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Johnston CN101 Maintenance Manual

Suction sweeper
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Maintenance
Manual
CN101
Suction Sweeper
Part No. 7032299
Revision Level A
E.C.N. Issue - 710570
Foreword
Page Issue Levels
Engine
Hydraulic System
Electrical System
Optional Equipment
Servicing Procedures
Service Tools
Health and Safety
Print date - August 2013
F
P
1
2
3
4
5
6
7

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Summary of Contents for Johnston CN101

  • Page 1 Foreword Page Issue Levels Engine Maintenance Hydraulic System Manual Electrical System Optional Equipment Servicing Procedures Service Tools Health and Safety CN101 Suction Sweeper Part No. 7032299 Revision Level A Print date - August 2013 E.C.N. Issue - 710570...
  • Page 2 CN101 - Maintenance Foreword Page Issue A...
  • Page 3 CN101 - Maintenance CHAPTER Page Issue Levels Chapter - Page Issue Levels Page Issue A...
  • Page 4 CN101 - Maintenance Page Issue Changed Page Issue Changed Front Sheet Foreword 1 Chapter - Page Issue Levels Page Issue Changed Page Issue Changed Chapter - Engine Page Issue Changed Page Issue Changed Chapter - Hydraulic System Page Issue Changed...
  • Page 5 CN101 - Maintenance Chapter - Servicing Procedures Page Issue Changed Page Issue Changed 5:10 5:11 5:12 Chapter - Service Tools Page Issue Changed Page Issue Changed Chapter - Health and Safety Page Issue Changed Page Issue Changed Chapter - Page Issue Levels...
  • Page 6 CN101 - Maintenance Chapter - Page Issue Levels Page Issue A...
  • Page 7 CN101 - Maintenance CHAPTER Engine Table of Contents Section Page Engine Component Overview 1 : 2 Supplemental Engine Information Links 1 : 3 Chapter - Engine Page Issue A...
  • Page 8 CN101 - Maintenance Chapter - Engine Page Issue A...
  • Page 9 CN101 - Maintenance For engine operator’s manual please refer to the following document; Deutz Operator’s Manual_English.pdf For engine timing belt replacement information please refer to the following document; Deutz Timing Belt Replacement.pdf Chapter - Engine Page Issue A...
  • Page 10 CN101 - Maintenance Chapter - Engine Page Issue A...
  • Page 11 CN101 - Maintenance CHAPTER Hydraulic System Table of Contents Section Page Hydraulic Block Location & Identification 2 : 2 Hydraulic Circuit 2 : 3 Vehicle Function Truth Table 2 : 4 Chapter - Hydraulic System Page Issue A...
  • Page 12 CN101 - Maintenance Chapter - Electrical System Page Issue A...
  • Page 13 CN101 - Maintenance Hydraulic Circuit (drawing reference: 400-3-019483 - Issue A) Transit = 59.8 l/min Work = 72.4 l/min Right Wheel 4WS Block 0-250 min-1 Motor (Option) Vg = 300 ccm Direction of travel Left Wheel Motor Transit = 59.8 l/min Work = 72.4 l/min...
  • Page 14 CN101 - Maintenance Vehicle Function Truth Table Chapter - Hydraulic System Page Issue A...

  • Page 15: Table Of Contents

    CN101 - Maintenance CHAPTER Electrical System Table of Contents Section Page Electrical Circuit Key 3 : 3 Ignition Switch Circuit 3 : 4 Rear Lighting System Circuit 3 : 5 Indicators Circuit 3 : 6 Front Lighting System Circuit 3 : 7...
  • Page 16 CN101 - Maintenance Chapter - Electrical System Page Issue A...

  • Page 17: Electrical Circuit Key

    CN101 - Maintenance Electrical Circuit Key (drawing reference: 7013052 - Issue D) Chapter - Electrical System Page Issue A...

  • Page 18: Ignition Switch Circuit

    CN101 - Maintenance Ignition Switch Circuit (drawing reference: 7013052, Sheet 1 - Issue D) Chapter - Electrical System Page Issue A...

  • Page 19: Rear Lighting System Circuit

    CN101 - Maintenance Rear Lighting System Circuit (drawing reference: 7013052, Sheet 2 - Issue D) Chapter - Electrical System Page Issue A...

  • Page 20: Indicators Circuit

    CN101 - Maintenance Indicators Circuit (drawing reference: 7013052, Sheet 3 - Issue D) Chapter - Electrical System Page Issue A...
  • Page 21 CN101 - Maintenance Front Lighting Circuit (drawing reference: 7013052, Sheet 4 - Issue D) Chapter - Electrical System Page Issue A...
  • Page 22 CN101 - Maintenance Reversing Camera Circuit (drawing reference: 7013052, Sheet 5 - Issue D) Chapter - Electrical System Page Issue A...
  • Page 23 CN101 - Maintenance Wipers Circuit (drawing reference: 7013052, Sheet 6 - Issue D) Chapter - Electrical System Page Issue A...

  • Page 24: Heater & Air Conditioning Circuit

    CN101 - Maintenance Heater / Air Conditioning Circuit (drawing reference: 7013052, Sheet 7 - Issue D) 3:10 Chapter - Electrical System Page Issue A...

  • Page 25: Water System 1 Circuit

    CN101 - Maintenance Water System 1 Circuit (drawing reference: 7013052, Sheet 8 - Issue D) 3:11 Chapter - Electrical System Page Issue A...

  • Page 26: Water System 2 Circuit

    CN101 - Maintenance Water System 2 Circuit (drawing reference: 7013052, Sheet 9 - Issue D) 3:12 Chapter - Electrical System Page Issue A...

  • Page 27: Engine Starter Circuit

    CN101 - Maintenance Engine Starter Circuit (drawing reference: 7013052, Sheet 10 - Issue D) 3:13 Chapter - Electrical System Page Issue A...

  • Page 28: Sensors Circuit

    CN101 - Maintenance Sensors Circuit (drawing reference: 7013052, Sheet 11 - Issue D) 3:14 Chapter - Electrical System Page Issue A...

  • Page 29: Ecu Controller Circuit

    CN101 - Maintenance ECU Controller Circuit (drawing reference: 7013052, Sheet 12 - Issue D) 3:15 Chapter - Electrical System Page Issue A...

  • Page 30: Transmission Circuit

    CN101 - Maintenance Transmission Circuit (drawing reference: 7013052, Sheet 13 - Issue D) 3:16 Chapter - Electrical System Page Issue A...

  • Page 31: Side Brush Positioning Circuit

    CN101 - Maintenance Side Brush Positioning Circuit (drawing reference: 7013052, Sheet 14 - Issue D) 3:17 Chapter - Electrical System Page Issue A...

  • Page 32: Suction Circuit

    CN101 - Maintenance Suction Circuit (drawing reference: 7013052, Sheet 15 - Issue D) 3:18 Chapter - Electrical System Page Issue A...

  • Page 33: Side Brush Sweeping Control Circuit

    CN101 - Maintenance Side Brush Sweeping Control Circuit (drawing reference: 7013052, Sheet 16 - Issue D) 3:19 Chapter - Electrical System Page Issue A...

  • Page 34: Hydraulics & Water Recirculation Circuit

    CN101 - Maintenance Hydraulics & Water Recirculation Circuit (drawing reference: 7013052, Sheet 17 - Issue D) 3:20 Chapter - Electrical System Page Issue A...

  • Page 35: Hopper & Heating Circuit

    CN101 - Maintenance Hopper & Heating Circuit (drawing reference: 7013052, Sheet 18 - Issue D) 3:21 Chapter - Electrical System Page Issue A...

  • Page 36: Ws Circuit

    CN101 - Maintenance 4WS Circuit (drawing reference: 7013052, Sheet 19 - Issue D) 3:22 Chapter - Electrical System Page Issue A...
  • Page 37 CN101 - Maintenance CHAPTER Optional Equipment Table of Contents Section Page 4WS Bleeding 4 : 2 Chapter - Water System Page Issue A...

  • Page 38: Engine

    CN101 - Maintenance 4WS Bleeding The following outlines the correct procedure for the removal of air from the Johnston CN101 rear hydraulic 4 wheel steering (4WS) cylinder. Should for any reason air be introduced into the 4WS hydraulic system (hose replacement, etc.) the following procedure must be undertaken to ensure that the 4WS system functions safely and as intended.
  • Page 39 CN101 - Maintenance 8. Refit the cover panel over the hydraulic controls and top up the hydraulic oil as required – see operator’s gu for further details. 9. Lower the hopper and test drive the vehicle to ensure correct operation.
  • Page 40 CN101 - Maintenance Figure Four Connection for test hose to test point at port PS on the charge pressure connector of the driving pump. Figure Five Banjo connector on the rear steering cylinder. Figure Six Whilst taking all necessary precautions, slowly release...
  • Page 41 CN101 - Maintenance CHAPTER Servicing Procedures Table of Contents Section Page Adjustment of Steering Components (TB 1519) 5 : 2 Front Axle Steering Components (TB 1522) 5 : 7 Engine Oil Consumption (TB 1549) 5 : 11 Chapter - Servicing Procedures...
  • Page 42 Renew split pin and secure. Note: Should any play exist between the ball joint and hub assembly following tightening of the nut, further action will be required – Please contact the appropriate Johnston Sweepers Ltd. service provider. Chapter - Servicing Procedures...
  • Page 43 CN101 - Maintenance 2. Adjust steering lock stops a) Check the steering cylinder ball joint locknut as this is paint marked at the factory – if the paint mark is intact it would suggest no prior adjustment has been undertaken, so the lock stops will not require adjustment –...
  • Page 44 Renew split pin and secure. Note: Should any play exist between the ball joint and hub assembly following tightening of the nut, further action will be required – Please contact the appropriate Johnston Sweepers Ltd. service provider. 2. Adjust cylinder ball joint a) Release the steering cylinder ball joint lock nut.
  • Page 45 Renew split pin and secure. Note: Should any play exist between the ball joint and hub assembly following tightening of the nut further action will be required – Please contact the appropriate Johnston Sweepers Ltd. service provider. Chapter - Servicing Procedures...
  • Page 46 CN101 - Maintenance Adjustment of Steering Components - Tools required 1 x Trolley jack (capable of safely lifting the vehicle to the required height). 2 x Axle stands (sufficient to support the vehicle safely at the required height) 1 x 22mm open ended spanner.
  • Page 47 CN101 - Maintenance Front Axle Steering Components (TB 1522) Further to TB1519 a retrofit campaign has been introduced to enhance the reliability of the front axle steering components utilising a larger ball joint and associated components.. The components must be replaced by following the procedures outlined below:- Replacement of Components 1.
  • Page 48 CN101 - Maintenance 7. Remove the steering lock stops (Item 5) from the swivel housing and discard the original swivel housing. 8. Using the revised swivel housing (Part number 7001770) re-assemble the components in reverse order of removal with the exception of the steering cylinder ball joint. The swivel housing retaining screw (Item 4) should be fitted using Loctite 243.
  • Page 49 CN101 - Maintenance Adjustment of Steering Lock Stops – 4WS Models Only 1. With the vehicle on a level surface, raise the front of the vehicle and support securely on axle stands. 2. Remove both front wheels. 3. Start the vehicle engine and engage 4WS, ensuring the vehicle remains stable and fully...
  • Page 50 CN101 - Maintenance 4. Rotate the steering until full right hand lock is achieved and the right hand rear most steering lock is in contact with the axle assembly. With the steering in this position adjust the left hand front steering lock until it also contacts the axle assembly.
  • Page 51 CN101 - Maintenance Engine Oil Consumption (TB 1549) The following instructions should be implemented for the Deutz engines fitted to the Johnston CN101. The instructions apply during the first 500 to 700 operating hours and are intended to prevent high oil consumption: •...
  • Page 52 CN101 - Maintenance 5:12 Chapter - Servicing Procedures Page Issue A...
  • Page 53 CN101 - Maintenance CHAPTER Service Tools Table of Contents Section Page Service Tools 6 : 2 Chapter - Service Tools Page Issue A...
  • Page 54 CN101 - 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.
  • Page 55 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.
  • Page 56 CN101 - 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.
  • Page 57 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:...
  • Page 58 CN101 - Maintenance Reminders Chemical materials remove chemical materials from the skin and clothing as soon as practical after soiling. Change heavily soiled clothing and have it cleaned. carefully read and observe hazard and precaution warnings given on hazardous material containers and in any accompanying leaflets, posters or other instructions.

  • Page 59: Electrical System

    CN101 - 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.
  • Page 60 CN101 - 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.
  • Page 61 CN101 - 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, spray- mists and keep containers tightly sealed.
  • Page 62 CN101 - Maintenance Chapter - Health and Safety Page Issue A...

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