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CN and CX200 Maintenance 91549 MH
Citation preview
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)
Chapter - Hydraulic System Page Issue 0615:4
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
)
Chapter - Hydraulic System Page Issue 0615:6
C200 - MaintenanceSt
eerin
g Sy
stem
Hyd
raul
ic C
ircui
t(d
raw
ing
refe
renc
e: 7
2225
6 - I
ssue
00)
Page Issue 06 Chapter - Hydraulic System 15:7
C200 - Maintenance
Chapter - Hydraulic System Page Issue 0615:8
C200 - Maintenance
Page Issue 06 Chapter - Hydraulic System 15:9
C200 - Maintenance
Chapter - Hydraulic System Page Issue 0615:10
C200 - Maintenance
3rd
Bru
sh H
ydra
ulic
Circ
uit
(dra
win
g re
fere
nce:
700
5697
- Is
sue
B)
Page Issue 06 Chapter - Hydraulic System 15:11
C200 - Maintenance
Chapter - Hydraulic System Page Issue 0615:12
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
Page Issue 06 Chapter - Hydraulic System 15:13
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
.
Chapter - Hydraulic System Page Issue 0615:14
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
.
Page Issue 06 Chapter - Hydraulic System 15:15
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.
Chapter - Hydraulic System Page Issue 0615:16
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
.
Page Issue 06 Chapter - Hydraulic System 15:17
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
Chapter - Hydraulic System Page Issue 0615:18
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
Page Issue 06 Chapter - Hydraulic System 15:19
C200 - Maintenance
Chapter - Hydraulic System Page Issue 0615:20
C200 - Maintenance
Page Issue 06 Chapter - Hydraulic System 15:21
C200 - Maintenance
Chapter - Hydraulic System Page Issue 0615:22
C200 - Maintenance
Page Issue 06 Chapter - Hydraulic System 15:23
C200 - Maintenance
Chapter - Hydraulic System Page Issue 0615:24
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
Page Issue 06 Chapter - Hydraulic System 15:25
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
1. Start engine and raise hopper.
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.
6. Disengage work mode.
Chapter - Hydraulic System Page Issue 0615:26
C200 - Maintenance
To Set/Check Brush/Spraybar Relief Valve
1. Start engine and raise hopper.
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.
6. Disengage work mode.
3rd Brush Relief Valve
1. Start engine and raise hopper.
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.
6. Disengage work mode.
Page Issue 06 Chapter - Hydraulic System 15:27
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.
Chapter - Hydraulic System Page Issue 0615:28
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
Page Issue 06 Chapter - Hydraulic System 15:29
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
Chapter - Hydraulic System Page Issue 0615:30
C200 - Maintenance
Flow Regulator - Valve & Port Identification(Part No. 70625-1)
3rd Brush Primary Block - Valve & Port Identification(Part No. 7005188)
Page Issue 06 Chapter - Hydraulic System 15:31
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)
Chapter - Hydraulic System Page Issue 0615:32
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
Euro 4 J-Plex Input/Outputs 16 : 36
Euro 5 J-Plex Input/Outputs 16 : 43
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)
Page Issue 04 Chapter - Electrical System 16:5
C200 - Maintenance
MK
2 M
ain
Cab
Loo
m -
Shee
t 4(d
raw
ing
refe
renc
e: 7
2254
5 - I
ssue
01)
Chapter - Electrical System Page Issue 0416:6
C200 - MaintenanceM
K2
Mai
n C
ab L
oom
- Sh
eet 5
(dra
win
g re
fere
nce:
722
545
- Iss
ue 0
1)
Page Issue 06 Chapter - Electrical System 16:7
C200 - Maintenance
J-Pl
ex C
hass
is N
ode
(dra
win
g re
fere
nce:
721
477
- Iss
ue A
)
Chapter - Electrical System Page Issue 0416:8
C200 - Maintenance
Main Chassis Loom - Euro 3(drawing reference: 721479 - Issue 04)
Page Issue 04 Chapter - Electrical System 16:9
C200 - Maintenance
Chapter - Electrical System Page Issue 0516:10
C200 - Maintenance
Main Chassis Loom (MK1) - Euro 4(drawing reference: 722142 - Issue 03)
Page Issue 05 Chapter - Electrical System 16:11
C200 - Maintenance
Chapter - Electrical System Page Issue 0516:12
C200 - Maintenance
Main Chassis Loom (MK2) - Euro 4 (LED Rear Lights)(drawing reference: 722667 - Issue A)
Page Issue 05 Chapter - Electrical System 16:13
C200 - Maintenance
Chapter - Electrical System Page Issue 0516:14
C200 - Maintenance
Main Chassis Loom - Tier 3 (LED Rear Lights)(drawing reference: 722805 - Issue A)
Page Issue 05 Chapter - Electrical System 16:15
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
Chapter - Electrical System Page Issue B16:18
C200 - MaintenanceO
verh
ead
Con
sole
(dra
win
g re
fere
nce:
721
545
- Iss
ue 0
9)
Page Issue B Chapter - Electrical System 16:19
C200 - Maintenance
Rea
r C
ab L
oom
- Eu
ro 3
(dra
win
g re
fere
nce:
721
595
- Iss
ue 0
4)
Chapter - Electrical System Page Issue B16:20
C200 - Maintenance
Rear Cab Loom - Euro 4 & 5(drawing reference: 722340 - Issue A)
Page Issue B Chapter - Electrical System 16:21
C200 - Maintenance
Chapter - Electrical System Page Issue B16:22
C200 - MaintenanceR
ear
LED
Str
obe
Bea
cons
(dra
win
g re
fere
nce:
722
944
- Iss
ue 0
0)
Page Issue B Chapter - Electrical System 16:23
C200 - Maintenance
Fron
t Fas
cia
Indi
cato
rs
(dra
win
g re
fere
nce:
722
943
- Iss
ue 0
0)
Chapter - Electrical System Page Issue B16:24
C200 - Maintenance
3rd Brush Circuit(drawing reference: 7006109 - Issue A)
Page Issue B Chapter - Electrical System 16:25
C200 - Maintenance
Chapter - Electrical System Page Issue B16:26
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
Page Issue B Chapter - Electrical System 16:27
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
Chapter - Electrical System Page Issue B16:28
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
Page Issue B Chapter - Electrical System 16:29
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
Chapter - Electrical System Page Issue B16:30
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
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
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
Page Issue B Chapter - Electrical System 16:31
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)
Low Side A11 NOT USED
Low Side A12 NOT USED
Relay 1 Com A13
Relay 2 Com A14 NOT USED
Low Side A15 NOT USED
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)
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
Chapter - Electrical System Page Issue B16:32
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
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
Digital 30 B36 NOT USED
C200 Euro 3
J-Plex Internal Node Connections (IN)
PLU
G B
- I
npu
t/O
utp
ut
Con
nec
tor
36
Way
28/02/2008
Issue 01
Page Issue B Chapter - Electrical System 16:33
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 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 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
Chapter - Electrical System Page Issue B16:34
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
5V Ref B15 Drive Foot Pedal - 5V 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
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 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
tor
6
Way
Issue 01
Page Issue B Chapter - Electrical System 16:35
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
Key
pad
- C
onn
ecto
r 0
2P
ower
&
Com
ms
Con
nec
tor
01
RH
Thu
mb
- C
onne
ctor
03
LH T
hum
b -
Con
nect
or 0
4
Issue 01
28/02/2008LH
Joy
stic
k -
Con
nect
or 0
6R
H J
oyst
ick
- C
onne
ctor
05
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
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 USEDInput 6 CV2-6 Fog Light Switch
Input 7 CV2-7 Heated Windscreen Switch
Input 8 CV2-8 NOT USEDInput 9 CV2-9 NOT USED
Input 10 CV2-10 Indicator RH
Input 11 CV2-11 Indicator Trailer
Input 12 CV2-12 NOT USED
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
J-Plex CANview Connections (CV)
29/09/2009
C200 Euro 4/Tier 3
Con
nec
tor
3 -
12
Way
Con
nec
tor
1 -
12
Way
Con
nec
tor
2 -
12
Way
Issue 02
Page Issue B Chapter - Electrical System 16:37
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 A7 Valve CT2a
High Side Output A8 Valve CT2b
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 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)
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
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 4/Tier 3
J-Plex Internal Node Connections (IN)
PLU
G A
- I
npu
t/O
utp
ut
Con
nec
tor
36
Way
29/09/2009
Issue 02
Chapter - Electrical System Page Issue B16:38
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
Low Side Input (-ve) B12 NOT USED
Low Side Input (-ve) B13 NOT USED
Low Side Input (-ve) B14 NOT USED
Low Side Input (-ve) B15 NOT USED
Low Side Input (-ve) B16 NOT USED
Low Side Input (-ve) B17 NOT USED
Low Side Input (-ve) B18 NOT USED
Low Side Input (-ve) B19 NOT USED
Low Side Input (-ve) B20 NOT USED
Low Side Input (-ve) B21 NOT USED
Low Side Input (-ve) B22 NOT USED
Low Side Input (-ve) B23 NOT USED
Low Side Input (-ve) 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
Low Side Input (-ve) B31 NOT USED
Low Side Input (-ve) B32 NOT USED
Low Side Input (-ve) B33 NOT USED
Low Side Input (-ve) B34 NOT USED
Low Side Input (-ve) B35 NOT USED
Low Side Input (-ve) B36 Outputs A11 & A15 Enable - Link
C200 Euro 4/Tier 3
J-Plex Internal Node Connections (IN)
PLU
G B
- I
npu
t/O
utp
ut
Con
nec
tor
36
Way
29/09/2009
Issue 02
Page Issue B Chapter - Electrical System 16:39
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
Output B3 Backlight LED #2
Input B4 Brush Speed - Decrease
Input B5 Third Brush Head - Twist ACW
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 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
n K
eypa
d -
Con
nec
tor
02
Pow
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Co m
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Co n
nec
tor
01
RH
Th
um
b -
Con
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03
LH T
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mb
-C
onn
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4
Issue 02
29/09/2009LH
Joy
stic
k -
Con
nec
tor
06
RH
Joy
stic
k -
Con
nec
tor
05
Chapter - Electrical System Page Issue B16:40
C200 - Maintenance
Type Pin No FunctionPower A1 Chassis Node - 12 Volts Power Supply
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 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 - GroundPWM 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 - Signal
Ground B20 Weight Load Indicator Sensor - Ground
Output B21 Valve CT24-B - Signal
Ground B31 Valve CT24-B - Ground
Input B22 Hopper 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 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
J-Plex Chassis Node Connections (CN)
29/09/2009
Inp
ut/
Ou
tpu
t C
onn
ecto
r 4
0 W
ayP
ower
& C
omm
sC
onn
ecto
r 6
Way
Issue 02
Page Issue B Chapter - Electrical System 16:41
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 Engine CAN bus (J1939) - Hi
CAN LO A4 Engine CAN bus (J1939) - 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 NOT USED
High Side Output - 5A B5 NOT USED
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 NOT USED
Transmit - OUT B13 J-Plex Communication Signal - Tx
0V Ref B14 Drive Foot Pedal - 0V Ref
5V Ref B15 Drive Foot Pedal - 5V 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 NOT USED
+ Input B21 Drive Foot Pedal - IVS
- Input (Freq.) B22 Road Speed Sensor - Signal
Receive - IN B23 J-Plex Communication Signal - Rx
0V Ref B24 NOT USED
5V Ref B25 NOT USED
PWM 3 Rtn B26 NOT USED
Analogue Input B27 NOT USED
Analogue Input B28 Fuel Level Sender (10-180)
Analogue Input B29 NOT USED
H - Bridge - B30 NOT USED
- Input B31 Air Filter Service Switch
- Input B32 Brake System Low Level Switch
- Input B33 Transmission Oil Low Level
- Input B34 Fuel Pre-Filter Water Sensor
- Input B35 Engine Cranking/Workmode Button
- Input B36 Forward Signal
- Input B37 Reverse Signal
- Input B38 Brake Pedal Input
+ input B39 NOT USED
+ input B40 Alternator D+ Terminal
C200 Euro 4
MegaJET Node Connections (MJ)
29/09/2009
I npu
t/O
utpu
t C
onne
ctor
40
Way
Pow
er &
Com
ms
Con
nect
or 6
Way
Issue 02
Chapter - Electrical System Page Issue B16:42
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 NOT USED
CAN LO A4 NOT USED
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 NOT USED
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
5V Ref B15 Drive Foot Pedal - 5V 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
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 Engine Fuel Actuator - H Bridge
- Input B31 Air Filter Service 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 Tier 3
MegaJET Node Connections (MJ)
29/09/2009
I npu
t/O
utpu
t C
onne
ctor
40
Way
Pow
er &
Com
ms
Con
nect
or 6
Way
Issue 02
Page Issue B Chapter - Electrical System 16:43
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
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 USEDInput 6 CV2-6 Fog Light Switch
Input 7 CV2-7 Heated Windscreen Switch
Input 8 CV2-8 NOT USEDInput 9 CV2-9 NOT USED
Input 10 CV2-10 Indicator RH
Input 11 CV2-11 Indicator Trailer
Input 12 CV2-12 NOT USED
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
J-Plex CANview Connections (CV)
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
Chapter - Electrical System Page Issue B16:44
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 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 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 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)
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
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 5/Tier 3
J-Plex Internal Node Connections (IN)
PLU
G A
- I
npu
t/O
utp
ut
Con
nec
tor
36
Way
29/09/2009
Issue 02
Page Issue B Chapter - Electrical System 16:45
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
Low Side Input (-ve) B12 NOT USED
Low Side Input (-ve) B13 NOT USED
Low Side Input (-ve) B14 NOT USED
Low Side Input (-ve) B15 NOT USED
Low Side Input (-ve) B16 NOT USED
Low Side Input (-ve) B17 NOT USED
Low Side Input (-ve) B18 NOT USED
Low Side Input (-ve) B19 NOT USED
Low Side Input (-ve) B20 NOT USED
Low Side Input (-ve) B21 NOT USED
Low Side Input (-ve) B22 NOT USED
Low Side Input (-ve) B23 NOT USED
Low Side Input (-ve) 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
Low Side Input (-ve) B31 NOT USED
Low Side Input (-ve) B32 NOT USED
Low Side Input (-ve) B33 NOT USED
Low Side Input (-ve) B34 NOT USED
Low Side Input (-ve) B35 NOT USED
Low Side Input (-ve) B36 Outputs A11 & A15 Enable - Link
C200 Euro 5/Tier 3
J-Plex Internal Node Connections (IN)
PLU
G B
- I
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t/O
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Con
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Way
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
Output B2 Backlight LED #1
Output B3 Backlight LED #2
Input B4 Brush Speed - Decrease
Input B5 Third Brush Head - Twist ACW
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 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)
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LH T
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Issue 02
29/09/2009LH
Joy
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Con
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06
RH
Joy
stic
k -
Con
nec
tor
05
Page Issue B Chapter - Electrical System 16:47
C200 - Maintenance
Type Pin No FunctionPower A1 Chassis Node - 12 Volts Power Supply
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 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 - GroundPWM 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 - Signal
Ground B20 Weight Load Indicator Sensor - Ground
Output B21 Valve CT24-B - Signal
Ground B31 Valve CT24-B - Ground
Input B22 Hopper 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 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
J-Plex Chassis Node Connections (CN)
29/09/2009
Inp
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Way
Issue 02
Chapter - Electrical System Page Issue B16:48
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 Engine CAN bus (J1939) - Hi
CAN LO A4 Engine CAN bus (J1939) - Lo
Earth A5 Earth
Earth A6 Earth
High Side Ouput B1 Drive Pump - Safety Valve
High Side Output B2 Engine Cranking Signal to Engine ECU
High Side Output - 3A B3 Transmission Dump Valve
High Side Output - 5A B4 NOT USED
High Side Output - 5A B5 NOT USED
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 NOT USED
Transmit - OUT B13 J-Plex Communication Signal - Tx
0V Ref B14 Drive Foot Pedal - 0V Ref
5V Ref B15 Drive Foot Pedal - 5V 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 NOT USED
+ Input B21 Drive Foot Pedal - IVS
- Input (Freq.) B22 Road Speed Sensor - Signal
Receive - IN B23 J-Plex Communication Signal - Rx
0V Ref B24 NOT USED
5V Ref B25 NOT USED
PWM 3 Rtn B26 NOT USED
Analogue Input B27 NOT USED
Analogue Input B28 Fuel Level Sender (10-180)
Analogue Input B29 NOT USED
H - Bridge - B30 NOT USED
- Input B31 Air Filter Service Switch
- Input B32 Brake System Low Level Switch
- Input B33 Transmission Oil Low Level
- Input B34 NOT USED
- Input B35 Engine Cranking/Workmode Button
- Input B36 Forward Signal
- Input B37 Reverse Signal
- Input B38 Brake Pedal Input
+ input B39 NOT USED
+ input B40 Alternator D+ Terminal
C200 Euro 5
MegaJET Node Connections (MJ)
29/09/2009
I npu
t/O
utpu
t C
onne
ctor
40
Way
Pow
er &
Com
ms
Con
nect
or 6
Way
Issue 02
Page Issue B Chapter - Electrical System 16:49
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 NOT USED
CAN LO A4 NOT USED
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 NOT USED
High Side Output - 7A B6 Re