Johnston RT655 Manual

Johnston Sweepers Limited
General Arrangement
Controls
Operation
Optional Equipment
Chapter not used
Routine Maintenance
RT655 Mk III
Regenerative Air
Twin Engine
Suction Sweeper
From Manufacture Sequence No. 7458
Part No 01288-1(GB)
Revision Level A
E.C.N. 712675 Print date - 16/11/2015
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Operator’s
Guide
Conformity Certificates 7

RT655 Operator’s Guide
Foreword Page Issue A
Foreword
The Johnston RT655 Air Regen 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 [EN 13019 refers], 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 (gutter broom) setting changing
9 Nozzle (pick-up head) setting
10 Daily and weekly maintenance items
11 Driving/operation assessment
12 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.

RT655 Operator’s Guide Johnston Sweepers Limited
Foreword
Page Issue A
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: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.johnstonsweepers.com
Ear defenders are recommended when working around the machine
Eye protection is recommended when working around the machine

RT655 Operator’s Guide
Foreword Page Issue A
Page Issue Levels
Page Issue Changed Page Issue Changed
Front Page A Foreword 1 A
Foreword 2 A Foreword 3 A
Foreword 4 A Foreword 5 A
OG1:1 A OG1:2 A
OG1:3 A OG1:4 A
OG2:1 A OG2:2 A
OG2:3 A OG2:4 A
OG2:5 A OG2:6 A
OG2:7 A OG2:8 A
OG3:1 A OG3:2 A
OG3:3 A OG3:4 A
OG3:5 A OG3:6 A
OG3:7 A OG3:8 A
OG3:9 A OG3:10 A
OG3:11 A OG3:12 A
OG4:1 A OG4:2 A
OG4:3 A OG4:4 A
OG4:5 A OG4:6 A
OG6:1 A OG6:2 A
OG6:3 A OG6:4 A
OG6:5 A OG6:6 A
OG6:7 A OG6:8 A
OG6:9 A OG6:10 A
OG6:11 A OG6:12 A
OG6:13 A OG6:14 A
OG6:15 A OG6:16 A
OG6:17 A OG6:18 A
OG7:1 A OG7:2 A
OG7:3 A OG7:4 A

RT655 Operator’s Guide Johnston Sweepers Limited
Foreword
Page Issue A
1. Water tank filler ports 1a = Hose Pipe
1b = Hydrant
2. Hydraulic oil tank filler
3. Fuel tank (diesel) filler
4. 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
RTOG.049
RTOG.049
4
1a
2
3
1b
4
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.

RT655 Operator’s Guide
Foreword Page Issue A
Safety Symbol Descriptions
Safety alert symbol
Read Operator’s Guide
Ensure body prop is engaged in rack before working under raised body
Body prop NOT engaged in rack
Body prop correctly engaged in rack
Keep clear of brushes
Do not open suction fan safety flap while fan is running
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
Sharp objects warning - there can be a risk of injury from sharp objects such
as discarded hypodermic needles becoming lodged in the sweeping system.
The use of ‘needle stick gloves’ is recommended when changing brushes,
using the wanderhose/Littasnatch and when cleaning out the machine

OG1:1
RT655 Operator’s Guide
CHAPTER 1
Johnston Sweepers Limited
General Arrangements
Chapter - General Arrangement
Page Issue A
Table of Contents
Subject Page
General Arrangement
General Arrangement Drawing OG1 : 2

RT655 Operator’s Guide
OG1:2 Chapter - General Arrangement Page Issue A
29
16
17
32
35
30
30
31 30
13 10
7
4
20
18
19 15
29
1
8
26
13
25 27
1
5
6
34


Cold Weather Drains
RTOG.051
2
8
11 9
21
2
12
14

37 3 22
34
23
26

36 33
28
24
30
GENERAL ARRANGEMENT
Figure 1
RH Sweep machine shown

OG1:3
RT655 Operator’s Guide Johnston Sweepers Limited
Chapter - General Arrangement
Page Issue A
Item Component See Chapter
1 Hopper/load compartment -
2 Auxiliary engine cowl -
3 Body (hopper and cowl) prop 3
4 Auxiliary engine 6
5 Fuel tank -
6 Fuel tank filler access flap -
7 Hydraulic oil reservoir 6
8 Suction fan case 6
9 Variable exhaust gate (VEG) -
10 Pick-up head (hood) 6
11 Blaster duct -
12 Suction duct -
13 Channel brush / gutter broom 6
14 Wear plate -
15 Filter screen 6
16 Filter screen curtain 6
17 Filter screen water sprays 6
18 ‘SepaVac’ separator box 3
19 ‘SepaVac’ access panel -
20 ‘SepaVac’ discharge door 3
21 ‘SepaVac’ water flush 3
22 ‘SepaVac’ water flush hydrant connection 3
23 * R.H. Water tank and contents gauge 6
24 * L.H. Water tank, contents gauge and hose filler 6
25 Water tank(s) hydrant filler 6
26 Water tank drain tap - under both tanks 6
27 Water pump suction filter 6
28 Rear door drainage hoses 3
29 Rear door access door 3
30 Low pressure water spray jets -
31 High pressure Water spray jets -
32 Washdown hose -
33 Master control panel 2
34 Air cleaner 6
35 Air cleaner filter state indicator 6
36 Hydrant hose stowage - optional -
37 Supawash hose reel & handlance 4
* Total water capacity 950 litres

RT655 Operator’s Guide
OG1:4 Chapter - General Arrangement Page Issue A

OG2:1
RT655 Operator’s Guide
CHAPTER 2
Johnston Sweepers Limited
Controls
Chapter - Controls
Table of Contents
Subject Page
Operating Controls - In Cab
Switch Panel OG2 : 2
Cab Mounted Controls OG2 : 6
Operating Controls - External
Load Discharge Control Pendant OG2 : 7
Fuse Functions
Fuse Functions OG2 : 8
Page Issue A

RT655 Operator’s Guide
OG2:2 Chapter - Controls Page Issue A
Sweeping Controls - Switch Panel
1200
2200
15hrs
RTOG.042
Src:Eng
SPN00000
A
B
C1 C2
D1 E1 F G E2 D2
J1 K1
M O R
T1
U
V
W
Y
B1
B3 B4
B6
B5
B7
B2
T2
X
Q
K1 J2K2 K3
L
N
S1
S2
P1
P2
H
*Denotes Optional Equipment

OG2:3
RT655 Operator’s Guide Johnston Sweepers Limited
Chapter - Controls
Page Issue A
Sweeping Controls
Symbol ID Description
AProgramme Button; ON/OFF switch illuminates when pressed and suspends
all sweeping and parks brushes. Pressing again reactivates previous settings.
B1 ‘Hopper Raise’ - red warning lamp and buzzer.
B2 ‘Low Air Pressure’ - amber warning lamp and buzzer.
B3 Hydraulic Oil ‘Temperature’ - red warning lamp.
B4 Hydraulic Oil ‘Low Level’ - amber warning lamp and buzzer.
15hrs B5 Rear Broom hours worked/clock.
B6 Push button to select hourmeter reading/clock - cancels after 10 seconds.
B7 Advance button - advances clock time when in clock setting mode.
C1 *LH Variabrush - spring centred switch moves brush out or in.
C2 *RH Variabrush - spring centred switch moves brush out or in.
E1/E2 LH/RH Gutter Broom 2 position switch - stowed/active illuminated when
selected.
D1 *LH Rotatilt - spring centred switch; alters angle of Gutter broom to suit road
camber.
D2 *RH Rotatilt - spring centred switch; alters angle of Gutter broom to suit road
camber.
J1/J2 LH/RH worklamp; 2 position switch OFF/ON. Illuminated when selected.
K1 Front Spray Bar. 2 position switch OFF/ON illuminated when selected.
L* Powathrust; - ON/OFF. Increases Channel Brush ground pressure to
preset level when on. Without the need to re-adjust the in cab regulator.
HBlank.
FPick-up head and water sprays; 3 position switch - stowed/active/water
sprays. Illuminated when selected.
GPick-up head hop; 2 position - push to make stowed / CLOSED / OPEN.
K3 Hopper Spray. 2 position switch OFF/ON illuminated when selected.
K3 Gutter Spray. 2 position switch OFF/ON illuminated when selected.

RT655 Operator’s Guide
OG2:4 Chapter - Controls Page Issue A
Sweeping Controls - Switch Panel
1200
2200
15hrs
RTOG.042
Src:Eng
SPN00000
A
B
C1 C2
D1 E1 F G E2 D2
J1 K1
M O R
T1
U
V
W
Y
B1
B3 B4
B6
B5
B7
B2
T2
X
Q
K1 J2K2 K3
L
N
S1
S2
P1
P2
H

OG2:5
RT655 Operator’s Guide Johnston Sweepers Limited
Chapter - Controls
Page Issue A
Sweeping Controls
Symbol ID Description
MSupawash option; 2 position switch - OFF/ON illuminated when selected.
QPowasave – 2 position switch – operates with gutterbroom. Overrides pre-
set pressure level to allow maximum down pressure on brush.
UVEG opening switch; 3 position sprung centred switch controls an electrical
actuator CLOSED / OFF / OPEN.
WIgnition switch - 2 position - OFF/ON.
NB : Only beacons will operate when switch is off.
XEngine throttle control; 3 position spring centred switch
REDUCE/OFF/ INCREASE.
RBeacons; 2 position switch - OFF / ON. illuminated when selected.
NHood reverse pick-up select switch; 2 position switch - OFF/ON.
ORear Worklamp; 2 position switch OFF/ON illuminated when selected.
P1 Water tank low level indicator - illuminated when tank empty.
P2 Water tank high level indicator - illuminated when tank is full.
VEngine crank button - push to crank. Flashes to indicate engine fault
requests.
Src:Eng
SPN00000
YCAN FED - John Deere, Diagnostics, Engine hours, Engine RPM, Coolant
Temperature, John Deere Fault codes.
S1 VEG - position 1. Regen Mode - Colour Red
S2 VEG - position 2. 60% Regen - Colour Yellow
T1 VEG - position 3. 30% Regen - Colour Blue
T2 VEG - position 4. Vacuum Mode - Colour Green
*Denotes Optional Equipment

RT655 Operator’s Guide
OG2:6 Chapter - Controls Page Issue A
Cab Mounted Controls
AA Channel brush speed control; clockwise rotation increases brush
speed.
BB Pressure control for each gutter broom Powasave; clockwise rotation
reduces brush pressure.
CC Fuse box is mounted inside relay box. Fuse functions - see page OG2:8.
DD Load discharge pendant unit mounted by driver’s seat.
FF Switch panel - see previous pages of this chapter.
RTOG. 010-2
FF
DD
CC
AA BB
Symbol Switch Description

OG2:7
RT655 Operator’s Guide Johnston Sweepers Limited
Chapter - Controls
Page Issue A
Load Discharge Control Pendant
(Located beside the driver’s seat)
Switch Function
M02OG-005
Opens rear door
Closes rear door
Raises body
Lowers body
Stows body prop when body is raised and not resting on it
Green safety switch must be pressed to enable discharge functions
Hand brake on - Pendant ready for operation
Hand brake off - Pendant not ready for operation
LED Function

RT655 Operator’s Guide
OG2:8 Chapter - Controls Page Issue A
Fuse Functions
RTOG.011-2
20A
F11
20A
F3
20A
F10
10A
F2
20A
F1
15A
F8
20A
F6
15A
F7
20A
F4
15A
F5
F9
10A
MARKER LIGHTS
CHASSIS
IGNITION
WATER/SUPAWASH/
ROTATILT
POWER I/O NODE
WORK LIGHTS/
WATER SWITCHES
CHASSIS IGNITION/
SUPAWASH CONTROLS/
VEG SENSORS
POWER VEG
GATE
AUX ENGINE
IGNITION
AUX ENGINE
CRANK
AUX ENGINE
ECU POWER
BEACONS
Fuse No. Function Amps
F1 Beacons 20
F2 Marker Lights 10
F3 Power I/O Node 20
F4 Water/Supawash/Rotatilt 20
F5 Work Lights/Water Switches 15
F6 Power VEG Gate 20
F7 Aux Engine Ignition 15
F8 Chassis Ignition 15
F9 Chassis Ignition/Supawash Controls/VEG Sensors 10
F10 Aux Engine ECU Power 20
F11 Aux Engine Crank 20
Fuse colour key
5 Orange 10 Red 15 Blue 20 Yellow

OG3:1
RT655 Operator’s Guide
CHAPTER 3
Johnston Sweepers Limited
Operation
Chapter - Operation
Table of Contents
Subject Page
Towing and Craning
Towing the Vehicle OG3 : 2
Craning the Vehicle OG3 : 2
Engine
Engine Starting and Operation Procedures - John Deere OG3 : 3
Sweeping
Commence Sweeping OG3 : 5
Hood Hop OG3 : 6
Interrupt Sweeping OG3 : 6
Terminate Sweeping OG3 : 6
Water Drainage OG3 : 6
Blocked Pick-up Head /Suction Duct OG3 : 7
Load Discharge and Auto Body Prop OG3 : 8
Emergency Discharge Pump OG3 : 10
Sweeping in Cold Temperatures OG3 : 11
Cold Weather Precautions OG3 : 12
Page Issue A

RT655 Operator’s Guide
OG3:2 Chapter - Operation
Craning the Vehicle
The vehicle may be lifted using conventional lifting systems that are slung from the vehicle road
wheels. However, it is necessary to ascertain the centre of gravity as it can be up to 20% from the
mid point of the wheelbase. The exact position is dependent upon chassis type and vehicle build.
Towing the Vehicle
Refer to the chassis handbook.
Please note the air system needs to be charged to ensure the channel brush / gutter
broom is raised.
Safety Notice