Johnston V Series Manual
Johnston Sweepers Limited
Foreword
General Arrangement
Controls
Operation
Optional Equipment
V Range Suction Sweepers
Incorporating
VT501 ● 651 ● 801
Twin engine machines
&
VS501 ● 651 ● 801
Single engine, Hydrostatic machines
Part No 01282-1-GB (A5 size)
Revision Level 02
E.C.M. Issue - 711837 Print date - 03.02.2014
F
1
2
3
4
Operator’s
Guide
Johnston Visual Module
Routine Maintenance
5
6
Conformity Certificates 7
VT - Twin Engine
VS - Single Engine
Specific to Twin engine sweepers.
Specific to Single engine sweepers.
All Copyright and rights are the property of Johnston Sweepers Ltd
Foreword 1 Issue 01
V Range 501 ●651 ●801 - Operator’s Guide
FOREWORD
The Johnston V501, 651 and 801 range of Suction Sweeper represents the highest grade of
craftsmanship and reliability that makes Johnston probably the world leader in sweeping technology.
This machine is designed for the removal of spoil on traffic or pedestrian areas, and litter collection
using the Wanderhose [Ref. EN 13019], and should only be driven by trained operatives.
This machine should not be used for sweeping hot or burning substances. In the unlikely event of
a fire, normal powder or foam fire fighting equipment can be used on this product.
An operator should receive training in the follow elements:
1 Safety Observations/Notices
2 Transit driving
3 Correct use of body prop
4 In cab controls
5 External controls
6 Sweeping techniques
7 Load discharge
8 Channel brush setting and changing
9 WSB setting and changing
10 Nozzle setting and Maxigap operation
11 Daily and weekly maintenance items
12 Driving/operation assessment
13 End of day cleaning of body and machine
Johnston Sweepers Limited can provide operator training upon request.
We would point out that it is the employers responsibility to carry out his own Risk Assessment on
the equipment in his particular working environment and work application.
This handbook should be carefully studied. In it you will find instructions for the operation and
maintenance of your JOHNSTON SWEEPER.
It is vitally important that the operator and maintenance staff have a copy of this book. The life of
the machine will depend upon following these instructions in respect of regular maintenance and
correct operating methods.
It is important that only GENUINE JOHNSTON SPARE PARTS are used when servicing and
maintaining the sweeper. This is especially important for consumables, filters etc, as the use of
non-genuine parts may cause premature failure and invalidation of warranty.
When carrying out maintenance or part replacement, additional explanatory illustrations can be
found in the Parts Manual, which shows and lists hardware, and availability of spares with the
orientation and positions of the various components.
All Copyright and rights are the property of Johnston Sweepers Ltd
Johnston Sweepers Limited
V Range 501 ●651 ●801 - Operator’s Guide
Issue 01
Foreword 2
Every endeavour has been made to ensure that the information contained in this Operator’s Guide
is correct, but due to continuous product development, the Company reserve the right to alter its
contents without notice. This document should not be interpreted as being part of a formal contract.
The universal safety symbol is used throughout this manual to indicate information which
is essential for health and safety for all operating personnel.
Safety Notice
Johnston®JOHNSTON®JOBRO®BROOMVAK®are registered trade marks of Johnston Sweepers Limited.
All copyrights and rights reserved. The reproduction, distribution and utilisation of this document
as well as the communication of its contents to others without express authorisation is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the
grant of a patent, utility model or design.
For further information and enquiries please contact:
Johnston Sweepers Limited
Curtis Road, Dorking, Surrey RH4 1XF, UK
Tel: +44 (0)1306 884722
Fax: +44 (0)1306 884151
E-mail: [email protected]
Web: www.johnstonsweepers.com
All Copyright and rights are the property of Johnston Sweepers Ltd
Foreword 3 Issue 02
V Range 501 ●651 ●801 - Operator’s Guide
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All Copyright and rights are the property of Johnston Sweepers Ltd
Johnston Sweepers Limited
Issue 01
Foreword 4
V Range 501 ●651 ●801 - Operator’s Guide
INTERNATIONAL SYMBOLS
Conforming to ISO 3767
Graphical symbols are used to indicate the water, fuel and hydraulic oil tank filler ports and air
cleaner servicing instructions.
Their location and descriptions are shown below.
M02OG-001
1a
1a
21b
1b
5
3/4
ULTRA LOW SULFUR
FUEL ONLY
S≤15 mg/kg
1. Water tank filler ports 1a = Hose Pipe
1b = Hydrant
2. Hydraulic oil tank filler
3. Fuel tank (diesel) filler
4. Fuel tank - Engine requires Ultra Low Sulfur fuel
5. Engine air cleaner instructions, i.e. use only genuine Johnston
replacement air cleaner elements and refer to Chapter 6 of this
guide for servicing instructions
All Copyright and rights are the property of Johnston Sweepers Ltd
Foreword 5 Issue 01
V Range 501 ●651 ●801 - Operator’s Guide
VEHICLE SAFETY LABELS
General safety alert symbol.
Read Operator’s Guide.
Crushing of whole body - force applied from above.
Body prop correctly engaged in rack.
Keep clear of brushes.
Severing of fingers or hand - Impeller blade.
Never reach in or drop tools into the fan case.
Release radiator cap carefully when hot to avoid scalding.
Stay at least 1 metre distance from the machine.
Wear ear defenders when working in this area.
General safety alert symbol.
General safety alert symbol.
General safety alert symbol.
General safety alert symbol.
All Copyright and rights are the property of Johnston Sweepers Ltd
Issue 02
V Range 501 ●651 ●801 - Operator’s Guide Johnston Sweepers Limited
DO NOT
● Workonoraroundtheenginewhilstitisrunningexcepttoadjustidlesettings.
● Remove engine radiator cap when the engine is hot, without first covering the
capwithacloth.Release itslowly,otherwise thereisa riskofbeing scaldedby
escaping coolant.
● Touch any part of the engine exhaust system without first allowing it to cool
sufficiently.
● Drainengineoiluntilithascooled,toavoidscalding.
● Disconnecthydraulicorwaterpipeswhilsttheengineisrunning.
● Approachfaninletoroutletwhilstthefanisrunning.
ALWAYS
● Ensure necessary precaution are taken when re-fuelling to avoid any risk from
spillage,duetotheheightofthefuelfiller.
● Ensurethemachineisstandingonfirm,levelgroundandtherearenoobstructions
above or to the rear before raising the hopper.
● Ensurethatthebodyisrestingonthebodyprop,beforeworkingunderneaththe
raised hopper - See Maintenance Section of the Technical Manual.
● Keephands,looseclothing,hairetc,wellclearofmovingparts.
● Useapproved safetyplatforms/gantrieswhen workingabove groundlevel.Get a
secondpersontocheckperiodicallywhenonlyonepersonisworkingonaccess
equipment or inside the body.
● Ensuretheoperatorsandservicepersonnelarefullyconversantwiththecontrols
and their operation.
● Disconnect the vehicle battery when working on the electrical system. Remove
the plugs from the Nodes and the Display when carrying out any welding on the
vehicle.
● Removeignitionkeywhenworkingonthevehicle.Ensureallpersonnelareclear
of the vehicle before restarting engine.
● Ensureallguardsandcoversarerefittedafterservicing.
● Disconnectorisolatetheairsysteminthesystemslockerbeforeworkingonany
pneumatic items.
● Alwaysfollow thechassis manufactures recommendationswhen usinga battery
boosterorstarterpacktoavoiddamagingelectroniccomponents.
Safety Notice
Foreword 6
All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 ●651 ●801 Operator’s Guide
Foreword 7 Issue 01
All Copyright and rights are the property of Johnston Sweepers Ltd
Johnston Sweepers Limited
General Arrangements
Chapter - General Arrangements
Page Issue 01 OG1:1
V Range 501 ●651 ●801 - Operator’s Guide
CHAPTER 1
Table of Contents
Subject Page
General Arrangement
General Arrangement Drawing OG1 : 2
Equipment Access OG1 : 4
All Copyright and rights are the property of Johnston Sweepers Ltd
Chapter - General Arrangements Page Issue 01
OG1:2
V Range 501 ●651 ●801 - Operator’s Guide
10
8
9
11
14
7
17
15
20
26
28
16
19
21
25
31
29
29
18
22
12
M02OG-002-2
5
6
30
1
2
4
13
27
3
29
23
24
GENERAL ARRANGEMENT
All Copyright and rights are the property of Johnston Sweepers Ltd
Johnston Sweepers Limited
Chapter - General Arrangements
Page Issue 01 OG1:3
V Range 501 ●651 ●801 - Operator’s Guide
Item Component See Chapter
1 Hopper/load compartment -
2 Cowling -
3 Body (hopper and cowl) prop 3
4 Auxiliary engine (VT Only) 6
5 Fuel tank -
6 Hydraulic oil reservoir 6
7 Suction fan case 6
8 Systems locker -
9 Channel brush 6
10 Suction nozzle 6
11 Wide sweep brush 6
12 Wanderhose - optional 4
13 Wanderhose extension tubes -
14 Cab Mounted Controls 2
15 Filter screens 6
16 Wearing plate(s) -
17 Hopper centre baffle - duals only -
18 Intake flaps -
19 Water tank -
20 Water tank filler 6
21 Water tank hydrant filler and filter - nearside 6
22 Water tank drain/flushing valve 6
23 Rear door screen -
24 Rear door drainage tap 3
25 Water tank flushing ports 6
26 Water pump primary suction filter 6
27 Water pump secondary suction filter 6
28 Extended water tank plug 4
29 Water spray jets -
30 Washdown hose and control valve 2
Top Mounted Wanderhose Water control valve - optional 2
Littasnatch Water control valve - optional 2
31 Supawash hose reel and hand lance - optional 4
dCold Weather Drains
All Copyright and rights are the property of Johnston Sweepers Ltd
Chapter - General Arrangements Page Issue 01
OG1:4
V Range 501 ●651 ●801 - Operator’s Guide
EQUIPMENT ACCESS
To gain access to any equipment mounted above ground level a folding ladder is provided together
with appropriate grab handles.
The ladder is unfolded into its extended position by de-latching the quick release securing pin.
M02OG-095
●AlwaysensurethattheBodypropislocatedintherackbeforeaccessingtheequipment.
●Always ensure the ladder is securely stowed prior to operating the equipment or
driving the vehicle.
Safety Notice
All Copyright and rights are the property of Johnston Sweepers Ltd
Johnston Sweepers Limited
Controls
Table of Contents
Subject Page
Operating Controls - In Cab
Cab Mounted Controls OG2 : 3
VT - Dual Engine Centre Console OG2 : 4
VS - Single Engine Centre Console OG2 : 6
Door Controller OG2 : 8
Sweeping Controls OG2 : 9
Multifunctional Remote Pendant Unit OG2 : 11
Fuse Functions
Fuse Functions OG2 : 12
OperatingControls-External
Rear Mesh Shaker OG2 : 13
Littasnatch OG2 : 13
Top Mounted Wanderhose OG2 : 13
Wash Down Hose OG2 : 13
Littasnatch Water OG2 : 13
Systems Locker OG2 : 13
Chapter - Controls
Page Issue 01 OG2:1
V Range 501 ●651 ●801 - Operator’s Guide
CHAPTER 2
All Copyright and rights are the property of Johnston Sweepers Ltd
Chapter - Controls Page Issue 01
OG2:2
V Range 501 ●651 ●801 - Operator’s Guide
Thispageisintentionallyblank
All Copyright and rights are the property of Johnston Sweepers Ltd
Johnston Sweepers Limited
Chapter - Controls
Page Issue 01 OG 2:3
V Range 501 ●651 ●801 - Operator’s Guide
CAB MOUNTED CONTROLS
Control Description
M02OG-004
A
B
C
D
E
ACentre Console
BDoor Controller
CMultifunctional Remote Pendant unit mounted by driver’s seat
(For application see Chapter 3 - Operation)
DPowasave Regulator
EDual Steer change over - (Optional - Chassis Dependant)
All Copyright and rights are the property of Johnston Sweepers Ltd
Chapter - Controls Page Issue 01
OG2:4
V Range 501 ●651 ●801 - Operator’s Guide
CENTRE CONSOLE
F1 F2 F3 F4
+
USB
MO2OG-015
F
G
E
L
HI
K
J
D
B
C
AA
12
3
4
AWarning LED’s
BInformation Bar
CDisplay Screen
1 Left hand sweep status
2 Right hand sweep status
3 Option status
4 Soft key function
DSoft Keys and Rotary Encoder
ESweeper Ignition
FEngine Start
GSweep Select
HBeacons
I* Supawash
JWork Lamps
K* Water Recirculation
L* Additional Water Sprays
* Denotes Optional Equipment
VT - Twin Engine
All Copyright and rights are the property of Johnston Sweepers Ltd
Johnston Sweepers Limited
Chapter - Controls
Page Issue 01 OG2:5
V Range 501 ●651 ●801 - Operator’s Guide
ENGINE
Symbol Description
1
st
INFORMATION BAR
Alternator Charge
Engine Management
Air Filter State Indicator
Engine no oil pressure
Engine coolant overheat
Electrical Faults
Hydraulic oil low level
Low air pressure and audible
warning
Vehicle overload
Body raise indicator/rear door
locks open
Symbol Description
Symbol Description
Symbol Description
MULTIFUNCTONALSOFTKEYSANDROTARYENCODER
SoftKeys
Depending on screen selection the functions change. The function is displayed above
the key with a blue icon.
Rotary Encoder
Enables you to navigate the menus. Pressing it selects the highlighted icon.
1st 50 Hour Service
A500 Hour Service
B1000 Hour Service
A1500 Hour Service
C2000 Hour Service or 12
Monthly
D4000 Hour Service or 24
Monthly
Water in Fuel System
Engine Coolant low level
Engine Oil low level
Hydraulic Filter State Indicator
Water Tank low level
Low Autolube
Mute internal buzzer
Hydraulic Oil Temperature
F1 F2 F3 F4
MO2OG-015
SYSTEMS
WARNING LED’s
VT - Twin Engine
All Copyright and rights are the property of Johnston Sweepers Ltd
Chapter - Controls Page Issue 01
OG2:6
V Range501 ●651 ●801 - Operator’s Guide
CENTRE CONSOLE
F1 F2 F3 F4
+
USB
MO2OG-055
F
G
E
L
HI
K
B
C
AA
J
M
D
12
3
4
AWarning LED’s
BInformation Bar
CDisplay Screen
1 Left hand sweep status
2 Right hand sweep status
3 Option status
4 Soft key function
DSoft Keys and Rotary Encoder
ESweeper Ignition and Initiates
engine rpm
FGearbox Engage/Dis-engage
GSweep Select
HBeacons
I* Supawash
JWork Lamps
K* Water Recirculation
L* Additional Water Sprays
M Directional drive selector
* Denotes Optional Equipment
VS - Single Engine
All Copyright and rights are the property of Johnston Sweepers Ltd
Chapter - Controls
Page Issue 01 OG 2:7
V Range 501 ●651 ●801 - Operator’s Guide Johnston Sweepers Limited
ENGINE
Symbol Description
INFORMATION BAR
Cruise Control Active
Transit Drive - Work Mode
Disengaged
Hydrodrive Drive - Work Mode
Enaged
Not used
Suction Fan Active
Electrical Faults
Hydraulic oil low level
Low air pressure and audible
warning
Vehicle overload
Body raise indicator/rear door
locks open
Symbol Description
Symbol Description
Symbol Description
MULTIFUNCTONALSOFTKEYSANDROTARYENCODER
SoftKeys
Depending on screen selection the functions change. The function is displayed above
the key with a blue icon
Rotary Encoder
Enables navigation of the menus. Pressing it selects the highlighted icon.
When Forward drive is selected, the encoder controls the cruise function. Pressing the
encoder enables it, and rotating the encoder CW increases and CCW decreases the
road speed.
Hydraulic Filter State Indicator
Water Tank low level
Low Autolube
Mute internal buzzer
Hydraulic Oil Temperature
F1 F2 F3 F4
MO2OG-015
SYSTEMS
WARNING LED’s
1
st
1st 50 Hour Service
A500 Hour Service
B1000 Hour Service
A1500 Hour Service
C2000 Hour Service or 12
Monthly
VS - Single Engine
All Copyright and rights are the property of Johnston Sweepers Ltd
Chapter - Controls Page Issue 01
OG2:8
V Range501 ●651 ●801 - Operator’s Guide
MO2OG-025
n/min
-
+
EF
B C
D
HI
J
G
A
DOOR CONTROLLER
* Powasave; - In cab regulator sets a Light Sweep to maximise brush life.
With the brush working, turn the regulator Anti-clockwise to set the ground
pressure to its maximum, now turn Clockwise to reduce the pressure to the
required setting.
IN-CAB REGULATOR
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