screw in for more flow.
6.
Disengage sweep/work mode mode, switch off engine.
7.
Refit cap to flow regulator block.
To Set/Check Pump Pressure (Supawash Option)

1.
Remove jetting gun from holster.
2.
Attach lead from pressure gauge to test point.
3.
Start engine and engage work mode.
4.
Activate supawash option using button on centre console.
5.
Point jetting gun in a safe direction, pull trigger and note what
pressure the gauge goes to. Supawash pressure is set at
1000PSI + 20.
6.
Adjust pressure using adjuster screw on side of the jetting

pump. Once adjustment is complete seperate lock nuts and
wind them all the way to the base of the adjuster screw to lock
it.
7.
Return gun to holster and switch off supawash.
17:4
Page Issue 04
Page Issue 05
Jetting
Pump
Water
Pump
Cab
"
"
6mm
Side Brush
Front Water
Jet
Side Brush
Front Water
Jet
3rd Brush
Front Water
Jet
(Option)
Lost Water Spray Circuit - Sweeper
RH Water Tank
Jetting
Option
Only
C200 - Maintenance
17:5
C200 - Maintenance
CW200 Water Hose Circuit - Expanding Spray Bars
17:6
Page Issue 04
C200 - Maintenance
CW200 Water Hose Circuit - Fixed Spray Bars
Page Issue 04
17:7
C200 - Maintenance
CW200 Water Hose Circuit - Folding Spray Bars
17:8
Page Issue 04
C200 - Maintenance
CHAPTER
18
Wearing Items
Table of Contents
Page Issue 04
Section
Page
Suction Fan
18 : 2
Suction Head and Flexible Intake Ducting
18 : 2
Suction Head Flap
18 : 3
Suction Head Slide
18 : 3
Suction Head Skids/Wheels
18 : 4
Side Brushes
18 : 5
Hopper Entry Duct
18 : 5
Flap Housing
18 : 5
18:1
C200 - Maintenance
The hinged props located at each hopper ram mounting must be used at all times to prop the
hopper when carrying out any inspection, servicing or maintenance work beneath the hopper.
To prevent damage to electrical components, the battery and alternator leads must be
disconnected before carrying out any re-work to the electrical system, or before starting electrical
welding to any part of the vehicle.
Suction Fan
Removal: Remove hose connectors from fan
motor on roof of hopper, mopping up any spilt oil.
Remove the ring of screws holding the fan case
cover plate to the fan case and lift out complete fan
drive assembly. The fan can then be removed by
undoing the retaining screw and pulling clear of the
shaft, ensuring the shaft key is not lost.
Fan
Motor
Refit: Lightly smear the fan shaft with grease,

refitting is then the reversal of the removal
procedure. Torque fan retaining screw to a figure of
200 Nm.
Cover Retaining
Screw
Fan Case
Cover
Suction
Fan
Fan Retaining
Screw
Suction Head and Flexible Intake Ducting

Suction Head
Removal: The suction head is best removed by first lowering
it together with the brushes, which should be positioned to
their full outward position. This can be done by stopping the
engine with the sweep gear engaged in the work position. The
suction head can then be removed by removing the bolt
holding the tow arm to the cab and loosening the worm drive
hose clip on the flexible trunking.
Refit: Refitting the suction head is the reverse of the removal
procedure. Ensure the trunking is not twisted or rucked and
does not foul anything when the nozzle is raised and lowered.
Failure to observe this precaution can cause premature wear.
Flexible Intake Trunking

Removal: This trunking is located underneath the cab and connects the suction head to the steel intake duct.
Removal is effected by first removing the suction head, (see suction head removal), once the suction head is
removed the trunking can be removed by loosening the worm drive hose clip at the lower end of the intake
duct.
Refit: Loosely fit the worm drive clips to each end of the trunking and refit to the intake tube, securing the
worm drive clip at the upper end once positioned. The suction head may then be refitted, (see suction head
refitting).
18:2
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C200 - Maintenance
Suction Head Flap

Removal: At the frontal end of the suction head is a
large rubber flap which is secured by seven bolts, a
clamp plate and flap support. A tie flap is attached at
the inner end to control the position of suction head
flap, the tie flap is secured by screw fasteners. The
purpose of the rubber flap is to produce an effective
air stream to collect any swept material. The rubber
flap being flexible adjusts automatically to working
conditions.
All of these items are easily removed by first removing
the suction head, (see suction head removal), and
then the tie flap which is secured to the upper panel of
the suction head and the inner end of suction head
flap. The seven bolts holding the clamp plate and
suction head flap to the flap support may then be
released and the flap removed. The flap support may also be removed, if required, by releasing the seven
additonal bolts holding it to the suction head.
The flap support gives the rubber suction head flap additional resistance to flexing. If the flap support is not
fitted a loos of suction performance may result, and therefore the component should be kept in good order.
Refitting: Is effected in the reverse of the removal procedure. Care must be taken that all parts are replaced.
The suction head should then be refitted, (see suction head refitting).
Suction Head Slide

Removal: The suction head slide is located around the rear
of the suction head and is manufactured from
polypropylene. To remove the slide, the suction head must
first be removed from the machine, (see suction head
removal). The suction head must be overturned and by
releasing the seven countersunk 8mm screws, the slide
may be removed.
Refitting: This is done by placing the slide on the suction
head and re-securing the screws, taking care not to over
tighten them, which can have the effect of pulling the screw
head through the material.
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18:3
C200 - Maintenance
Suction Head Skids/Wheels

Suction Head Skids
There are three suction head skids one at the rear and one
either side of the suction head. These can be removed and
adjusted without removing the suction head from the
machine. Each skid is held on by two nyloc nuts and bolts
and the skid is adjusted by releasing the nuts and
adjusting in the slots provided.
Suction Head Wheels

There are three suction head wheels, one at the rear and one
either side of the suction head. The tyres can be removed
without removing the suction head from the machine. Each
wheel rubber tyre is held on by three retaining screws " UNC
and a wheel flange. By releasing the retaining fixings and
flange the tyre may be removed.
When refitting the skids/wheels/tyres make sure they are adjusted so that there is a 5 - 10 mm air gap
between the sweeping surface and the suction head slide, see Operators Guide for further details.
18:4
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C200 - Maintenance
Side Brushes
Removal: It is preferable to have the brushes in the
working position and stationary. This is effected by
stopping the engine with the sweep gear engaged.
Release the four nuts from the bolts securing the brush
stock to the driving plate, remove brush.
Brush Stock
Securing Nuts
Refitting: Refitting of the brush is the reverse of the

removal procedure.
See Operators Guide for details on Brush Settings.
Entry Duct
Removal: The entry duct is located in the intake to
the hopper. To remove the duct the hopper should be
in the raised position, with the hopper props in place.
The entry duct may then be released by removing the
four retaining bolts, and withdrawing the duct.
Retaining
Screws
Hopper
Entry Duct
Refitting: Refitting of the entry duct is the reverse of

the removal procedure.
Flap Housing
Flap
Mechanism
Recirculation
Water Pipe
Removal: The flap housing is located between the

flexible intake trunking and the hopper entry duct. To
remove the housing the hopper should be raised with
the hopper props in place. Remove nozzle trunking as
described previously. Disconnect flap operation
mechanism. Disconnect recirculation water pipe.
Remove four bolts retaining housing to chassis. Lift
upwards to remove.
Refitting: Refit procedure is the reverse of the
removal procedure. Firstly, fit the flap operation
mechanism ensuring it is greased and lubricated prior
to fitment of the flap housing.
Retaining
Bolts
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18:5
C200 - Maintenance
18:6
Page Issue 04
C200 - Maintenance
CHAPTER
19
Remove & Refit Procedures
Table of Contents
Page Issue 05
Section
Page
Suspension Spring & Damper Unit

Third Brush Remove & Refit Procedure
19 : 2
19 : 5
19:1
C200 - Maintenance
Suspension Spring & Damper Unit

1. In order to replace a damper unit, the damper and coil spring assembly needs to be removed from the
vehicle.
In the event that the damper to be replaced is at the front of the vehicle, the front of vehicle must be raised
such that both front tyres are clear of the ground. This can be achieved by using the bottle jack with the
front axle jacking point (if fitted) or a trolley jack under the middle of the front axle.
If a rear damper needs to be replaced, only the tyre of the affected corner of the vehicle needs to be
raised clear of the ground. Again this can be achieved with the bottle jack at the rear jacking point or a
trolley jack under the relevant rear trailing-arm. It may be deemed desirable to raise the whole of the rear
of the vehicle for greater stability. This can done using a trolley jack under the cross-member between the
rear wheels.
2. Place a chassis stand under the vehicle at a suitable point that will carry the vehicle's weight once the
jack is removed. Remove the wheel/tyre from the affected corner but leave the jack in place.
3. At the front of the vehicle, a wire rope check strap limits suspension rebound-travel. Undo and remove
the M12 nyloc nut from the lower end of the check strap. Discard the nut.
At the rear of the vehicle, a fabricated steel bracket limits suspension rebound-travel. Undo and remove
the M10 nyloc nut and long bolt that secures the bracket to the trailing-arm.
4. Undo, remove and discard the M16 nyloc nut that secures the damper assembly's bottom eye to the front
axle/rear trailing-arm. Do not attempt to remove the bolt at this stage.
5. Withdraw the jack, leaving the vehicle supported by the chassis stand.
6. Withdraw the M16 bolt from the damper's bottom mounting eye. Remove the 2 locknuts from the top end
of the damper and lift off the large washer and upper-top mounting bush. Especially if working on the front
of the vehicle, space constraints may dictate that the washer and upper-top bush are left in place and
retrieved after the damper is removed. In this case care should be exercised not to dislodge and loose
these components. It may prove easier to undo the bottom locknut if the damper assembly is supported
from under the vehicle. A trolley jack can be used quite effectively for this purpose.
Extract the damper assembly from the vehicle.
7. Carefully inspect the upper and lower top bush for splits and excessive compression-set damage. Pay
particular attention to the lower-top bush around the locating spigot. Renew any damaged bushes.
8. At the lower end of the front damper there is a balljoint inside a rubber boot. Inspect the boot for cuts,
tears and perishing and replace if necessary. Any of these failings could result in the ingress of dirt
causing premature wear of the balljoint.
Using side-cutters carefully cut the cable tie from the top of the rubber boot. Ease the boot over the
bottom mounting bosses.
If the damper is to be refitted the balljoint should be inspected for wear or damage. Closely examine both
the internal and external bearing faces for pitting and scoring. The balljoint should be renewed if any
damage is evident. It is pressed into the damper's bottom eye and secured by 2 circlips, one either side.
To remove the balljoint first remove both circlips, then press the balljoint from the damper's eye using
suitably sized tubular spacers. Be sure to press only on the outer part of the bearing.
If the damper is to be renewed remove the mounting bosses so that they can be reused.
If working on the rear of the vehicle inspect the bottom bush. This is a two-part bush; one part is pressed
into the damper's bottom eye from each side. A supporting steel sleeve is then pressed into the middle of
the bush.
19:2
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C200 - Maintenance
9. In order to dismantle the damper/coil spring assembly it is necessary to compress the springs in order to
relieve the load on the damper and access the locknut that secures the damper top. This will enable the
threaded damper top to be unscrewed from the damper shaft.
The easiest way to achieve this is by using a suitably sized hydraulic or pneumatic press, blocks on which
to stand the assembly and Johnston special tool TN8362.
Position the blocks on the press bed such that there is sufficient gap between them for the damper lower
mounting eye. Stand the damper/coil spring assembly on the blocks such that the damper's bottom spring
seat locating ring is against the top of the blocks and the damper's lower mounting eye is between them.
Fit TN8362 to the assembly with the underside of the horseshoe section against the top face of the top
spring seat and the shaft of the damper top through the hole in the tool. Fit a spacer over the damper
top's shaft.
10. Use the press to gently apply force to the special tool
via the spacer tube until the fork plate from the special
tool can be inserted between the top face of the upper
spring seat and the bottom face of the damper top's
lock nut (ie: the nut in the centre of the coil springs).
11. Ensure the fork plate is pushed in as far as possible.
Release the press and remove the spacer and the
loose part of the special tool. Hold the locknut using a
thin open-ended spanner and hold the damper top by
its machined flats using either a second open-ended
spanner or by clamping it in a vice. Unscrew the
damper top from the damper. This may require some
considerable force, as thread-locking compound will
have been used during assembly.
Spacer
TN8362
12. Once the damper top has been removed from the assembly, refit the
special tool and spacer tube. Position the assembly on the press as
before. Again, apply force to the special tool via the spacer tube until
the fork plate from the special tool is loose. Remove the fork plate
and carefully release the pressure of the press from the springs.
13. The springs and spring seats can now be removed from the damper.
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19:3
C200 - Maintenance
14. Re-assembly is the reverse of the dismantling process. The following points should be noted:
I.
Use only matched sets of springs on any axle. The springs are colour coded; front springs are painted
red; rear springs are painted black. It is also ill advised to replace springs individually: the suspension
springs can soften with use and age and should always be replaced as an axle set. Failure to do so
may result in unpredictable and potentially dangerous handling in, for example, an emergency
braking situation.
II. Ensure that the damper's shaft is fully extended before attempting to assemble the unit.
III. Ensure that the bump-rubber is in place on the damper-shaft.
IV. Use a suitable thread-locking compound when securing the damper-shaft to the damper top.
V. Ensure that the spigots on the upper- and lower-top bushes are correctly located in the mounting hole
in the chassis. Tighten the locknuts until the washer is 29mm from the very end of the damper top.
Once fully reassembled, briefly road test the vehicle and re-check the upper-top bush. If this bush is
not securely located, tighten the locknuts further as necessary.
VI. The front damper bottom balljoint MUST NOT BE LUBRICATED. This is a dry bearing and any form
of lubrication can result in the bearing swelling and failing. Ensure that an intact protective boot is
fitted and secured to the bottom section of the outside of the damper's body using a cable tie.
VII. Use new nyloc nuts. This is especially important on the end of the front axle check-strap and the
bottom-eye mounting bolts. Torque the bottom mounting bolts to 174Nm.
VIII.The front axle check straps are set by tightening the M12 nyloc nut on the bottom end of the strap
until the adjacent front springs are compressed by a nominal 8mm.
IX. Ensure that the rear fabricated travel limiter bracket is correctly fitted. Loosely fit the M16 bolt through
the trailing arm, damper bottom bush and the bracket with the 10mm holes pointing down. Jack up
the trailing arm until the bracket can be swung into place. Fit the M10 bolt and torque it to 40Nm.
19:4
Page Issue 04
C200 - Maintenance
Third Brush Remove & Refit Procedure

The following stages outline the recommended procedure for the safe de-mounting and storage of the third
brush equipment.
8
10
6
1.
Position vehicle in workshop location where third brush is to be stored; allowing for an adequate
working area around the front of the vehicle.
2.
Start engine and position side brush arms to their outermost position using joysticks G16/G17.
3.
Activate third brush controls on arm controller by pressing switch G14. Using joystick controls G16/G17
move third brush until it is in the fully extended/raised position.
4.
Turn off vehicle ignition and remove key (for safety).
5.
Slide in brush arm lock and locate in position using M10Cx110 bolt and nyloc nut.
6.
Insert two M8Cx50 bolts to lock arm assembly into position.
7.
Position third brush support as illustrated using locating bolts and secure using M14C plain nuts.
8.
Attach jockey wheels to either end of third brush support. Adjust leg to allow for free movement of
wheel and to take load of third brush.
9.
Disconnect all third brush hydraulic/water quick release couplings and electrical connections (located
on underside of chassis nose-cone). Insert quick release coupling caps for hydraulic/water connections.
Insert electrical blanking cap (supplied in tool kit).
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19:5
C200 - Maintenance
10. Remove lower then upper brush arm mounting plate bolts; the third brush assembly will tip forwards
slightly once the bolts are fully removed.
11. Pull third brush assembly clear of vehicle. It is advisable to support the fully de-mounted third brush
assembly with an axle stand or similar during storage.
12. Start engine; side brushes will return to their parked position automatically.
13. To re-mount the third brush assembly follow the above procedure in reverse. Ensure that the electrical
harness connection is fully locked into position when re-connecting.
14. Once the third brush assembly has been refitted; test for correct operation to ensure that any trapped
air has been fully purged from the system.
19:6
Page Issue 05
C200 - Maintenance
CHAPTER
20
Fault Diagnosis
Table of Contents
Page Issue 04
Section
Page
Engine
20 : 2
Cab
20 : 2
Lights
20 : 3
Brushes
20 : 4
Suction Nozzle/System
20 : 4
Water System
20 : 5
20:1
C200 - Maintenance
Engine
Engine not cranking
-
Check that the transmission stalk is in the neutral position.

Check rear cab fuses A4 & A5, megajet controller.
Ensure battery has adequate charge to crank engine.
Ensure brake pedal is depressed fully.
Check brake pedal switch.
Engine cranking but not starting

-
Check fuel gauge for fuel level.

Check rear cab fuses A4 & A5, megajet controller.
Slacken bleed screws on injection pump to check for fuel and the omission of air.
Check glow plug operation.
Cab
CANview inoperative
- Check overhead console fuse D4.
Handbrake warning buzzer inoperative
- Check handbrake switch at base of handbrake.
Cab heater inoperative
-
Check
Check
Check
Check
rear cab fuse A6.

feed at heater switch.
feed and connections to cab heater motor.
earth connection.
Windscreen wiper/washer inoperative

-
Check steering column fuse C6.

Check column switch operation.
Check for feed at wiper motor.
Inspect wiper motor assembly/mechanism.
Horn inoperative
- Check steering column fuse C6.
- Check live feed at horn when switch depressed.
- Check earth point.
20:2
Page Issue 04
C200 - Maintenance
Lights
Brake lamps inoperative
-
Check
Check
Check
Check
rear cab fuses A4 & A5, megajet controller.

bulbs.
connections to bulb holder.
wiring and connections to brake lamp switch.
Side lamps inoperative

- Check bulbs in lamp clusters.
Indicator lamps inoperative
- Check steering column fuse C1 for lhd or fuse C2 for rhd vehicles.
- Check bulbs.
- Check wiring to indicator lamps.
Head lamps dip beam inoperative
- Check feed to headlamp bulbs.
Beacon inoperative
-
Check
Check
Check
Check
rear cab fuse A7.

feed at beacon.
switch operation.
drive band condition.
Work lamps inoperative

- Check feeds to work lamps.
- Check switch operation.
Page Issue 04
20:3
C200 - Maintenance
Brushes
Brush arm water sprays inoperative
- Check earthing point at rear of cab.
- Check water pump relay R2.
- Check rear cab fuse A2, internal control node.
Brushes bounce when operated
- Check brush plates for damage, replace if bent.
- Check for excessive wear in brush arm linkage.
Brushes do not sweep effectively
-
Check
Check
Check
Check
brush
brush
brush
brush
angles are correct.

balance is set correctly, i.e; brush is touching the ground.
overlaps the nozzle opening.
speed.
Excessive brush wear

- Check brush balance is not too heavy.
- Check earth connection on powathrust pedal (i.e; bad earth).
Suction Nozzle/System
No pick up performance
-
Ensure nozzle duct blanking plate is not activated for wanderhose.

Check hopper door is shut correctly.
Suction nozzle or trunking is not blocked or restricted by debris.
Hopper full, discharge load and clean out.
Poor pick up perfomance

-
20:4
Remove and clean hopper mesh screens, ensure that ducting to the mesh is clean.
Check suction nozzle slide ground clearance, 5mm.
Check suction nozzle trunking and hopper inlet duct for wear, replace if necessary.
Check suction nozzle flap, flap support and tie.
Check condition of all hopper seals, replace if necessary.
Ensure fan impeller is clean and not blocked.
Check wanderhose is correctly stowed, not holed or worn allowing air to be drawn through.
Check recirculating water pump operates and is not seized.
Page Issue 04
C200 - Maintenance
Water System
Clean water system inoperative
-
Ensure sufficient water is in tanks and pump is primed.

Check filter behind jet is not blocked.
Check and clean water spray pump suction filter, if blocked.
Check electrical feed to pump.
Recirculating water system inoperative

-
Check pipe to inlet duct is not blocked.

Ensure recirculating tank cover mesh filter is clean.
Check water pump impeller is not seized.
Ensure recirculating screens to the front and sides of the hopper sludge drainage channels are
clean.
High pressure washer inoperative

-
Check
Check
Check
Check
drive selection is in neutral.

machine is not in work mode.
switch illuminates when pressed.
feed to valve on pump.
No water pressure
- Check pump inlet for air leaks.
Page Issue 04
20:5
C200 - Maintenance
20:6
Page Issue 04
C200 - Maintenance
CHAPTER
21
Service Tools
Table of Contents
Page Issue 04
Section
Page
Service Tools
21 : 2
21:1
C200 - Maintenance
The following tools are available through our Spares Network

Tool No.
Description
Function
437/3
Pressure Gauge Set
Used to measure hydraulic and water pressures.
437/4
Optical Tachometer
Used to measure fan rpm.
437/7
0.55 Litres/min Flow Gauge
Used to measure hydraulic flows.
437/8
Impulse Adaptor
Connects to 437/4 to measure engine speeds

from fuel injection pipes.
21:2
Page Issue 04
C200 - Maintenance
CHAPTER
22
Health and Safety
Introduction
The information presented in this chapter does not infer that there are
hazards associated with the Johnston sweepers. It is given as a guide to
general precautions that should be exercised in the course of their
maintenance work.
Whilst every effort has been made to ensure completeness of this
document, owners and operators of Johnston sweepers are reminded of
their responsibilities to comply with all relevant legislation including
Risk/COSHH Assessments and Approved Codes of Practice.
Page Issue B
Chapter - Health and Safety
22:1
C200 - Maintenance
Health and Safety Precautions
The information presented in this section does not infer there are any particular hazards
associated with these machines. It is given as a guide to the general precautions that
should be taken in any workshop environment when working on machines of this nature
in the course of their maintenance.
Safety symbol:
The universal symbol is used throughout this manual to indicate information which is
essential for health and safety of all operating personnel.
Refer to all state, district/company, or council Health and Safety Regulations and follow
the procedures laid down.
The repair and maintenance of machinery such as this can involve physical hazards or
other risks to health. This section lists some of these hazards and the precautions
necessary to avoid them.
The list is only general but all other operations, procedures and the handling of materials
should be carried out in accordance with the requirement of health and safety laws, which
is the responsibility of the Owner/Operator/Maintainer.
Anti Freeze:
Anti-freeze may be absorbed though the skin in toxic or harmful quantities.
If swallowed, seek medical attention immediately.
Some types, i.e., isopropanol, ethylene glycol and methanol are flammable.
Batteries:
Gases released during charging are explosive. Never use naked flames or allow sparks
near charging or recently charged batteries.
Disconnection:
Disconnect the negative battery lead from battery first. The positive cable must always be
disconnected last.
Reconnection:
Always reconnect the positive battery cable first.
Jump-starting and use of auxiliary (booster) batteries:

Do not jump-start maintenance free batteries if in a deeply discharged state as internal
short circuits may occur.
If a maintenance free battery is found to be in a deeply discharged state, it is essential to
remove the battery and recharge off the vehicle. Jump-starting will not enable the vehicles
own charging system to initiate the charging process.
22:2
Page Issue B
C200 - Maintenance
Jump starting procedure:
Always follow this procedure when connecting a booster battery.
Take care not to cause sparking which could ignite hydrogen gas being given off by the
batteries.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Apply the park brake, turn off ignition, lights and other electrical loads.
If the slave battery is mounted on another vehicle, ensure that the vehicles are not
touching.
Ensure that the donor battery voltage is compatible with the vehicle battery.
Ensure that adequate ventilation is available to the vehicle and slave batteries.
Connect positive terminal of the donor battery group to positive terminal of the
discharged battery group.
Connect negative terminal or slave battery group to chassis earth of the
discharged battery group.
Attempt to start the casualty vehicle.
Once the vehicle has started, remove the negative lead from the chassis and then
the slave battery.
Remove positive lead from discharged chassis and then the donor chassis.
If the vehicle will not start with a booster battery, contact your local Johnston Service
Network.
Chemical materials:
Chemical materials such as solvents, sealers, adhesive, paints, resin foams, battery acids,
anti-freezes, brake fluids, oils and grease should always be used with caution and stored
and handled with care.
Chemical materials may be toxic, harmful, corrosive, irritant or highly flammable and give
rise to hazardous fumes and dust.
Always consult the appropriate safety standards for handling such materials.
Typical biohazard symbol
Typical radioactive material symbol
Typical poison symbol
Always use appropriate protective clothing
Page Issue B
22:3
C200 - Maintenance
Reminders
Chemical materials
DO
remove chemical materials from the skin and clothing as soon as practical after soiling.
Change heavily soiled clothing and have it cleaned.
DO
carefully read and observe hazard and precaution warnings given on hazardous material
containers and in any accompanying leaflets, posters or other instructions. Hazardous
material health and safety data can be obtained from manufacturers.
DO
organise work practices and use protective clothing to avoid soiling of the skin and eyes;
breathing vapours, aerosols, dust, and fumes; inadequate container labelling; fire and
explosive hazards.
DO
wash before job breaks, before eating, smoking, drinking or using toilet facilities when
handling chemical materials.
DO
keep work areas clean, uncluttered and free of spills.
DO NOT
mix chemical materials except in accordance with the manufacturers instructions. Some
chemicals can form other toxic or harmful substances; give off toxic or harmful fumes; be
explosive when mixed together.
DO NOT
spray chemical materials, particularly those based on solvents, in confined spaces; for
example, when people are inside a vehicle.
DO NOT
apply heat or flame to chemical materials, except under the manufacturer's instructions.
Some are highly flammable and some may release toxic or harmful fumes.
DO NOT
leave containers open. Fumes given off can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than air and will accumulate in confined areas,
pits, etc.
DO NOT
transfer chemical materials to unlabelled containers.
DO NOT
clean hands or clothing with chemical materials. Chemicals, particularly solvents and
fuels will dry the skin and may cause irritation with dermatitis. Some can be absorbed
through the skin in toxic or harmful quantities.
22:4
Page Issue B
C200 - Maintenance
Dusts:
Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from
powdery chemical materials or those arising from dry abrasion operations.
Wear respiratory protection in accordance with the requirement of the Health and Safety
Acts.
Electric shocks:
When working on electrical systems, remove watches, bracelets and rings as these can
conduct electricity and cause shorts and/or burns.
Electric shocks can result from the use of faulty electrical equipment or from the misuse
of equipment even in good condition.
Ensure that electrical equipment is maintained in good condition and frequently inspected
and tested.
Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or
otherwise damaged.
Ensure that electrical equipment is protected by the correct rated fuse and if used outside
an earth-leakage circuit breaker is used.
Never misuse electrical equipment and never use equipment that is in any way faulty. The
results could be fatal.
Use reduced voltage equipment (110 or 24 volt) for inspection and working lights where
possible.
Ensure that the cables of mobile electrical equipment cannot be trapped and damaged
such as in a vehicle hoist, trolley jacks, etc.
Use air operated mobile equipment where possible in preference to electrical equipment.
Exhaust fumes:
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon
oxides, nitrogen oxides, aldehydes, leads and aromatic hydrocarbons.
Engines should only be run under conditions of adequate extraction or general ventilation
and not in confined spaces.
NB : Catalyst exhausts/silencers can run at extremely high temperatures.
Fire and welding:

Observe strict fire safety when storing and handling flammable materials or solvents,
particularly near electrical equipment or welding processes.
Disconnect battery, microprocessors, etc. before commencing welding. Failure to observe
this could cause failure of components.
Ensure before using electrical or welding equipment that there is no fire hazard present.
Have a suitable fire extinguisher available when using welding or heating equipment.
Special precautions must be taken before any welding or cutting takes place on vessels
which have contained combustible materials, e.g. fuel tanks.
The sound insulation foam used on the equipment must be removed if any welding is to
be carried out in that area of the machine.
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C200 - Maintenance
First aid:
It is desirable for someone in the workshop to be trained in the first aid procedures.
Splashes or particles in the eye should be flushed with clean water for at least ten minutes
and medical attention sought.
Soiled skin should be washed with soap and water.
Inhalation affected individuals should be removed to fresh air immediately.
If hazardous material has been swallowed or if the effects of exposure to hazardous
materials persist, consult a doctor with information (label) on material used.
Do not induce vomiting (unless indicated by the manufacturer).
High-pressure air and lubrication equipment:

Always keep high-pressure equipment in good condition and regularly maintained,
particularly at joints and unions.
Never direct a high (or low) pressure nozzle at the skin as the fluid may penetrate to the
underlying tissue, etc, and cause serious and potentially fatal injury.
Oils and greases:

Prolonged and repeated contact with mineral oil may result in the removal of natural fats
from the skin, leading to dryness, irritation and dermatitis.
Gross and prolonged contact, especially with used engine oil, which contains potentially
harmful contaminants, may cause skin cancer.
Where there is a risk of eye contact, e.g., by splashing, eye protection should be worn, for
example, chemical goggles or face shields; in addition, an eyewash facility should be
provided.
Adequate means of skin protection and washing facilities should be provided.
Repeated or prolonged skin contact should be avoided by wearing protective clothing,
including impervious gloves where practical. Particular care should be taken with used
oils and greases containing lead.
First Aid treatment should be obtained immediately for open cuts and wounds.
Apply barrier cream before each work period to help when removing oil from the skin.
Use proprietary hand cleaners only if they can be removed from the skin using water.
Overalls must be cleaned regularly. Discard clothing that cannot be cleaned and footwear
that has become impregnated.
In the event of a skin condition occurring consult a doctor and tell him/her that your work
involves using oil.
22:6
Page Issue B
C200 - Maintenance
Solvents:
Solvents such as acetone, white spirit, toluene, xylene and trichloroethane are flammable.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and
clothing.
When using solvents ensure good ventilation; avoid breathing fumes, vapours, spraymists and keep containers tightly sealed. Do not use in confined spaces. When spraying
materials containing solvents, for example paints, adhesives or coatings, use extraction
ventilation or personal respiratory protection in the absence of adequate general
ventilation.
Do not apply heat or flame except under specific and detailed manufacturer's instructions.
Suspended loads:
Never work under an unsupported, suspended or raised load. For example, jacked up
vehicle, raised tipper body, suspended engine, etc.
Always ensure that lifting equipment e.g., jacks, hoists, axle stands, slings, etc are
adequate and suitable for the job, in good condition and regularly maintained.
NEVER improvise lifting tackle. ALWAYS ensure body props and/or axle stands are used
when working under bodies or chassis.
Workshop tools and equipment:

Only use tools and equipment for their intended purposes.
Never overload equipment such as hoists, jacks, axles stands or lifting slings. Damage
caused by overloading is not always immediately apparent and may result in a fatal failure
the next time the equipment is used.
Never use damaged or defective tools or equipment.
Always wear suitable eye protection when using grinding, chiselling or air guns.
Always wear a suitable breathing mask when using sand blasting equipment, working with
asbestos based materials (such as brake linings) or using spraying equipment.
Page Issue B
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C200 - Maintenance
22:8
Page Issue B

CN and CX200 Maintenance 91549 MH

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Maintenance

Page Issue Levels

Remove and Refit Procedures

Health & Safety

Print date - November 2010

Page Issue Levels

Chapter - Page Issue Levels

Chapter - Page Issue Levels

Chapter - Scheduled Maintenance

Chapter - Hydraulic System

Chapter - Electrical System

Chapter - Page Issue Levels

Chapter - Electrical System continued . . .

Chapter - Water System

Chapter - Wearing Items

Chapter - Remove & Refit Procedures

Chapter - Fault Diagnosis

Chapter - Page Issue Levels

Chapter - Service Tools

Chapter - Health & Safety

Chapter - Page Issue Levels

Setting Engine Tickover & Maximum Revs

Torque Wrench Settings

Chapter - Scheduled Maintenance

Maintenance & Adjustment Instructions

Hydraulic Oil Filters

Hydraulic Cylinder Maintenance

Chapter - Scheduled Maintenance

Chapter - Scheduled Maintenance

Setting Engine Tickover & Maximum Revs

Start engine and run machine until normal running

Disconnect actuator rod.

Attach magnetic pick-up of digital tachometer to engine

4. Loosen locknut on idle adjustment screw.

8. Adjust actuator rod length to obtain 970 rpm. Once correct

Chapter - Scheduled Maintenance

Torque Wrench Settings

Front Axle Suspension Bolts

Rear Wheel Motor Bolts

Front Axle Suspension Pivot Bolts

Steering/Pedal Box Mounting Bolts

Rear Suspension Bolts

Cab Mounting Bolts

Tow Hitch Mounting Bolts (Option)

Wiper Motor Arm Nut

Engine Lifting Lugs

Wheel Motor Adaptors

Chapter - Scheduled Maintenance

Chapter - Scheduled Maintenance

Modus Operandi - CX/CN200

Modus Operandi - CW200

Test Point Function Table

To Set/Check Relief Valves

To Check Fan Motor Pressure & Fan Speed

Hydraulic Blocks - Valve & Port Identification

Chapter - Hydraulic System

Chapter - Hydraulic System

(drawing reference: 722461 - Issue 01)

Sweep System Hydraulic Circuit