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
Page Issue Changed Page Issue Changed
P1 B C P2 B C
P3 B C P4 B C
1 Chapter - Scheduled Maintenance
Page Issue Changed Page Issue Changed
1:1 B C 1:2 B C
1:3 B C 1:4 B C
1:5 B C 1:6 B C
1:7 B C 1:8 B C
1:9 B C 1:10 B C
1:11 B C 1:12 B C
1:13 B C 1:14 B C
1:15 B C 1:16 B C
1:17 B N 1:18 B N
2 Chapter - Hydraulic System
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2:1 A 2:2 A
2:3 B C 2:4 B C
2:5 B C 2:6 B C
2:7 B C 2:8 B C
2:9 B C 2:10 B C
2:11 B C 2:12 B C
2:12 B C 2:13 B C
2:14 B C 2:15 B C
2:16 B C 2:17 B C
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 B C
3:15 B C 3:16 B C
3:17 B C 3:18 B C
3:19 B C 3:20 B C
3:21 B C 3:22 B C
3:23 B C 3:24 B C
3:25 B C 3:26 B C
3:27 B C 3:28 B C
3:29 B C 3:30 B C
3:31 B C 3:32 B C
3:33 B C 3:34 B C
3:35 B C 3:36 B C
3:37 B C 3:38 B C
3:39 B C 3:40 B C
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 ...
Page Issue Changed Page Issue Changed
3:41 B C 3:42 B C
3:43 B C 3:44 B C
3:45 B C 3:46 B C
3:47 B C 3:48 B C
3:49 B C 3:50 B C
3:51 B C 3:52 B C
3:53 B C 3:54 B C
3:55 B C 3:56 B C
3:57 B C 3:58 B C
3:59 B C 3:60 B C
3:61 B C 3:62 B C
3:63 B C 3:64 B C
3:65 B C 3:66 B C
3:67 B C 3:68 B C
3:69 B C 3:70 B C
3:71 B C 3:72 B C
3:73 B C 3:74 B C
3:75 B C 3:76 B C
3:77 B N 3:78 B N
3:79 B N 3:80 B N
4 Chapter - Water System
Page Issue Changed Page Issue Changed
4:1 A 4:2 A
4:3 A 4:4 A
4:5 A 4:6 B C
4:7 B C 4:8 A
4:9 A 4:10 A
4:11 A 4:12 B C
4:13 B C 4:14 B C
4:15 B C 4:16 B C
4:17 B C 4:18 B C
4:19 B C 4:20 B C
5 Chapter - Pneumatic System
Page Issue Changed Page Issue Changed
5:1 A 5:2 A
5:3 B C 5:4 A
5:5 B C 5:6 B C
5:7 B C 5:8 B C
5:9 B C 5:10 B C
5:11 B C 5:12 B C
5:13 B C 5:14 B C
5:15 B C 5:16 B C
5:17 B C 5:18 B C
5:19 B C 5:20 B C
5:21 B C 5:22 B C
5:23 C N 5:24 C N
Page Issue B

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual
Foreword Page Issue B
6 Chapter - Wearing Items
Page Issue Changed Page Issue Changed
6:1 A 6:2 B C
6:3 B C 6:4 B C
6:5 A 6:6 A
7 Chapter - Remove and Refit Procedures
Page Issue Changed Page Issue Changed
7:1 A 7:2 B C
7:3 A 7:4 A
7:5 B C 7:6 B C
7:7 B C 7:8 B C
7:9 B C 7:10 B C
7:11 B C 7:12 A
8 Chapter - Fault Diagnosis
Page Issue Changed Page Issue Changed
8:1 A 8:2 A
8:3 A 8:4 A
8:5 A 8:6 A
8:7 A 8:8 A
8:9 A 8:10 A
8:11 B C 8:12 A
8:13 A 8:14 A
9 Chapter - Service Tools
Page Issue Changed Page Issue Changed
9:1 A 9:2 A
9:3 A 9:4 A
9:5 A 9:6 A
9:7 A 9:8 A
10 Chapter - Health and Safety
Page Issue Changed Page Issue Changed
10:1 A 10:2 A
10:3 A 10:4 A
10:5 A 10:6 A
10:7 A 10:8 A

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)

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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

All Copyright and rights are the property of Johnston Sweepers Ltd
MA1:7
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
Wide Sweep
Brush
Brush motor adapter (Includes removal
and retting of brushes)
60 None 1
Wide Sweep
Brush
Motor plate (Includes removal and
retting of brushes)
75 None 1
Wide Sweep
Brush
WSB bearing 45 None 1
Wide Sweep
Brush
Bearing plate (Includes swap bearing
over)
45 None 1
Wide Sweep
Brush
Slew ram (Includes removal and
retting of WSB, brushes and tow bar)
120 None 1
Wide Sweep
Brush
WSB curtain (Replace) 25 None 1
Wide Sweep
Brush
WSB low press spray bar (located
under front bumper)
30 None 1
Wide Sweep
Brush
WSB lift cylinder (each) 15 None 1
Wide Sweep
Brush
Suspension regulator (Includes set up
- each)
25 None 1
Wander Hose Trunking 15 None 1
Wander Hose Boom 240 None 1
Wander Hose Turret (Boom removed) 15 None 1
Wander Hose Turret bearing (Boom and turret removed) 15 None 1
Wander Hose Boom gaiter (Boom removed) 15 None 1
Mesh Shaker Shaker cylinder (each) 25 None 1
Mesh Shaker Push button 10 None 1
Hydraulics Hydraulic valve bank (Includes check
and top up hydraulic oil level)
70 None 1
Hydraulics Rear door lock valve block (Includes
check and top up hydraulic oil level)
30 None 1
Hydraulics Supa-wash valve block (Includes check
and top up hydraulic oil level)
45 None 1
Pneumatic Vitalizer 20 None 1
Pneumatic Low pressure air switch 15 None 1
Pneumatic Recirc. Valve (each) 30 None 1
Pneumatic Pneumatic valve (PV) (each) 15 None 1
Pneumatic WSB regulator (Suspension regulator - each) 25 None 1
Pneumatic Powa-save control regulator 35 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

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual
MA1:8 Chapter - Scheduled Maintenance
Area Remove / Ret Time Taken
(Mins)
Special Tools
Required
1 or 2
Persons
Water System Hose reel 60 None 1
Water System Low pressure spray bar (Located under
front spray bar)
30 None 1
Water System Low pressure nozzle (Includes cleaning
nozzle (All nozzles)
10 None 1
Water System Low pressure gutter spray (Includes
cleaning nozzles)
20 None 1
Water System High pressure spray bar (Located
under front bumper)
30 None 1
Water System High pressure spray bar mounting
(Spray bar removed)
15 None 1
Water System Suction box low pressure nozzles 15 None 1
Water System Suction box high pressure spray bar 10 None 1
Water System Nozzles (Includes cleaning) 15 None 1
Water System Wander hose low pressure nozzle
(Includes cleaning)
10 None 1
Water System Wander hose low pressure water tap 15 None 1
Water System Supa-wash pump (Includes check and
top up hydraulic oil level)
60 None 1
Water System Water solenoids (Includes cleaning seal
and valve - each)
15 None 1
Water System High pressure water tap (Front high
pressure spray bar and suction box
high pressure spray bar - each)
20 None 1
Water System Water ller neck lter (hydrant ller) 10 None 1
Water System Water tank suction lter 15 None 1
Water System Water tank breather 25 None 1
Water System Water lter assembly (R/H rear) 30 None 1
Electrical
System
Centre Console (Including software
update and test)
20 TB1570 1
Electrical
System
JVM Screen (Including software update
and test)
30 TB1555 & TB1570 1
Electrical
System
Keypad Node (Including software
update and test)
20 None 1
Electrical
System
Pendant (Including software update
and test)
15 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

All Copyright and rights are the property of Johnston Sweepers Ltd
MA1:9
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
Electrical
System
Multi-camera Module (Including
software update and test)
20 None 1
Electrical
System
Systems Locker Node (Including
software update and test)
15 None 1
Electrical
System
Powapack Node (Including software
update and test)
15 None 1
Electrical
System
Subframe Node (Including software
update and test)
25 None 1
Electrical
System
High Current Node (Including software
update and test - each)
25 None 1
Electrical
System
Pneumatic Valve Island (Including
software update and test - each)
30 None 1
Electrical
System
Emergency hydraulic pump (Including
test)
45 None 1
Electrical
System
Rear beacon (each) 15 None 1
Engine Skid
Unit
Engine tub assembly 480 None 1
Maintenance 50 Hour Service 90 None 1
Maintenance ‘A’ Service 180 None 1
Maintenance ‘B’ Service 300 None 1
Maintenance ‘C’ Service 420 None 1
Maintenance ‘D’ Service 500 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

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual
MA1:10 Chapter - Scheduled Maintenance
Throttle Settings
These engines have their own ECU and the speeds are preset and can only be checked. (Except for
Dieselmax Stage 3a).
1 Raise the body.
2 With the fan safety flap closed and a plate (suitably secured with clamps) completely blanking the fan inlet.
3 Start the engine and allow to warm up.
4 Check the tickover speed and the maximum flight speeds. If these are incorrect, they must be reset
by an authorised distributor.
5 NOTE : Stop the engine before removing the fan inlet blanking plate and lowering the body.
ENGINE
TYPE
JOHNSTON
PART NO.
IDLE SPEED
Rev./Min.
(Max Off Load)
Rev./Min.
JCB Ecomax 444
Standard Power Engine 24V (55kW - S3b) 7017176 850 2000
JCB Ecomax 444
Standard Power Engine 12V (55kW - S3b) 7028433 850 2000
JCB Ecomax 444
High Power Engine 24V (93kW - S3b) 7017181 850 2000
JCB Ecomax 444
High Power Engine 12V (93kW - S3b) 7025710 850 2000
John Deere 4045HF285
High Power Engine 12V only (86kW - Tier 3) 283791-12 850 2000
JCB Dieselmax 444
Standard Power Engine 24V (85kW - S3a) 7028407 900 2200
JCB Ecomax 444
High Power Engine 24V (93kW - Tier 4) 7039194 850 2000
JCB Ecomax 444
High Power Engine 12V (93kW - Tier 4) 7039193 850 2000
AUXILIARY ENGINE
Page Issue B
VT - Twin Engine
M02MA-058
AB
Auxiliary Engine and Gearbox Drain Plugs
The drain plugs for the auxiliary engine (B) and gearbox
(A) are located on a bracket near to the Powapack access
ladder.

All Copyright and rights are the property of Johnston Sweepers Ltd
MA1:11
V Range 501 l651 l801 Maintenance Manual Johnston Sweepers Limited
Chapter - Scheduled Maintenance
The fluid flywheel transmits power from the engine to the gearbox. Its design allows for the minimum of
maintenance, minimal mechanical wear and superior longevity to the remainder of the transmission system.
With the correct attention it should last the life of the sweeper.
M02MA-028
D
C
AB
Fluid Flywheel Filling Ports
(Viewed with fan case and fan not shown for clarity)
Maintenance
After the first 50 hours operation check the fluid level; this operation must be carried out with the unit cold.
Repeat this check every 500 hours. The fluid flywheel is fitted with a fusible plug which melts at 198°C
(recognised by four equally spaced indentations round the hexagonal socket). Oil should be replaced after
4,000 hours operation.
Draining Instructions
• Ensure the flywheel is cool before removing the level filler plug
• Using a propriety vacuum pump or oil extractor/syringe, drain the oil from the flywheel.
Filling Instructions
Ensure the flywheel’s filler port aligns with sight hole (B) in either of the two flywheel side covers (C),
approximately 2 o’clock and 10 o’clock.
Remove the side cover and spacers. Remove filler plug using a 5/16 AF allen key and fill with the
correct oil until it reaches the level of the port. (See Operators Guide page OG6:17 for oil specification)
‘‘
During filling, carefully rock the flywheel to ensure that no air pockets form below the oil level.
DO NOT OVERFILL AS THIS WILL CAUSE THE UNIT TO OVERHEAT AND RAPID SEAL
DETERIORATION WILL OCCUR
Replace the filler plug using thread sealant to ensure a good seal. Visually check for oil leaks and replace
the flywheel cover.
(A) Flywheel with side cover (C) removed.
(B) Flywheel filler/inspection port visible
through side cover sight hole.
(C) Flywheel side cover.
(D) Step-up gearbox.
Page Issue B
FLUID FLYWHEEL
VT - Twin Engine

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual
MA1:12 Chapter - Scheduled Maintenance
Hydraulic Oil Reservoir
Return Filter
The filter should be changed every 1000 hours, 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.
Renewing the Return Filter
Unscrew cover (A) and lift out the cartridge element (B). Fit new cartridge and screw on the cover
Renewing the Suction Filters
Note: Drain Oil Before Removing Suction Filters.
The oil can be drained by removing the drain plug (C) located under the systems locker or by using a
propriety vacuum pump or oil extractor/syringe.
The filters (D) should be changed whilst the system is empty.
System Refilling
The system capacity dry is 61 litres.
Raise the body and engage the body prop (E) in its highest
position. The bottom of the level indicator (F) should not be higher
than the Maximum line as shown on the gauge.
It is important that the correct level is maintained as under filling
can adversely affect the heat dissipation rate of the oil, whilst over
filling can cause oil to overflow when the body is lowered.
M02MA-055
C
B
A
D
Hydraulic Oil
Reservoir Gauge
MO2OG-003-3
F
EMAX
Before changing the filter ensure the oil is cold.
Before removing the return filter. Ensure no pressure is present by allowing the system to
rest for a short time after turning off the equipment.
Safety Notice
Page Issue B
VT - Twin Engine
HYDRAULICS

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MA1:13
V Range 501 l651 l801 Maintenance Manual Johnston Sweepers Limited
Chapter - Scheduled Maintenance
Page Issue B
Hydraulic Oil Reservoir
Return Filter
The filter should be changed every 1000 hours, 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.
Renewing the Return Filter
Unscrew cover (A) and lift out the cartridge element (B). Fit new cartridge and screw on the cover
Renewing the Suction Filters
Note: Drain Oil Before Removing Suction Filters.
The oil can be drained by removing the drain plug (C) located under the systems locker or by using a
propriety vacuum pump or oil extractor/syringe.
The filters (D) should be changed whilst the system is empty.
System Refilling
The system capacity dry is 61 litres.
Raise the body and engage the body prop (E) in its highest
position. The level (F) should be 10mm above the lower red line
(G) on the gauge.
It is important that the correct level is maintained as under filling
can adversely affect the heat dissipation rate of the oil, whilst over
filling can cause oil to overflow when the body is lowered.
M02MA-056
A
B
D
C
Hydraulic Oil
Reservoir Gauge
M02MA-057
10mm
max
G
F
E
Before changing the filter ensure the oil is cold.
Before removing the return filter. Ensure no pressure is present by allowing the system to
rest for a short time after turning off the equipment.
Safety Notice
VS - Twin Engine
HYDRAULICS

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual
MA1:14 Chapter - Scheduled Maintenance Page Issue B
Filter Regulator Unit
Comprises of a combined air filter/pressure regulator. It is mounted in the systems locker.
MO2MA-052
B
D
C
A
IN
The Air Filter Regulator Unit incorporates The following features;-
(A) Pressure regulator ensures the equipment is not over pressurised. It is factory set and sealed at
7.5 bar (108 psi).
(B) Isolation/drain valve, automatically dumps accumulated water when the machine is shut down or
when the air supply is isolated by the shut off valve
(C) Pressure switch is fitted to illuminate the low air pressure warning lamp on the JVM.
(D) Service connection enabling the system to be charged using a workshop air supply.
The shut off valve must be used when servicing any item on the air system
Safety Notice
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.
Avoid playing the water washdown hose or high pressure hand lance over the body tip cylinder when
in the fully raised condition.
PNEUMATICS

All Copyright and rights are the property of Johnston Sweepers Ltd
MA1:15
V Range 501 l651 l801 Maintenance Manual Johnston Sweepers Limited
Chapter - Scheduled Maintenance
Page Issue B
Special notes for cleaning vehicles with vinyl livery or reflective markings
The Supawash handlance or similar can be used for cleaning areas of the vehicle with
vinyl or reflective markings subject to the following precautions being taken
80 bar
(1000 psi)
●Care MUST be taken not to damage sign written areas when cleaning. See special notes
for cleaning vehicles with vinyl livery below.
●ALWAYS keep pressure equipment in good condition and regularly maintained,
particularly at joints and unions.
●The use of safety goggles is recommended in case of deflected spray/debris.
●NEVER direct a high pressure nozzle at the skin as the fluid may penetrate the
underlying tissue etc. and cause serious injury.
Safety Precautions
90°- 75°
M02OG-130a
●The spray angle should be maintained between 90 and 75
degrees to the panel 
●The nozzle distance should be greater than 1 metre minimum
from the panel 
●The spray pattern should be a wide fan pattern 
●The nozzle pressure should be 80 bar (1000PSI) max 
●The water temperature should not exceed 60 ºC 
●Do not use acid or solvent cleaning solutions û
M02OG-131
1M
Alternative Methods
●Do Clean with a sponge or soft cloth using cold or warm water
with a soap or detergent, followed by a cold water rinse 
CLEANING THE VEHICLE

All Copyright and rights are the property of Johnston Sweepers Ltd
V Range 501 l651 l801 Maintenance Manual
MA1:16 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 Chassis Handbook relating to the post delivery check
over.
Engine Management ECU
Please note that the chassis manufacturers Engine Management System has been set in
accordance with our requirements. If a malfunction of the ECU occurs and the component replaced
then the parameters would require downloading and reset in the new component.
Failure to do this will cause the machine to malfunction.
Important ensure that the Safety Precautions shown at the front of this chapter are observed
when working on the equipment
Safety Notice
ADDITIONAL INFORMATION - VS
VS - Twin Engine