. Maintenance Scheduled Maintenance Section Hydraulic System Electrical System Water System Pneumatic System Wearing Items Remove and Refit Procedures VT551 Twin Engined Fault Diagnosis Suction Sweeper With Mk II CANview Software Service Tools Stage 3a VM Engine Part No 02634-1-M Warranty. VT551 - Maintenance. VT551 - Maintenance CHAPTER Page Issue Levels Description This chapter lists each page in the Maintenance section, it’s issue level and whether it has changed since the previous revision level. Changed pages are indicated by the letter ‘C’ in the changed column, and new pages by the letter ‘N’. VT551 - Maintenance Chapter - Page Issue Levels Page Issue Changed Page Issue Changed Chapter - Scheduled Maintenance Page Issue Changed Page Issue Changed Chapter - Hydraulic System Page Issue Changed Page Issue Changed 8:10 8:11 8:12 Chapter - Electrical System. VT551 - Maintenance Chapter - Water System Page Issue Changed Page Issue Changed 10:1 10:2 10:3 10:4 10:5 10:6 10:7 10:8 10:9 10:10 10:11 10:12 10:13 10:14 Chapter - Pneumatic System Page Issue Changed Page Issue Changed 11:1 11:2 11:3.
VT551 - Maintenance Chapter - Service Tools Page Issue Changed Page Issue Changed 15:1 15:2 Chapter - Warranty Page Issue Changed Page Issue Changed 16:1 16:2 16:3 16:4 Chapter - Health and Safety Page Issue Changed Page Issue Changed 17:1. VT551 - Maintenance CHAPTER Scheduled Maintenance Table of Contents Section Page Introduction Regular Maintenance 7: 2 Security of Sweeping Equipment 7: 3 Circuit Diagrams Fluid Finder 7: 4 Diagram Index 7: 5 Auxiliary Engine Fuel System Bleeding. VT551 - Maintenance INTRODUCTION REGULAR MAINTENANCE It is impossible to over emphasise the importance of regular maintenance, inspection and running adjustments to maintain efficiency and obtain trouble free service from the machine. Attention is drawn to the recommendation in the Auxiliary Engine Handbook relating to the post delivery check over. VT551 - Maintenance SECURITY OF SWEEPING EQUIPMENT It is necessary to check every six months the security of various components as part of the maintenance programme. These fixings are detailed on the illustration below. ALTERNATIVE END MOUNTING POSITIONS (HARDWARE AS PREFERED POSITIONS ie.
‘C’ and ‘D’) 95MA. VT551 - Maintenance Fluid Finder - Diagram SF300z03 Chapter - Scheduled Maintenance Page Issue 01.
VT551 - Maintenance Diagram Index - SE300z01 Chapter - Scheduled Maintenance Page Issue 02. VT551 - Maintenance Please refer to the Operator’s Guide, Chapter 6, for the Routine Maintenance Schedules.
The following items are not covered in the Operator’s Guide. MAINTENANCE AND ADJUSTMENT INSTRUCTIONS AUXILIARY ENGINE - FUEL SYSTEM BLEEDING Please refer to the Auxiliary Engine Handbook for information. VT551 - Maintenance Please refer to the Operator’s Guide Section 6 for the Routine Maintenance Schedules. The following covers items not included in the above guide. HYDRAULIC OIL RETURN FILTER The filter should be changed every B Service, however there is an integral filter indicator on the side of the filter head and, should this indicate red whilst the suction fan is operating, i.e.
VT551 - Maintenance FILTER REGULATOR UNIT Comprises of a combined air filter/pressure regulator (A). It is mounted near the fan case on the right hand side of the machine. Safety Precautions The shut off valve must be used when servicing any item on the air system 93MA. VT551 - Maintenance CHAPTER Hydraulic System Table of Contents Section Page Introduction General Description 8: 2 Circuit Pressures Brushes 8: 2 Water System 8: 3 Suction Fan 8: 3 Hopper Raise/Lower 8: 3 Fan Pump Set Up. VT551 - Maintenance GENERAL DESCRIPTION The hydraulic system may be divided into four hydraulic circuits fed from a common hydraulic reservoir. Sweep system.
Water system. Fan drive system and load discharge.
Hydraulic filtration is provided by suction filters within the hydraulic tank, together with replaceable type ‘in line’. VT551 - Maintenance WATER SYSTEM - MENU 4.11.2 14:00 4.11.2 Connect a suitable 250 bar gauge to test point T9. BLOCK 4 Follow the on screen CANview instructions. This pressure should be 220 bar. Remember to cap off n/min 1800 hose 206 when port W1 is plugged. VT551 - Maintenance FAN PUMP If the fan pump is changed it is necessary to check the pump pressure setting.
Standby - 20 bar.Run the auxiliary engine and measure the pressure on test point T8. The standby pressure should be set at 20 bar. VT551 - Maintenance HYDRAULIC SYSTEM INITIAL OPERATION Start the auxiliary engine and open and close the rear door three times to ensure all air is purged from the system. Failure to carry out this procedure may cause the rear door lock to function incorrectly. VT551 - Maintenance Hydraulic Tank Connections - Diagram SH301a02 Chapter - Hydraulic System Page Issue 01. VT551 - Maintenance Single Sweep - Diagram SH302z02 Chapter - Hydraulic System Page Issue 01. VT551 - Maintenance Dual Sweep - Diagram SH303z02 Chapter - Hydraulic System Page Issue 01.
VT551 - Maintenance Suction Fan / Load Discharge - Diagram SH304a01 Chapter - Hydraulic System Page Issue 01. VT551 - Maintenance Pump Services - Diagram SH306a02 Chapter - Hydraulic System 8:10 Page Issue 01. VT551 - Maintenance Emergency Hand Pump - Diagram SH307z01 Chapter - Hydraulic System 8:11 Page Issue 01.
VT551 - Maintenance Chapter - Hydraulic System 8:12 Page Issue 01. VT551 - Maintenance CHAPTER Electrical System Table of Contents Section Page Introduction General Description 9: 2 System Description 9: 2 Component Identification Relay Box 9: 3 Relays/Fuses and Connector Refs. 9: 4 Electrical Components Diagrams 9: 9. VT551 - Maintenance GENERAL DESCRIPTION The system is integrated with that of the chassis in that it shares its battery and power source. The auxiliary engine is equipped with a second alternator to supplement power generation.
The system activates all operational functions of the machine. VT551 - Maintenance The electrical system is protected by various fuses mounted in the relay box - See Operators Guide Chapter 2. The main feed from the battery to the electrical system is protected by a circuit breaker (MCB) which is also mounted in the relay box. VT551 - Maintenance Relays Ident.
Description / Function Circuit(s) Ref. Location Notes Main Power Relay SE302 Relay Box Fuses 01-03 Main Power Relay SE302 Relay Box Fuses 05-08 Main Power Relay SE302 Relay Box Fuses 09-12 Main Power Relay SE302.
VT551 - Maintenance Fuses Rating (A) Ident. Description / Function Circuit(s) Ref. Location Notes 12V/24V Master Circuit Breaker 30/30 SE304 Relay Box Work Mode 10/10 SE304 Relay Box Auxiliary Engine Crank Solenoid 15/15 SE304 Relay Box Spare Spare Spare Additional Beacon. VT551 - Maintenance Connectors - Numeric Harness Ref. No.Ways Location (Female) (Male) Relay Box 293716-1 293714-1 Relay Box 293714-1 293717-1 Engine Bay 293719-1 293717-1 Engine Bay 293719-1 293717-1 Subframe – Rear 293718-2 293717-1 Subframe – Rear 293718-3. VT551 - Maintenance Connectors Alphanumeric Harness Ref. No.Ways Location (Female) (Male) Subframe – Autolube 293717-1 ALT-D Auxiliary Engine – Alternator 293719-1 AR-1 Armrest Connector 293716-1 741928-1 Subframe – Additional Beacon 293717-1 Subframe – Additional Worklamp 293717-1 BEAC.
VT551 - Maintenance LH Work Lamp 293717-1 Marker Lamp 293717-1 Node 1 – Power 293717-1 293725-1 Node 1 – I/O 293725-1 Powapak 293717-1 293725-1 Node 2 – Power 293717-1 293726-1 Node 2 – I/O 293726-1 Powapak 293717-1 293726-1 Number Plate 293717-1 Auxiliary Engine –. VT551 - Maintenance Electrical Components Diagram - SE300z02 Chapter - Electrical System Page Issue 02. VT551 - Maintenance Electrical Components Diagram - SE300z03 Chapter - Electrical System 9:10 Page Issue 02.
VT551 - Maintenance System Map Diagram - SE301z01 Chapter - Electrical System 9:11 Page Issue 02. VT551 - Maintenance Relay and Fuse Box Diagram 24 Volt - SE302z01 Chapter - Electrical System 9:12 Page Issue 02. VT551 - Maintenance Relay and Fuse Box Diagram 12 Volt - SE302z02 Chapter - Electrical System 9:13 Page Issue 02. VT551 - Maintenance Node 1 Diagram - SE303z01 Chapter - Electrical System 9:14 Page Issue 02. VT551 - Maintenance Node 2 Diagram - SE304z01 Chapter - Electrical System 9:15 Page Issue 02. VT551 - Maintenance P1 CANview Diagram - SE305z03 Chapter - Electrical System 9:16 Page Issue 02. VT551 - Maintenance P2 Subframe Diagram - SE306z02 Chapter - Electrical System 9:17 Page Issue 02.
VT551 - Maintenance Body Rear Beacon / Marker Lamp Diagram - SE307z01 Chapter - Electrical System 9:18 Page Issue 02. VT551 - Maintenance Switch Panel Diagram - SE308z01 Chapter - Electrical System 9:19 Page Issue 02.
VT551 - Maintenance VM Engine Diagram - SE309z01 Chapter - Electrical System 9:20 Page Issue 02. VT551 - Maintenance CHAPTER Water System Table of Contents Section Page Introduction General Description 10: 2 Supawash 10: 2 Circuit Pressures 10: 2 Component Maintenance and Settings Relief Valve 10: 3 Solenoid Valves 10: 3. VT551 - Maintenance GENERAL DESCRIPTION Pressure for the water supply is provided by a piston pump hydraulically driven from the auxiliary engine. Pressure regulation is by a relief valve situated at the rear of the machine.
Filtration is by a in-line type located at the right hand rear of the machine. VT551 - Maintenance RELIEF VALVE This valve is factory set and should not normally be touched, but should it be necessary to make adjustments, the pressure is set as follows. PRESSURE SETTING Remove the cover (A) and loosen adjuster locknut (B).
VT551 - Maintenance Piping Diagram - Low Pressure System BLOCK 3 RH SINGLE LH SINGLE W10 W3 W3 W10 DUAL W9 W10 DUAL SWEEP (D/S) SHOWN 93MA. 011-4 Chapter - Water System 10:4 Page Issue 01.
VT551 - Maintenance Illustration Component Key Water tank Tank overflow vent Water pump - output 30 l/m Unloader Suction filter Tank flushing ports Tank filler port - hosepipe Water level sight glass Tank drain/flushing valve Hydrant filler port for water tank Type ‘A’. VT551 - Maintenance Single Sweep Low Pressure Water - Diagram SW301a02 Chapter - Water System 10:6 Page Issue 01. VT551 - Maintenance Water System Low Pressure Dual Sweep - Diagram SW302a01 Chapter - Water System 10:7 Page Issue 01. VT551 - Maintenance LP / HP Valve Location Chapter - Water System 10:8 Page Issue 01.
VT551 - Maintenance Water Pump Repair Water pumps by their very nature are subject to erosion and wear from the process of pumping water. The life of the pump will depend on the quality of the water being used. The more particles that are in suspension in the water the sooner the seals and valves in the pump will wear and require replacing and are therefore considered as consumable items. VT550 - Maintenance P22/34-100 Johnston Water pump 283701-1 Seal and Valve Maintenance Instructions The following shows the overhaul procedure for the valves and plunger seals 1.
With a 22mm socket, 2. With a pair of needle nose pliers remove the spring. VT550 - Maintenance 9. Remove and inspect the 10.
Turn over intermediate 11. Remove the seal case low pressure seal (50) and casting (48) Remove (39) from the valve casing replace if necessary. And inspect the high (29) and inspect both O pressure seal (31) and the Rings (40) for wear. VT550 - Maintenance 18.
Replace the three 19. Install the pressure 20. Secure the intermediate spacer sleeves (26a) over rings (30) over the plungers casing (48) to the valve the plunger (24a) with the (24a). Make sure that the casing (29) with the inner f anged side toward the small o ring (49) is in place hexagon screws (46).
VT550 - Maintenance Exploded view of Pump Item Number Quantity Part Number Description 283701-13 Woodruff Key 283701-14 Connecting Rod 283701-12 Ceramic Liner 31,32,40,49,50 1 Kit 283701-10 Plunger Seal kit - for 3 plungers 34,35,36,37,38 1 Kit 283701-11 Valve Kit - for the 6 valves Chapter - Water System 10:13 Page Issue 01. VT551 - Maintenance High Pressure Water - Diagram SW303z02 Chapter - Water System 10:14 Page Issue 01. VT551 - Maintenance CHAPTER Pneumatic System Table of Contents Section Page Introduction General Description 11: 2 Circuit Pressures 11: 2 Pneumatic Pipe Colours 11: 2 Component Valve Identification 11: 3 Component Removal Air Filtration and Regulator (FR). VT551 - Maintenance GENERAL DESCRIPTION The air supply for the pneumatic system is taken from the vehicle braking system via a safety regulating valve that ensures the braking system receives priority in the event of a failure to the sweeper air system. VT551 - Maintenance COMPONENT IDENTIFICATION NODE 5 93MA. 003 Regulators A1 - B2 Wide Sweep Brush Balance - adjustable Channel brush Powasave - adjustable Wide sweep brush Powascrub - fixed Channel brush Powathrust (yellow) - fixed Left hand channel brush Kickback - adjustable.
VT551 - Maintenance AIR FILTRATION AND REGULATOR (FR) A filter regulator unit, located near the fan case in the right hand side of the body, filters the air for the sweeper section of the pneumatic system to prolong the life of the components served by it. VT551 - Maintenance Pneumatic Valve Island Configuration Chapter - Pneumatic System 11:5 Page Issue 01. VT551 - Maintenance WIDE SWEEP BRUSH REGULATOR MAINTENANCE Before any work can be carried out on these units, they must be removed from their locations under the ends of the subframe crossmember+ as follows. Exhaust the system using filter regulator shut off valve, disconnect pipes from regulator and shuttle valve, unscrew regulator securing nut. VT551 - Maintenance Maxigap Single Sweep - Diagram SP301z02 Chapter - Pneumatic System 11:7 Page Issue 01. VT551 - Maintenance Maxigap Dual Sweep - Diagram SP302z03 Chapter - Pneumatic System 11:8 Page Issue 01. VT551 - Maintenance Mesh Shakers and Littasnatch Option - Diagram SP305z01 Chapter - Pneumatic System 11:9 Page Issue 01.
VT551 - Maintenance Chapter - Pneumatic System 11:10 Page Issue 01. VT551 - Maintenance CHAPTER Wearing Items Table of Contents Section Page Replacement Instructions Fan Impeller 12: 2 Intake Duct Flap 12: 3 Wear Plate 12: 3 Intake Duct 12: 4 Intake Trunking 12: 4 Intake Seat. VT551 - Maintenance WEARING PARTS REPLACEMENT INSTRUCTIONS It is important that the following safety precautions are observed when working on the machines. Safety Precautions E nsure the machine is standing on firm, level ground and there are no obstructions above or to the rear before raising the body. VT551 - Maintenance REFITTING Replacement is the reverse of removal. Lightly grease the fan motor spline using grease part number 94-24 before fitting the impeller. Fit a new Tuflok capscrew and torque up to 101 Nm (75lbf.
Refit fan case cover with a suitable silicone sealant between the mating surfaces. VT551 - Maintenance INTAKE DUCT These parts are also abraded by the material being conveyed from the suction nozzle and must be periodically inspected and replaced when worn or holed. The duct is 250mm diameter.
REMOVAL Enter body after carrying out the same precautions as for intake flap replacement. VT551 - Maintenance INTAKE SEAT REMOVAL Firstly tip body and support on prop. Release trunking from tube as described on previous page. Release and remove the three countersunk screws and nuts (A).
Lift seat (B) clear of bracket. REFITTING Reverse of removal procedure. As no adjustment for seal compression is provided, it is wise to check seal compression when the body is lowered. VT551 - Maintenance NOZZLE WHEEL BEARINGS REMOVAL To withdraw bearing remove wheel assembly from carriage and remove the three setscrews from the retaining plate. Refit washer and nut, insert M6c x 50mm setscrews, Part No. 124-113, in the three unused retainer plate holes.
VT551 - Maintenance WIDE SWEEP BRUSH FILLS There are two types of brush fills: Plastic ‘throw away’ stock tines. Replacement segments. Plastic Throw Away Stock The stock (H) is removed and can be recycled as plastic waste. Replaceable Segment Option REMOVAL Release and remove the retaining screws (F) securing the end plate / adaptor (A).
VT551 - Maintenance Chapter - Wearing Items 12:8 Page Issue 01. VT551 - Maintenance CHAPTER Remove and Refit Procedures Table of Contents Section Pages Removal and Refitting Instructions Water Pump 13: 2 Wide Sweep Brush Motor 13: 2 Channel Brush Motor 13: 3 Channel Brush Cylinder 13: 3. VT551 - Maintenance This section describes the removal and refitting of some of the major components on the machine. These are not routine jobs and should normally only need to be undertaken when overhauling or exchanging these units. Safety Precautions The hinged prop stowed beneath the body SHOULD BE USED AT ALL TIMES to prop the body when carrying out any inspection, servicing or maintenance work beneath the body. VT551 - Maintenance CHANNEL BRUSH MOTOR - REMOVAL AND REFITTING Unscrew the four nuts (A) from the coach b olts securing the channel brush to the drive adaptor plate and remove brush. Unscrew the retention screw (B) from the centre of the drive adaptor plate and remove plate.
VT551 - Maintenance LIFTING OR REMOVAL OF THE BODY If it is necessary to raise the body, 2 holes are provided in the front of the body. Remove blanking bolts (A).
Insert eye bolt item (B) part no. 422-1 into the M16 socket.
VT551 - Maintenance The hydraulic hoses to the tip ram can now be removed. Fit a nylon strap round the tip ram and remove the 4 bolts holding the trunnion brackets to body front after ensuring the strap will hold the ram correctly. VT551 - Maintenance 10.
FAN CASE AND FAN MOTOR - REMOVAL AND REFITTING Remove the air regulator unit (FR). Remove the red hand rail (2 bolts). Remove the auxiliary engine exhaust bracket (6 bolts). Remove the hydraulic hoses to the fan motor.
VT551 - Maintenance 12. FUEL TANK LH (RED DIESEL) - REMOVAL AND REFITTING Drain fuel tank. Remove the red hand rail. Remove left hand worklamp and access ladder. Manual general ledger template. Remove fuel tank sender and fuel pipes. Remove high pressure lance bracket (if fitted). VT551 - Maintenance Chapter - Remove and Refit Procedures 13:8 Page Issue 01.
VT551 - Maintenance CHAPTER Fault Diagnosis Table of Contents Section Page Power Systems Hydraulic 14: 2 Pneumatic 14: 2 Water 14: 2 Electrical 14: 3 Suction System Suction System 14: 4 Power Pack Auxiliary Engine. Relief valve pressure too low - reset. PNEUMATIC SYSTEMS FAULT SYMPTOM POSSIBLE CAUSE Low pressure warning Air pressure switch faulty. Buzzer on continuously Insufficient pressure in Johnston system. Constant air leak from Cylinder seals leaking internally.
Solenoid block Air solenoid faulty. WATER SYSTEMS FAULT SYMPTOM. VT551 - Maintenance ELECTRICAL SYSTEM FAULT SYMPTOM POSSIBLE CAUSE Beacon not working Check vehicle ignition is on Check beacon bulb/motor Check feed to beacon Check earth wire Check fuse No. 15 or 6 for additional beacons Check switches Check multi plugs to beacon. VT551 - Maintenance SUCTION SYSTEM FAULT SYMPTOM POSSIBLE CAUSE No pick-up performance Hopper full, causing airflow to be throttled: - Discharge load. Nozzle or nozzle trunking blocked or restricted by debris. Check the nozzle water jets are not blocked, are working correctly and lubricating the intake duct.
VT551 - Maintenance AUXILIARY ENGINE FAULT SYMPTOM POSSIBLE CAUSE Auxiliary engine fails to turn over Check truck ignition is on Check battery and connections Check ignition switch Check starter motor Auxiliary engine starts Check feed to actuator but will not accelerate. VT551 - Maintenance WIDE SWEEP BRUSH FAULT SYMPTOM POSSIBLE CAUSE Not rotating Worn drive adaptor and plate Bearings seized Motor seized Foreign matter jammed in brush Check electrical feed to solenoid/Plug LED valve C Check hydraulic system for pressures for diagnosis of. VT551 - Maintenance CHANNEL BRUSH FAULT SYMPTOM POSSIBLE CAUSE Brush slows down after Hydraulic pump worn Channel brush motor worn Check hydraulic pressure for fault diagnosis Works intermittently Check switch in control panel and looms for loose connections - using J-plex. VT551 - Maintenance BODY TIP FAULT SYMPTOM POSSIBLE CAUSE Rear door will not open Check handbrake is on and earth at plug PC1A pin 2 Check master switch V is illuminated Check green safety run button is pressed on pendant unit. VT551 - Maintenance CHAPTER Service Tools Table of Contents Section Page Service Tools Service Tools 15: 2 Chapter - Service Tools 15:1 Page Issue 01. Check valve insertion tool To fit check valve 421-278 422-1 Body Eye Bolt Raising/lifting of body KT 01893 Workshop Prop VT551 tip ram - see Chapter 13 283643-1 Scraper Cleaning fan impeller Chapter - Service Tools 15:2 Page Issue 01.
VT551 - Maintenance CHAPTER Warranty Table of Contents Section Page Warranty Warranty 16: 2 Chapter - Warranty 16:1 Page Issue 01. Provided that the claim is justified and that the correct procedure has been followed, claims will be paid within 30 days of receipt. Offset of claims against sums due to Johnston is hereby specifically prohibited.
Chapter - Warranty. VT551 - Maintenance ENGINES The standard warranty from the engine’s supplier is passed on in full without reduction as specified in the engine manufacturers standard Terms and Conditions. FUELS In line with the engine manufacturers specifications all fuel used must be in line with EN590:1993 and can incorporate a maximum of 5% Bio-diesel. VT551 - Maintenance YOUR COMMITMENT In order to register your warranty please complete and return the form below. I have read the Warranty Terms and Conditions as shown above and understand that the equipment must be operated and maintained in accordance with requirements of this warranty to retain entitlement to its benefit.
Introduction The information presented in this chapter does not infer that there are hazards associated with the Johnston Sweepers. It is given as a guide to general precautions that should be exercised in the course of their maintenance work. Whilst every effort has been made to ensure completeness of this document, owners. VT551 - 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. 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. VT551 - 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. VT551 - 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. VT551 - 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. VT551 - 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. VT551 - Maintenance Chapter - Health and Safety 17:8 Page Issue 01.
The World’s #1 manufacturer of street sweepers and street sweeping equipment. The Stainless Steel Company – Johnston is the only street sweeper manufacturer to offer as standard, “Complete Hopper Constructed of Stainless Steel”- not lined. We don’t use just any stainless steel. We exclusively utilize Nirosta® Stainless Steel – the very best for this application. Johnston street sweeper bodies provide 250-times better corrosion resistance than mild steel and our abrasion resistance is not only better than mild steel, but also better than 304 stainless steel.
Our commitment to this level of excellence is what has gained us the commanding leading position in the vacuum sweeper marketplace. Johnston North America is a wholly owned subsidiary of Johnston Sweepers Ltd. And is our North American hub based in Mooresville, North Carolina. Founded in 1904, Johnston Sweepers is the world leading manufacturer of outdoor surface cleaning equipment – street sweepers.
With two factories in the UK, and over 200 distributors worldwide, Johnston Sweepers is a major global business which as a result gives us stability and access to major financial backing. Johnston’s global reach provides us with unique insight and knowledge, experience gained in a range of international environments that we can use to provide even better sweeping solutions for our customers.
Johnston – Sweeping the World Johnston Sweepers has been manufacturing road sweepers in Dorking, Surrey for more than 75 years, and today is one of the world market leaders in street cleansing vehicles. Johnston exports over 70% of its sweeper production to more than 80 countries worldwide, helping to keep city streets from all over the world cleaned. Our global reach provides us with unique insight and knowledge, experience gained in a range of international environments that we can use to provide even better sweeping solutions for our customers.
. 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. CN101 - Maintenance Foreword Page Issue A. CN101 - Maintenance CHAPTER Page Issue Levels Chapter - Page Issue Levels Page Issue A. 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.
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. CN101 - Maintenance Chapter - Page Issue Levels Page Issue A. 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. CN101 - Maintenance Chapter - Engine Page Issue A.
Johnston Sweeper Vt650
CN101 - Maintenance For engine operator’s manual please refer to the following document; Deutz Operator’s ManualEnglish.pdf For engine timing belt replacement information please refer to the following document; Deutz Timing Belt Replacement.pdf Chapter - Engine Page Issue A. CN101 - Maintenance Chapter - Engine Page Issue A. 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. CN101 - Maintenance Chapter - Electrical System Page Issue A. 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.
CN101 - Maintenance Vehicle Function Truth Table Chapter - Hydraulic System Page Issue A. 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. CN101 - Maintenance Chapter - Electrical System Page Issue A. CN101 - Maintenance Electrical Circuit Key (drawing reference: 7013052 - Issue D) Chapter - Electrical System Page Issue A. CN101 - Maintenance Ignition Switch Circuit (drawing reference: 7013052, Sheet 1 - Issue D) Chapter - Electrical System Page Issue A. CN101 - Maintenance Rear Lighting System Circuit (drawing reference: 7013052, Sheet 2 - Issue D) Chapter - Electrical System Page Issue A.
CN101 - Maintenance Indicators Circuit (drawing reference: 7013052, Sheet 3 - Issue D) Chapter - Electrical System Page Issue A. CN101 - Maintenance Front Lighting Circuit (drawing reference: 7013052, Sheet 4 - Issue D) Chapter - Electrical System Page Issue A. CN101 - Maintenance Reversing Camera Circuit (drawing reference: 7013052, Sheet 5 - Issue D) Chapter - Electrical System Page Issue A. CN101 - Maintenance Wipers Circuit (drawing reference: 7013052, Sheet 6 - Issue D) Chapter - Electrical System Page Issue A. CN101 - Maintenance Heater / Air Conditioning Circuit (drawing reference: 7013052, Sheet 7 - Issue D) 3:10 Chapter - Electrical System Page Issue A. CN101 - Maintenance Water System 1 Circuit (drawing reference: 7013052, Sheet 8 - Issue D) 3:11 Chapter - Electrical System Page Issue A.
CN101 - Maintenance Water System 2 Circuit (drawing reference: 7013052, Sheet 9 - Issue D) 3:12 Chapter - Electrical System Page Issue A. CN101 - Maintenance Engine Starter Circuit (drawing reference: 7013052, Sheet 10 - Issue D) 3:13 Chapter - Electrical System Page Issue A. CN101 - Maintenance Sensors Circuit (drawing reference: 7013052, Sheet 11 - Issue D) 3:14 Chapter - Electrical System Page Issue A. CN101 - Maintenance ECU Controller Circuit (drawing reference: 7013052, Sheet 12 - Issue D) 3:15 Chapter - Electrical System Page Issue A. CN101 - Maintenance Transmission Circuit (drawing reference: 7013052, Sheet 13 - Issue D) 3:16 Chapter - Electrical System Page Issue A. CN101 - Maintenance Side Brush Positioning Circuit (drawing reference: 7013052, Sheet 14 - Issue D) 3:17 Chapter - Electrical System Page Issue A. CN101 - Maintenance Suction Circuit (drawing reference: 7013052, Sheet 15 - Issue D) 3:18 Chapter - Electrical System Page Issue A.
Johnston Sweeper Vt650 Truck Mounted Pdf
CN101 - Maintenance Side Brush Sweeping Control Circuit (drawing reference: 7013052, Sheet 16 - Issue D) 3:19 Chapter - Electrical System Page Issue A. CN101 - Maintenance Hydraulics & Water Recirculation Circuit (drawing reference: 7013052, Sheet 17 - Issue D) 3:20 Chapter - Electrical System Page Issue A.
CN101 - Maintenance Hopper & Heating Circuit (drawing reference: 7013052, Sheet 18 - Issue D) 3:21 Chapter - Electrical System Page Issue A. CN101 - Maintenance 4WS Circuit (drawing reference: 7013052, Sheet 19 - Issue D) 3:22 Chapter - Electrical System Page Issue A. CN101 - Maintenance CHAPTER Optional Equipment Table of Contents Section Page 4WS Bleeding 4: 2 Chapter - Water System Page Issue A. 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. 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. Lower the hopper and test drive the vehicle to ensure correct operation.
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. 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. 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.
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 –. 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. Adjust cylinder ball joint a) Release the steering cylinder ball joint lock nut. 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. 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. 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. CN101 - Maintenance 7. Remove the steering lock stops (Item 5) from the swivel housing and discard the original swivel housing. 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.
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. Remove both front wheels. Start the vehicle engine and engage 4WS, ensuring the vehicle remains stable and fully. 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.
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:. CN101 - Maintenance 5:12 Chapter - Servicing Procedures Page Issue A. CN101 - Maintenance CHAPTER Service Tools Table of Contents Section Page Service Tools 6: 2 Chapter - Service Tools Page Issue A. 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. 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. 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. 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. 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. 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. 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. 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. CN101 - Maintenance Chapter - Health and Safety Page Issue A.
Mastercam x2 guide 3d. Mastercam X2 Training Guide - Mill 2D and 3D. This Instructional Training Guide provides all the instructions you need to learn 2D and 3D Geometry Creation.
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