Johnston VT551 Instructions for use

E.C.M. Issue - 707668 Print date - 05.10.2011
Maintenance
Section
VT551
Twin Engined
Suction Sweeper
With Mk II CANview Software
Stage 3a VM Engine
Part No 02634-1-M
Revision Level 02
Pneumatic System
Page Issue Levels
Scheduled Maintenance
Hydraulic System
Electrical System
Water System
11
Wearing Items
Remove and Refit Procedures
Fault Diagnosis
Service Tools
Warranty
Health and Safety
7
P
8
9
10
12
13
14
15
16
17
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VT551 - Maintenance
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Page Issue Levels
CHAPTER P
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’.
P1
VT551 - Maintenance
Section Revision Level 02
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Page Issue LevelsP2
P Chapter - Page Issue Levels
Page Issue Changed Page Issue Changed
P1 02 C P2 02 C
P3 02 C P4 02 C
7 Chapter - Scheduled Maintenance
Page Issue Changed Page Issue Changed
7:1 01 7:2 01
7:3 01 7:4 01
7:5 02 C 7:6 01
7:7 01 7:8 01
8 Chapter - Hydraulic System
Page Issue Changed Page Issue Changed
8:1 01 8:2 01
8:3 02 C 8:4 01
8:5 01 8:6 01
8:7 01 8:8 01
8:9 01 8:10 01
8:11 01 8:12 01
9 Chapter - Electrical System
Page Issue Changed Page Issue Changed
9:1 01 9:2 01
9:3 01 9:4 01
9:5 01 9:6 01
9:7 01 9:8 01
9:9 02 C 9:10 02 C
9:11 02 C 9:12 02 C
9:13 02 C 9:14 02 C
9:15 02 C 9:16 02 C
9:17 02 C 9:18 02 C
9:19 02 C 9:20 02 C
Section Revision Level 02
VT551 - Maintenance
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10 Chapter - Water System
Page Issue Changed Page Issue Changed
10:1 01 10:2 01
10:3 01 10:4 01
10:5 01 10:6 01
10:7 01 10:8 01
10:9 01 10:10 01
10:11 01 10:12 01
10:13 01 10:14 01
11 Chapter - Pneumatic System
Page Issue Changed Page Issue Changed
11:1 01 11:2 01
11:3 01 11:4 01
11:5 01 11:6 01
11:7 01 11:8 01
11:9 01 11:10 01
12 Chapter - Wearing Items
Page Issue Changed Page Issue Changed
12:1 01 12:2 01
12:3 01 12:4 01
12:5 01 12:6 01
12:7 01 12:8 01
13 Chapter - Remove and Refit Procedures
Page Issue Changed Page Issue Changed
13:1 01 13:2 01
13:3 01 13:4 01
13:5 01 13:6 01
13.7 01 13.8 01
14 Chapter - Fault Diagnosis
Page Issue Changed Page Issue Changed
14:1 01 14:2 01
14:3 01 14:4 01
14:5 01 14:6 01
14:7 01 14:8 01
Page Issue Levels P3Section Revision Level 02
VT551 - Maintenance
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Page Issue LevelsP4 Section Revision Level 01
VT551 - Maintenance
15 Chapter - Service Tools
Page Issue Changed Page Issue Changed
15:1 01 15:2 01
16 Chapter - Warranty
Page Issue Changed Page Issue Changed
16:1 01 16:2 01
16:3 01 16:4 01
17 Chapter - Health and Safety
Page Issue Changed Page Issue Changed
17:1 01 17:2 01
17:3 01 17:4 01
17:5 01 17:6 01
17:7 01 17:8 01
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Chapter - Scheduled Maintenance
CHAPTER 7
Scheduled Maintenance
7:1
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 7 : 6
Hydraulics
Hydraulic Oil Reservoir 7 : 7
Pneumatics
Filter Regulator Unit 7 : 8
Page Issue 01
VT551 - Maintenance
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Page Issue 01Chapter - Scheduled Maintenance7:2
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.
The maintenance schedule specified are for average operating conditions. Under particularly dry and
dusty conditions, it is essential that more frequent attention is given to:
1 Air cleaner servicing.
2 Engine oil changes.
3 Fluid oil changes.
4 Gearbox oil changes.
5 Hydraulic oil changes.
Attention to the servicing of air cleaners fitted to both auxiliary and vehicle engines is of vital importance
as clean air is essential for the proper functioning and ultimate life of an engine. Badly serviced air
cleaners can allow dust particles to be directly induced into the internal working surfaces with a resulting
rapid increase in engine wear and eventually complete failure. This also applies to any air leaks occurring
between the air cleaner and the engine inlet manifold. See separate instructions for Air Cleaner Servicing.
It is important that the following Safety Precautions are observed when working on the machine.
 Ensure the machine is standing on firm, level ground and there are no obstructions above or
to the rear before raising the body.
 Ensure the safety prop is used at all times when working under the body.
 Ensure operators are fully conversant with the controls and operation.
 Isolate the air in the filter regulator unit before working on any pneumatically operated or
controlled equipment.
 Disconnect or isolate the vehicle battery when working on the electrical system.
 Ensure the auxiliary engine is switched off once the channel brush has been lowered for
adjustment.
 Be aware of the safety instructions relative to the suction fan given in the equipment
maintenance notes.
 Keep hands, loose clothing, hair etc. well clear of moving parts.
 Do not climb on the engine walkways unnecessarily or approach the fan inlet whilst the
engine is running.
 Do not grasp any part of the engine or exhaust system without first ascertaining whether it
has cooled sufficiently to avoid scalding.
 Do not use ill-fitting tools such as spanners that may slip and cause injury.
 Use approved safety platforms/gantries when working above ground level. Get a
second person to check periodically when only one person is working on access
equipment or inside the body.
 The use of ‘needle stick gloves’ is recommended when changing brushes, using the
wanderhose/Littasnatch and when cleaning out the machine.
Safety Precautions
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Page Issue 01 Chapter - Scheduled Maintenance 7:3
VT551 - Maintenance
95MA. 024
ALTERNATIVE END MOUNTING POSITIONS
(HARDWARE AS PREFERED POSITIONS ie. ‘C’ and ‘D’)
‘A’ = M12 Standard ‘B’ = M12 Grade 10.9 ‘C’ = M14 Grade 10.9
‘D’ = M12, M14 Grade depending on chassis10.9 or M16 Standard
Torque Settings
M12 Standard = 95 Nm (70 lbf/ft)
M12 Grade10.9 = 135 Nm M16 = 235 Nm
M14 Grade 10.9 = 215 Nm (160 lbf/ft)
(100 lbf/ft) Standard (150 lbf/ft)
C
C
CC
C
AA
DDDD
CC
A
A
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.
CIRCUIT DIAGRAMS
A chart can be found overleaf to assist in finding the circuit diagram required.
The actual circuit diagrams will be found in the appropriate chapter.
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Page Issue 01Chapter - Scheduled Maintenance7:4
VT551 - Maintenance
Fluid Finder - Diagram SF300z03
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Page Issue 02 Chapter - Scheduled Maintenance 7:5
VT551 - Maintenance
Diagram Index - SE300z01
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Page Issue 01
Chapter - Scheduled Maintenance
7:6
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.
THROTTLE SETTINGS
The engine tick-over speed is adjustable and is set by the tick-over screw on the injector pump. The
engine maximum speed is controlled by the CANbus system and is not adjustable. The relevant speeds
are given in the chart below.
ENGINE
TYPE
JOHNSTON
PART NO.
IDLE
SPEED
Rev/min
MAXIMUM
FLIGHT SPEED
(Off Load)
Rev/Min
VM D754TE3
VM D754TE3
7015088 (12V)
7008519 (24V)
850
850
1800
1800
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Page Issue 01 Chapter - Scheduled Maintenance 7:7
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. body raised, then the
filter is contaminated and requires changing at an earlier interval.
HYDRAULIC OIL RESERVOIR
Note: The filters can only be changed when the tank has been drained.
RENEWING THE RETURN FILTER
Unscrew cover (A) with a suitable spanner and lift out the cartridge element (B). Refit cartridge and screw
on the cover, some force will be required to compress the carriage retaining spring.
SYSTEM DRAINING
The oil can be drained by opening the tap
(G) and draining into a suitable receptacle.
RENEWING THE SUCTION FILTER
Change the filter whilst the system is empty.
The filter is changed as follows:
Remove the hydraulic hoses (D) to gain
access to the filter element (E). Replace
element and reassemble.
SYSTEM REFILLING
The system capacity dry is 80 litres. Refer to
Chapter 6 of the Operator’s Guide detailing
the correct oil level in the reservoir.
This should only be changed when the oil is cold, as the system could be
pressurised. Leave for 60 seconds after stopping for any pressure to be
dissipated before removing the return filter.
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Page Issue 01Chapter - Scheduled Maintenance7:8
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
IN
A
B
C
D
CURRENT TYPE ‘A’ UNIT
(WITH SHUT OFF BALL VALVE ‘C’)
93MA. 017-2
The air filter unit incorporates a semi automatic drain which automatically dumps accumulated water when
the air supply is isolated by the shut off valve (C). It can also be drained by pushing up the drain tube (B)
that protrudes from the underside.
The pressure regulator (A) ensures the equipment is not over pressurised. It is factory set and sealed at
7.5 bar (108 psi).
A pressure switch (D) is fitted to illuminate the low air pressure warning lamp on the cab switch panel.
PNEUMATIC CYLINDER MAINTENANCE
Periodically inspect the cylinder rods for damage, blemishes or build up of material such as tar, cement,
paint etc. The rods can be cleaned with fine wire wool and/or spirit and should be kept clean to ensure
long seal life.
HYDRAULIC CYLINDER MAINTENANCE
Observe the notes on damage etc. described under pneumatic cylinders, especially with regard to the
wide sweep brush slewing cylinder on dual sweep machines and the channel brush lift cylinder.
Avoid playing the water washdown hose over the body tip cylinder when in the fully raised condition.
CLEANING THE VEHICLE
With the advent of high pressure steam and washdown equipment, damage can be caused by playing
this equipment onto the electrical control system, paintwork etc. and great care should be exercised when
it is carried out.
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CHAPTER 8
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 8 : 4
Hydraulic System
Initial Operation 8 : 5
Valve Identification 8 : 5
Circuit Diagrams
Hydraulic Tank Connections 8 : 6
Single Sweep 8 : 7
Dual Sweep 8 : 8
Suction Fan / Load Discharge 8 : 9
Pump Services 8 : 10
Emergency Hand Pump 8 : 11
Chapter - Hydraulic System 8:1
Page Issue 01
VT551 - Maintenance
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Page Issue 01Chapter - Hydraulic System8:2
VT551 - Maintenance
GENERAL DESCRIPTION
The hydraulic system may be divided into four hydraulic circuits fed from a common hydraulic reservoir.
1 Sweep system.
2 Water system.
3 Fan drive system and load discharge.
Hydraulic filtration is provided by suction filters within the hydraulic tank, together with replaceable type ‘in
line’ return filter mounted externally on the upper face of the hydraulic tank.
CIRCUIT PRESSURES
Test points are provided on the hydraulic system to carry out pressure checks.
POINT NO. FUNCTION
T7 Sweep system test point
T8 Fan drive system/body discharge
T9 Water system (i.e. Supawash)
To set the hydraulic pressures select menu 4. Set
pressures from the main CANview screen and choose
sub menu 11.
NB : There is a default setting on this menu 4.11.6
to input default figures, in order for you to be able to
initially set the machine up and run the engine.
BRUSH PRESSURE - MENU 4.11.1
Connect a suitable 250 bar gauge to test point T7 (see
Valve Identification).
It is necessary to remove hose 201 in port C1 of the
‘sweep block 4’ and plug with a suitable plug and
also cap off the hose. Follow the on screen CANview
instructions.
This pressure should be 225 bar.
If necessary manually adjust RV1.
NB : DO NOT run the pressure test for longer than 30 seconds or damage maybe caused to the system.
93OG. 027-35
50% 14:00 25%4.0
93OG. 027-41
50% 14:00 25%
4.11
4.11
&
1 3 5
2 4 6
93OG. 027-36
50% 14:00 25%4.11.1
T7
C1
BLOCK 4
RV1
1800
n/min
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Page Issue 02 Chapter - Hydraulic System 8:3
VT551 - Maintenance
WATER SYSTEM - MENU 4.11.2
Connect a suitable 250 bar gauge to test point T9.
Follow the on screen CANview instructions.
This pressure should be 220 bar. Remember to cap off
hose 206 when port W1 is plugged.
If necessary manually adjust RV2.
SUCTION FAN - MENU 4.11.3
Fit a 250 bar minimum pressure gauge to test point T8.
Follow the on screen CANview instructions.
This pressure should be 150 bar.
If necessary press + or - to adjust the pressure to 150 bar
± 5. Press  to save setting.
HOPPER RAISE - MENU 4.11.4
Connect a suitable 250 bar gauge to Test Point T8.
Follow the on screen CANview instructions.
This pressure should be 175 bar.
If necessary press + or - to adjust the pressure to 175 bar
± 5. Press  to save setting.
HOPPER LOWER - MENU 4.11.5
Connect test point as detailed above and follow the on
screen CANview instructions.
This pressure should be 80 bar.
If necessary adjust pressure by pressing + or -.
Press  to save setting.
93OG. 027-37
50% 14:00 25%4.11.2
T9
W1
BLOCK 4
RV2
1800
n/min
93OG. 027-38
50% 14:00 25%4.11.3
T8
1800
n/min
+-
+-
RP
409MA
93OG. 027-39
50% 14:00 25%4.11.4
T8
1400
n/min
+-
+-
RP
348MA
93OG. 027-40
50% 14:00 25%4.11.5
T8
1400
n/min
+-
+-
RP
204MA
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Page Issue 01Chapter - Hydraulic System8:4
VT551 - Maintenance
FAN PUMP
If the fan pump is changed it is necessary to check the pump pressure setting.
1. Standby - 20 bar.
*Run the auxiliary engine and measure the pressure on test point T8. The standby pressure should
be set at 20 bar.
2. Main Operating Pressure - 150 bar
To check this setting enter the suction fan pressure menu 4.11.3, follow on screen instructions and
increase RP output until the pressure reading on T8 remains the same. Ensure  is pressed to save
the settings.
Please note that if the CANview node (node 3) is changed, the fan pump set up will need to be
re-checked.
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Page Issue 01 Chapter - Hydraulic System 8:5
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.
VALVE IDENTIFICATION
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Page Issue 01Chapter - Hydraulic System8:6
VT551 - Maintenance
Hydraulic Tank Connections - Diagram SH301a02
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