Johnston VT501 Instructions for use

Johnston Sweepers Limited
All Copyright and rights are the property of Johnston Sweepers Ltd
Pneumatic System
Page Issue Levels
Scheduled Maintenance
Hydraulic System
Electrical System
Water System
Wearing Items
Remove and Refit Procedures
Fault Diagnosis
Service Tools
Health and Safety
Maintenance
Section
P
1
2
3
4
5
6
7
8
9
10
ECN 712655 Print date - 10/02/2016
VT - Twin Engine Specific to Twin engine sweepers.
VS - Single Engine Specific to Single engine sweepers.
V Range Suction Sweepers
Incorporating
VT501 ● 651 ● 801
Twin engine machines
&
VS501 ● 651 ● 801
Single engine, Hydrostatic machines
(MKII Systems Wafer)
Part No 7037358
Revision Level B

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual
Foreword
P Chapter - Page Issue Levels
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1 Chapter - Scheduled Maintenance
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2 Chapter - Hydraulic System
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Page Issue B

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual Johnston Sweepers Limited
Foreword
3 Chapter - Electrical System continued ...
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4 Chapter - Water System
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Page Issue B

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V Range 501 l651 l801 Maintenance Manual
Foreword Page Issue B
6 Chapter - Wearing Items
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6:3 B C 6:4 B C
6:5 A 6:6 A
7 Chapter - Remove and Refit Procedures
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MA1:1
V Range 501 l651 l801 Maintenance Manual
CHAPTER 1
Johnston Sweepers Limited
Scheduled Maintenance
Chapter - Scheduled Maintenance
All Copyright and rights are the property of Johnston Sweepers Ltd
Table of Contents
Section Page
Introduction
Regular Maintenance 1 : 2
Safety Precautions 1 : 3
Security of Sweeping Equipment 1 : 4
Standard Repair Times 1 : 5
Auxiliary Engine
Throttle Settings 1 : 10
Auxiliary Engine and Gearbox Drain Plugs 1 : 10
Fluid Flywheel - VT
Maintenance 1 : 11
Draining and Filling Instructions 1 : 11
Hydraulics - VT
Hydraulic Oil Reservoir 1 : 12
Hydraulics - VS
Hydraulic Oil Reservoir 1 : 13
Pneumatics
Filter regulator Unit 1 : 14
Cleaning the Vehicle 1 : 15
Additional Information - VS
Regular Maintenance 1 : 16
Engine Management ECU 1 : 16
Transmission Pump Oil Filter Replacement 1 : 17
Page Issue B

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual
MA1:2 Chapter - Scheduled Maintenance Page Issue B
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.
INTRODUCTION

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MA1:3
V Range 501 l651 l801 Maintenance Manual Johnston Sweepers Limited
Chapter - Scheduled Maintenance
Page Issue B
l Ensure the machine is standing on firm, level ground and there are no obstructions above or to
the rear before raising the body and that the vehicle’s parking brake is applied.
l Ensure the safety prop is used at all times when working under the body.
l Ensure operators are fully conversant with the controls and operation.
l Isolate the air in the systems locker before working on any pneumatically operated or controlled
equipment.
l Disconnect or isolate the vehicle battery when working on the electrical system.
l Ensure the engine is switched off once the channel brush has been lowered for adjustment.
l Be aware of the safety instructions relative to the suction fan given in the equipment maintenance
notes.
l Keep hands, loose clothing, hair etc. well clear of moving parts.
l Do not climb on the walkways unnecessarily or approach the fan inlet whilst the engine is
running.
l Do not grasp any part of the engine or exhaust system without first ascertaining whether it
has cooled sufficiently to avoid scalding.
l Do not use ill-fitting tools such as spanners that may slip and cause injury.
l 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.
l The use of ‘needle stick gloves’ is recommended when changing brushes, using the Wanderhose/
Littasnatch and when cleaning out the machine.
Safety Precautions

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual
MA1:4 Chapter - Scheduled Maintenance
Security of Equipment
As part of the maintenance programme it is recommended to check the security of various components (see
‘B’ Service in Operators Guide).
HS-031
FA-0051 Tightening Torque
Bolts with metric coarse thread Bolts with metric fine thread
Zinc Plated or Dacromet Bolts/setscrews & Nuts (Friction coefficient 0.12 assembled dry) or
Stainless Steel (Friction coefficient 0.1 assembled lubricated with Molycote grease)
Generally bolts and nuts of the same grade material are used together.
Property Class
Thread 8.8 Steel 10.9 Steel
12.9 Steel
M 8 x 1 25 Nm 35 Nm 45 Nm
M 10 x 1,25 50 Nm 75 Nm 85 Nm
M 12 x 1,25 90 Nm 135 Nm 155 Nm
M 12 x 1,5 90 Nm 125 Nm 150 Nm
M 14 x 1,5 140 Nm 205 Nm 245 Nm
M 16 x 1,5 215 Nm 320 Nm 370 Nm
M 18 x 1,5 325 Nm 460 Nm 545 Nm
M 20 x 1,5 450 Nm 645 Nm 755 Nm
M 22 x 1,5 610 Nm 870 Nm 1020 Nm
M 24 x 2 765 Nm 1095 Nm 1280 Nm
M 27 x 2 1150 Nm 1600 Nm 1950 Nm
M 30 x 2 1600 Nm 2250 Nm 2700 Nm
Property Class
Thread
4.8/5.6 Steel 8.8 Steel
A1- 50 S/S
10.9 Steel
A2-70 S/S
12.9 Steel
A4- 80 S/S
0.13 Nm 0.35 Nm 0.5 Nm 0.6 Nm
M 2
0.1 Nm 0.23 Nm 0.3 Nm
0.60 Nm 1.3 Nm 1.8 Nm 2.1 Nm
M 3
0.4 Nm 0.8 Nm 1.1 Nm
1.4 Nm 3.0 Nm 4.5 Nm 5.0 Nm
M 4
0.86 Nm 1.85 Nm 4.0 Nm
2.8 Nm 6 Nm 8.5 Nm 10 Nm
M 5
1.6 Nm 3.6 Nm 4.8 Nm
4.3 Nm 10 Nm 16 Nm 20 Nm
M 6
2.9 Nm 6.3 Nm 8.5 Nm
11.5 Nm 25 Nm 35 Nm 40 Nm
M 8
7.1 Nm 15 Nm 20 Nm
23 Nm 48 Nm 70 Nm 80 Nm
M 10
14 Nm 30 Nm 40 Nm
40 Nm 84 Nm 120 Nm 140 Nm
M 12
24 Nm 50 Nm 70 Nm
60 Nm 135 Nm 195 Nm 230 Nm
M 14
38 Nm 82 Nm 110 Nm
95 Nm 205 Nm 300 Nm 355 Nm
M 16
58 Nm 125 Nm 165 Nm
130 Nm 290 Nm 420 Nm 485 Nm
M 18
82 Nm 175 Nm 235 Nm
185 Nm 410 Nm 580 Nm 680 Nm
M 20
115 Nm 245 Nm 375 Nm
250 Nm 560 Nm 800 Nm 940 Nm
M 22
157 Nm 337 Nm 450 Nm
320 Nm 710 Nm 1000 Nm 1180 Nm
M 24
1050 Nm 1480 Nm 1750 Nm
M 27
1420 Nm 2030 Nm 2380 Nm
M 30
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Version 00 25/10/2010
These torques apply unless specified on the drawing.
For steel bolts used in conjunction with aluminium parts the
follwing rule applies:
Use the next lower value from the column for property class 10.9.
This directive is valid for all thread diameters and grades.
(e.g. M10 grade 10.9 bolt clamping aluninium parts should be
torque to 35 Nm not 70 Nm)
Page Issue B

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MA1:5
V Range 501 l651 l801 Maintenance Manual Johnston Sweepers Limited
Chapter - Scheduled Maintenance
Area Remove / Ret Time Taken
(Mins)
Special Tools
Required
1 or 2
Persons
Hopper Side Locker Door 10 none 1
Hopper Side Locker Gas strut 10 none 1
Hopper Side Locker door catch mechanism 10 none 1
Hopper Side Door (each) 10 none 1
Hopper Side Door Seal (each) 25 none 1
Hopper Side Door lock and catch (each) 15 none 1
Hopper Mesh Screen (each) 10 none 1
Hopper Body Tip Cylinder 60 none 1
Hopper Body tip Hinges 120 none 1
Hopper Door Lock Hydraulic cylinder 25 none 1
Hopper Door Lock Proximity switch (each) 10 none 1
Hopper Rear Door Chute plate 30 none 1
Hopper Wear Plate (each). 30 none 1
Hopper Intake Duct 45 none 1
Hopper Centre Bafe (Dual machines only). 15 none 1
Hopper Rear Door 70 none 1
Hopper Rear Door Cylinder 35 none 1
Hopper Rear Door Seal 30 none 1
Hopper Fan Case Seal 20 none 1
Hopper Cowl Seal 45 none 1
Hopper Cowl NAF 90 none 1
Hopper Intake duct ap air cylinder 15 80 bar Pressure 1
Hopper Intake duct ap Actuator 10 none 1
Hopper Intake duct ap 10 TB1556 1
Hopper Intake duct ap Shaft 60 none 1
Hopper Flap shaft bush (inside body) 30 none 1
Hopper Flap shaft bearing (outside body) 15 none 1
Subframe Body tip mount. 40 none 1
Subframe Water lter assembly 30 none 1
Subframe Body prop 15 Workshop body prop
PN:7030765
1
Subframe Body prop release assembly 25 none 1
Used oils and filters should be disposed of in accordance with the local
waste disposal regulations.
These procedures should be carried out by qualified service personnel.
This Guide Detail the time taken to remove, ret and validate the item listed. Where the task is listed as 2
person the total time taken is shown in the table however certain aspects of the tasks may require 2 persons
for the safe completion of the task.
Page Issue B
STANDARD REPAIR TIMES (SRT)

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual
MA1:6 Chapter - Scheduled Maintenance
Area Remove / Ret Time Taken
(Mins)
Special Tools
Required
1 or 2
Persons
Sweepgear Channel Brush position ram (Includes
check and top up hydraulic oil)
30 None 1
Sweepgear Channel brush curtain (each) 10 None 1
Sweepgear Channel brush kick back fork (Includes
replacement of spring)
20 None 1
Sweepgear Channel brush lift ram 15 None 1
Sweepgear Channel brush motor (with brush and
brush plate removed). Includes check
and top up of hydraulic oil
25 None 1
Sweepgear Channel brush motor mounting (with
motor, brush and brush plate removed)
10 None 1
Sweepgear Brush plate (with brush removed) 10 None 1
Sweepgear Brush head 10 None 1
Sweepgear Nozzle assembly 30 None 1
Sweepgear Nozzle carriage (Nozzle assembly
removed)
15 None 1
Sweepgear Nozzle rubbers 30 None 1
Sweepgear Nozzle water jets (low pressure) 15 None 1
Sweepgear Nozzle tow bar (With tow eye removed) 25 None 1
Sweepgear Nozzle tow eye 10 None 1
Sweepgear Nozzle box lift cylinder (each) 15 None 1
Sweepgear Maxi gap cylinder 15 None 1
Sweepgear Carriage wheel (Includes remove and
ret auto lube pipe)
10 None 1
Sweepgear Nozzle box bumper 10 None 1
Sweepgear Trunking 10 None 1
Wide Sweep
Brush
WSB Assembly (Dual and single ma-
chines )
90 None 1
Wide Sweep
Brush
Brushes (Replace) 30 None 1
Wide Sweep
Brush
Tow bar (Includes removal and retting
of WSB and brushes)
40 None 1
Wide Sweep
Brush
Tow bar compensator (Includes
removal and retting of WSB, brushes
and tow bar)
45 None 1
Wide Sweep
Brush
Brush motor (Includes removal and
retting of brushes)
75 None 1
Used oils and filters should be disposed of in accordance with the local
waste disposal regulations.
These procedures should be carried out by qualified service personnel.
This Guide Detail the time taken to remove, ret and validate the item listed. Where the task is listed as 2
person the total time taken is shown in the table however certain aspects of the tasks may require 2 persons
for the safe completion of the task.
Page Issue B