Johnston CN101 Maintenance Manual Download

Page: 1 / 62

E.C.N. Issue - 710570

Print date - August 2013

Maintenance

Manual

CN101

Suction Sweeper

Part No. 7032299

Revision Level A

Servicing Procedures

Foreword

Page Issue Levels

Engine

Hydraulic System

Electrical System

Optional Equipment

Service Tools

Health and Safety

All

and

rights

are

the

property

Johnston

Sweepers

Ltd.

Summary of Contents for CN101

Page 1: ...tion Sweeper Part No 7032299 Revision Level A Servicing Procedures Foreword Page Issue Levels Engine Hydraulic System Electrical System Optional Equipment 5 Service Tools Health and Safety F P 1 2 3 4 6 7 All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 2: ...Foreword F 2 Page Issue A CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 3: ...Chapter Page Issue Levels CHAPTER P Page Issue Levels P 1 Page Issue A CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 4: ...ydraulic System Page Issue Changed Page Issue Changed 2 1 A 2 2 A 2 3 A 2 4 A 3 Chapter Electrical System Page Issue Changed Page Issue Changed 3 1 A 3 2 A 3 3 A 3 4 A 3 5 A 3 6 A 3 7 A 3 8 A 3 9 A 3 10 A 3 11 A 3 12 A 3 13 A 3 14 A 3 15 A 3 16 A 3 17 A 3 18 A 3 19 A 3 20 A 3 21 A 3 22 A 4 Chapter Optional Equipment Page Issue Changed Page Issue Changed 4 1 A 4 2 A 4 3 A 4 4 A Page Issue A CN101 M...

Page 5: ...5 6 A 5 7 A 5 8 A 5 9 A 5 10 A 5 11 A 5 12 A 6 Chapter Service Tools Page Issue Changed Page Issue Changed 6 1 A 6 2 A 7 Chapter Health and Safety Page Issue Changed Page Issue Changed 7 1 A 7 2 A 7 3 A 7 4 A 7 5 A 7 6 A 7 7 A 7 8 A Page Issue A CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 6: ...Chapter Page Issue Levels P 4 Page Issue A CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 7: ...APTER 1 Engine 1 1 Table of Contents Section Page Engine Component Overview 1 2 Supplemental Engine Information Links 1 3 Page Issue A CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 8: ...nt Bomba para aceite lubricante y refrigerante Verbrennungsluftansaugleitung Air intake mainfold Collecteur d admission Colector de admisión Integriertes Kühlgebläse mit Schutzgitter Integrated Colling Fan with Guard Ventilateur de refroidissement intégré avec grille de protection Ventilador de refrigeración integrado con rejilla de protección Generator Alternator Alternateur Generador Drehzahlreg...

Page 9: ... 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 All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 10: ...Page Issue A Chapter Engine 1 4 CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 11: ...lic System 2 1 Table of Contents Section Page Hydraulic Block Location Identification 2 2 Hydraulic Circuit 2 3 Vehicle Function Truth Table 2 4 Page Issue A CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 12: ...Page Issue A Chapter Electrical System 3 2 CN101 Maintenance Hydraulic Block Location Identification All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 13: ...ower Right Brush Position Left Brush Position Nozzle Raise Lower Brush Speed Balance Idle 8 900 r min Transit 1900 r min Work 2300 r min Max 2800 r min i 1 1 Transmission Pump Settings Pressure cut off 300 bar Secondary pressure 350 bar Feed pump 25 bar Transit 119 7 l min Work 144 9 l min 8 l min Transit 36 1 l min Work 43 7 l min Transit 65 l min Work 77 l min Transit 20 9 l min Work 25 3 l min ...

Page 14: ...Page Issue A Chapter Hydraulic System 2 4 CN101 Maintenance Vehicle Function Truth Table All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 15: ...3 9 Heater Air Conditioning Circuit 3 10 Water System 1 Circuit 3 11 Water System 2 Circuit 3 12 Engine Starter Circuit 3 13 Sensors Circuit 3 14 ECU Controller Circuit 3 15 Transmission Circuit 3 16 Side Brush Positioning Circuit 3 17 Suction Circuit 3 18 Side Brush Sweeping Control Circuit 3 19 Hydraulics Water Recirculation Circuit 3 20 Hopper Heating Circuit 3 21 4WS Circuit 3 22 Page Issue A ...

Page 16: ...Page Issue A Chapter Electrical System 3 2 CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 17: ...Page Issue A Chapter Electrical System 3 3 CN101 Maintenance Electrical Circuit Key drawing reference 7013052 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 18: ...Page Issue A Chapter Electrical System 3 4 CN101 Maintenance Ignition Switch Circuit drawing reference 7013052 Sheet 1 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 19: ...Page Issue A Chapter Electrical System 3 5 CN101 Maintenance Rear Lighting System Circuit drawing reference 7013052 Sheet 2 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 20: ...Page Issue A Chapter Electrical System 3 6 CN101 Maintenance Indicators Circuit drawing reference 7013052 Sheet 3 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 21: ...Page Issue A Chapter Electrical System 3 7 CN101 Maintenance Front Lighting Circuit drawing reference 7013052 Sheet 4 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 22: ...Page Issue A Chapter Electrical System 3 8 CN101 Maintenance Reversing Camera Circuit drawing reference 7013052 Sheet 5 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 23: ...Page Issue A Chapter Electrical System 3 9 CN101 Maintenance Wipers Circuit drawing reference 7013052 Sheet 6 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 24: ...Page Issue A Chapter Electrical System 3 10 CN101 Maintenance Heater Air Conditioning Circuit drawing reference 7013052 Sheet 7 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 25: ...Page Issue A Chapter Electrical System 3 11 CN101 Maintenance Water System 1 Circuit drawing reference 7013052 Sheet 8 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 26: ...Page Issue A Chapter Electrical System 3 12 CN101 Maintenance Water System 2 Circuit drawing reference 7013052 Sheet 9 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 27: ...Page Issue A Chapter Electrical System 3 13 CN101 Maintenance Engine Starter Circuit drawing reference 7013052 Sheet 10 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 28: ...Page Issue A Chapter Electrical System 3 14 CN101 Maintenance Sensors Circuit drawing reference 7013052 Sheet 11 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 29: ...Page Issue A Chapter Electrical System 3 15 CN101 Maintenance ECU Controller Circuit drawing reference 7013052 Sheet 12 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 30: ...Page Issue A Chapter Electrical System 3 16 CN101 Maintenance Transmission Circuit drawing reference 7013052 Sheet 13 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 31: ...Page Issue A Chapter Electrical System 3 17 CN101 Maintenance Side Brush Positioning Circuit drawing reference 7013052 Sheet 14 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 32: ...Page Issue A Chapter Electrical System 3 18 CN101 Maintenance Suction Circuit drawing reference 7013052 Sheet 15 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 33: ...e Issue A Chapter Electrical System 3 19 CN101 Maintenance Side Brush Sweeping Control Circuit drawing reference 7013052 Sheet 16 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 34: ... Issue A Chapter Electrical System 3 20 CN101 Maintenance Hydraulics Water Recirculation Circuit drawing reference 7013052 Sheet 17 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 35: ...Page Issue A Chapter Electrical System 3 21 CN101 Maintenance Hopper Heating Circuit drawing reference 7013052 Sheet 18 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 36: ...Page Issue A Chapter Electrical System 3 22 CN101 Maintenance 4WS Circuit drawing reference 7013052 Sheet 19 Issue D All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 37: ...Chapter Water System CHAPTER 4 Optional Equipment 4 1 Table of Contents Section Page 4WS Bleeding 4 2 Page Issue A CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 38: ... test point facing vertically see figure two 3 From the hydraulic test kit use one of the test hoses to connect between the test point at HB on the 4WS hydraulic valve block see figure three and the test point at port PS on the charge pressure connector of the driving pump see figure four 4 Start the engine 5 Whilst taking all necessary precautions to protect the any personnel and the surrounding ...

Page 39: ... 9 Lower the hopper and test drive the vehicle to ensure correct operation Figure One Rear steering cylinder extended to its maximum stroke Figure Two Installation of tee piece and test point to port HB of the 4WS hydraulic valve block Figure Three Test hose connected to test point at port HB on the 4WS hydraulic valve block All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 40: ...ctor of the driving pump Figure Five Banjo connector on the rear steering cylinder Figure Six Whilst taking all necessary precautions slowly release the banjo connector bolt on the rear steering cylinder until any trapped air is seen to be released from the connection and then retighten All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 41: ...s 5 1 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 Page Issue A CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 42: ...ocedures should be followed to ensure correct adjustment 1 Check security of ball joint b With the vehicle on a level surface raise the front of the vehicle and support securely on axle stands c Remove both front wheels d Remove the split pin from the steering cylinder ball joint nut on the front of the right hub assembly and check the security of the ball joint by tightening the nut to 40Nm also ...

Page 43: ...ported on the axle stands steer the vehicle to the right until the rear steering just contacts the appropriate lock stops at this point no further steering wheel movement should be undertaken and the vehicles engine switched off f In this position the appropriate front axle steering locks can be adjusted until they contact the axle beam and the lock nuts secured Front adjuster on the left hand sid...

Page 44: ... the front of the vehicle and support securely on axle stands b Remove both front wheels c Slacken the lock nuts and adjust the steering lock stops to a minimum setting the head of the lock stop setscrew should contact the king pin hub assembly in the minimum setting d Remove the split pin from the steering cylinder ball joint nut on the front of the right hub assembly and check the security of th...

Page 45: ... 100Nm e Return the vehicle to the ground and road test to ensure full operation of steering Periodic inspection All Models 2WS and 4WS As prescribed periodic inspection of the steering cylinder ball joint should be undertaken to ensure that security of its fixing is maintained 1 Check security of ball joint a With the vehicle on level ground with the handbrake applied rotate the steering to give ...

Page 46: ... at the required height 1 x 22mm open ended spanner 2 x 17mm spanner 1 x 19mm socket 1 x 17mm socket 1 x torque wrench Suitable for above sockets and able to give 40Nm and 100Nm measurements 1 x Paint pen Parts required Split pin 2mm x 30mm as required Standard Repair Time Adjustment of lock stops steering and initial periodic inspection 60 Minutes Periodic inspection 15 Minutes All Copyright and ...

Page 47: ... side front hub assembly remove the clamp from the drive hoses item 1 shown below 4 Remove the four screws Item 2 and the drive motor with the hoses still connected support until refitted to ensure hoses are not damaged 5 Remove the split pins and nuts from the two steering ball joints Item 3 and disconnect them from the swivel housing using a ball joint separator Remove and discard the ball joint...

Page 48: ...ted to the cylinder and tightened using Loctite 243 on both thread faces shown below 10 The ball joint should now be fitted to the swivel housing and tightened to 80Nm shown below 11 Refit the road wheel and torque to 100Nm and return the vehicle to the ground 12 Carry out adjustment to the front wheel alignment using propriety tracking equipment to give a figure of 0 40 Toe in by adjusting the le...

Page 49: ...ns stable and fully supported on the axle stands steer the vehicle to the right until the rear steering just contacts the appropriate lock stops at this point no further steering wheel movement should be undertaken and the vehicles engine switched off 6 In this position the appropriate front axle steering locks can be adjusted until they contact the axle beam and the lock nuts secured Front adjust...

Page 50: ...icle to the ground and road test to ensure full operation of steering 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 27mm spanner 1 x 22mm spanner 2 x 17mm spanner 1 x 13mm spanner 1 x 13 19 17 and 22mm sockets with a ratchet 1 x Torque wrench Suitable for above sockets...

Page 51: ...s prior to checking the level to allow the oil to settle If you want to compare oil levels ensure that the oil levels to be compared are checked under similar conditions When filling only fill up to the halfway mark on the dipstick If you fill to the upper mark the engine will use the excess oil until the level drops to the halfway mark Often this is declared as the normal oil consumption of the e...

Page 52: ...Page Issue A Chapter Servicing Procedures 5 12 CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 53: ...Chapter Service Tools CHAPTER 6 Service Tools 6 1 Page Issue A CN101 Maintenance Table of Contents Section Page Service Tools 6 2 All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 54: ...on 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 All Copyright and rights are the property of Johnston Sweepers Ltd ...

Page 55: ...iven 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 All Copyright and rights are the prop...

Page 56: ...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 explos...

Page 57: ...rth of the discharged battery group 7 Attempt to start the casualty vehicle 8 Once the vehicle has started remove the negative lead from the chassis and then the slave battery 9 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 solvent...

Page 58: ...erials except in accordance with the manufacturer s instructions Some chemicals can form other toxic or harmful substances give off toxic or harmful fumes be explosive when mixed together spray chemical materials particularly those based on solvents in confined spaces for example when people are inside a vehicle apply heat or flame to chemical materials except under the manufacturer s instructions...

Page 59: ...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 cond...

Page 60: ...n 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 A...

Page 61: ...ehicle 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 intend...

Page 62: ...Page Issue A Chapter Health and Safety 7 8 CN101 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd ...

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