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Johnston VT652 Maintenance Manual

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Maintenance
Section
V Range Suction Sweepers
Incorporating
VT502 ● 652 ● 802
Twin engine machines
VS502 ● 652 ● 802
Single engine, Hydrostatic machines
VM502 ● 652 ● 802
Single engine, Semi-Hydrostatic machines
Part No 7063773
Revision Level A
VT - Twin Engine
VS - Single Engine
VM - Single Engine
ECN - 718631
Scheduled Maintenance
Hydraulic System
Electrical System
Water System
Pneumatic System
Wearing Items
Remove and Refit Procedures
Fault Diagnosis
Service Tools
Health and Safety
Specific to Twin engine sweepers.
Specific to Single engine sweepers.
Specific to Single engine sweepers.
Johnston Sweepers Limited
Print date - 25/10/2018
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  • Page 1 Electrical System Water System Pneumatic System Wearing Items V Range Suction Sweepers Remove and Refit Procedures Incorporating VT502 ● 652 ● 802 Fault Diagnosis Twin engine machines VS502 ● 652 ● 802 Service Tools Single engine, Hydrostatic machines Health and Safety VM502 ●...
  • Page 2 V Range 502 802 Maintenance Manual...
  • Page 3 V Range 502 802 Maintenance Manual Johnston Sweepers Limited CHAPTER Scheduled Maintenance 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...
  • Page 4 V Range 502 802 Maintenance Manual 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.
  • Page 5 V Range 502 802 Maintenance Manual Johnston Sweepers Limited FOR YOUR SAFETY Basic safety precautions are described in Section 3. SIGNAL words: Important operating and safety information is marked with the following NOTICE, CAUTION, WARNING and DANGER. SIGNAL WORDS AND SYMBOLS ARE SHOWN AS FOLLOWS:- SIGNAL WORD Type and source of hazard.
  • Page 6 V Range 502 802 Maintenance Manual 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). FA-0051 Tightening Torque 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.
  • Page 7 V Range 502 802 Maintenance Manual Johnston Sweepers Limited STANDARD REPAIR TIMES (SRT) This Guide Detail the time taken to remove, refit 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 8 V Range 502 802 Maintenance Manual This Guide Detail the time taken to remove, refit 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 9 V Range 502 802 Maintenance Manual Johnston Sweepers Limited This Guide Detail the time taken to remove, refit 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 10 V Range 502 802 Maintenance Manual This Guide Detail the time taken to remove, refit 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 11 V Range 502 802 Maintenance Manual Johnston Sweepers Limited This Guide Detail the time taken to remove, refit 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 12 Check the tickover speed and the maximum flight speeds. If these are incorrect, they must be reset by an authorised distributor. CAUTION: Stop the engine before removing the fan inlet blanking plate and lowering the body. ENGINE JOHNSTON IDLE SPEED (Max Off Load) TYPE PART NO. Rev./Min.
  • Page 13 V Range 502 802 Maintenance Manual Johnston Sweepers Limited VT - Twin Engine FLUID FLYWHEEL 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.
  • Page 14 V Range 502 802 Maintenance Manual VT - Twin Engine HYDRAULICS CAUTION: 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. Hydraulic Oil Reservoir Return Filter The filter should be changed every 1000 hours, however there is an integral filter indicator on the side...
  • Page 15 V Range 502 802 Maintenance Manual Johnston Sweepers Limited VS - Single Engine HYDRAULICS CAUTION: 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.
  • Page 16 V Range 502 802 Maintenance Manual PNEUMATICS CAUTION: The shut off valve must be used when servicing any item on the air system Filter Regulator Unit Comprises of a combined air filter/pressure regulator. It is mounted in the systems locker. MO2MA-052 The Air Filter Regulator Unit incorporates The following features;- (A) Pressure regulator ensures the equipment is not over pressurised.
  • Page 17 V Range 502 802 Maintenance Manual Johnston Sweepers Limited CLEANING THE VEHICLE WARNING: 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.
  • Page 18 V Range 502 802 Maintenance Manual VS - Twin Engine ADDITIONAL INFORMATION - VS WARNING: Important ensure that the Safety Precautions shown at the front of this chapter are observed when working on the equipment 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.
  • Page 19 V Range 502 802 Maintenance Manual Johnston Sweepers Limited VS - Single Engine Transmission Pump Oil Filter Replacement This filter should be changed every 500 hours. With the vehicle engine not running, remove the filter alongside the transmission pump. Fit a new filter as quickly as possible to minimise the loss of any hydraulic oil.
  • Page 20 V Range 502 802 Maintenance Manual MA1:18 Chapter - Scheduled Maintenance...
  • Page 21 V Range 502 802 Maintenance Manual Johnston Sweepers Limited CHAPTER Hydraulic System Table of Contents Section Page Introduction General Description 2 : 2 Circuit Pressures Test Points - VT & VS 2 : 2 Body Discharge System - VT & VS 2 : 2 Supawash Option / Sweeping System - VT &...
  • Page 22 V Range 502 802 Maintenance Manual HYDRAULIC SYSTEM - INTRODUCTION CAUTION: Do not remove any hydraulic components without first ensuring that any residual pressure has decayed. If in doubt ask. NOTICE: Only competent trained personnel should work on this equipment. General Description The hydraulic system may be divided into four hydraulic circuits fed from a common hydraulic reservoir.
  • Page 23 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Hopper Lower Pressure: Select option 2 from menu 4.12 and follow the on screen prompts: Connect a suitable 250 bar gauge to test point H-8Z2 on the discharge system block on the LH side of the machine in front of the rear wheels.
  • Page 24 V Range 502 802 Maintenance Manual VS - Single Engine Suction Fan Pressure - VS Fan Drive System - VS Fit a 250 bar minimum pressure gauge to test point P1 on block H-13Z1 located in front of the fancase in the Powapack tub. Open rear door, open inlet flap.
  • Page 25 V Range 502 802 Maintenance Manual Johnston Sweepers Limited HYDRAULIC SYSTEM - INITIAL OPERATION HOOD RAISE Rear Door Block When the hydraulic system is first commissioned, or after changing a hydraulic hose on the hydraulic HOOD LOWER (Attached to sub-frame under body) Y023 pumps on the body discharge circuit, it is necessary to purge any air from the system.
  • Page 26 V Range 502 802 Maintenance Manual Hydraulic Tank Connections - Twin Engine Machine - Sheet 1/10 Rev A MA2:6 Chapter - Hydraulic System...
  • Page 27 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Hydraulic Tank Connections - Hydrostatic Machine - Sheet 2/10 Rev A MA2:7 Chapter - Hydraulic System...
  • Page 28 V Range 502 802 Maintenance Manual Discharge System Controls - Sheet 3/10 Rev A MA2:8 Chapter - Hydraulic System...
  • Page 29 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Single Sweep Controls - Sheet 4/10 Rev A MA2:9 Chapter - Hydraulic System...
  • Page 30 V Range 502 802 Maintenance Manual Dual Sweep Controls - Sheet 5/10 Rev A MA2:10 Chapter - Hydraulic System...
  • Page 31 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Suction Fan Hydrostatic - Sheet 6/10 Rev A MA2:11 Chapter - Hydraulic System...
  • Page 32 V Range 502 802 Maintenance Manual Hydrostatic Transmission (HGB-1) - Sheet 7/10 Rev A MA2:12 Chapter - Hydraulic System...
  • Page 33 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Tandem Pump Controls - Sheet 8/10 Rev A MA2:13 Chapter - Hydraulic System...
  • Page 34 V Range 502 802 Maintenance Manual Combivak Nozzle Controls - Sheet 9/10 Rev A MA2:14 Chapter - Hydraulic System...
  • Page 35 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Powaboom/Rear Wanderhose Controls - Sheet 10/10 Rev A MA2:15 Chapter - Hydraulic System...
  • Page 36 V Range 502 802 Maintenance Manual MA2:16 Chapter - Hydraulic System...

  • Page 37: Table Of Contents

    General Description 3 : 2 System Description 3 : 2 Component Identification Systems Locker 3 : 3 Johnston Visual Module (JVM) Engine / Chassis Control 3 : 4 System Can - CANOPEN 3 : 4 CAN Line Setup 3 : 4...

  • Page 38: Introduction

    V Range 502 802 Maintenance Manual INTRODUCTION General Description The system is integrated with that of the chassis in that it shares its battery and power source. The auxiliary engine is equipped with a second alternator to supplement power generation. The system activates all operational functions of the machine.

  • Page 39: Component Identification

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited COMPONENT IDENTIFICATION Systems Locker K126 F120 F100 F121 F101 F122 F102 F103 F104 F106 F108 F109 F110 F123 F124 F125 F105 F107 F111 K120 K121 K122 K123 K124 K125 XB01 XB02...

  • Page 40: Engine / Chassis Control 3

    V Range 502 802 Maintenance Manual JVM (JOHNSTON VISUAL MODULE) Engine/Chassis Control CANbus J1939 CAN stands for Controller Area Network. It represents dedicated wiring that connects the control units of a vehicle (ECU). For the V Range sweepers the J1939 CANbus connects the auxiliary engine ECU to the in cab Centre Console allowing control of engine RPM and other engine data to be exchanged.

  • Page 41: Vdb Communication Line Schematic 3

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited VDB Communication Line Schematic Johnston Visual Module Centre Console Node Door Controller Node Discharge Pendent Node Systems Locker Node Subframe Node Powerpack Node Power Multi Camera Module Engine Management Control Unit...

  • Page 42: How To Update Control System Software 3

    How To Update Control System Software Step One: Prepare USB Flash Drive 1.1. Obtain the “TMS_SoftwareServicePackage_partnumber_x.zip” from Johnston Customer Service at: http://www.johnstonsweepers.co.uk/after-sales/software_updates.php The last digit of the file name will indicate the Software Pack Revision level. For example: TMS_SoftwareServicePackage_partnumber_C.zip = Revision level C.
  • Page 43 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Step Two: Software Download 2.1. Ensure the ignition is off. 2.2. Carefully open the rubber cover on the front of the JVM to expose the USB port. 2.3. Insert the USB flash drive into USB port.
  • Page 44 V Range 502 802 Maintenance Manual Step Three: Passcode Entry 3.1. Press button F3 to access the Main Menu 4.0. 09:45 20.01.2016 4.00 Menu 4.0 Main Menu 3.2. Select Menu 4.14 - Security 09:45 4.14 20.01.2016 0 0 0 0 Menu 4.14 System Security 3.3.
  • Page 45 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Step Four: Operating System (OS) Update 4.1. Go to Menu 4.11 - Service, and select option 2, OS Downloads. 09:45 4.11 20:01:2016 Menu 4.11 Service 4.2. Move the blue halo and select (for example) the machine cab area.
  • Page 46 V Range 502 802 Maintenance Manual Step Four: Operating System (OS) Update (continued) 4.3. Compare the “Current OS” version with the “New OS” version numbers. If the OS version numbers are different, then the Node OS must be updated. 09:45 4.11.2.1.2 20:01:2016 Menu 4.11.2.1.2 Centre Console OS Download...
  • Page 47 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Resetting the Service Acknowledgment indicator Once a service has been completed it must be acknowledged on the JVM display by resetting the service indicator as follows: Switch on the ignition. Select the Main Menu (F3) on the JVM display.

  • Page 48: Data Capture Download 3

    Data Capture Download The V Range has a standard feature of ‘Data Capture’. Data capture allows the vehicle operator or fleet manager to view or download data logged information directly onto a Johnston USB stick and download onto any PC.
  • Page 49 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Logged data values can be viewed from the JVM (Johnston Visual Module) display. Press F1 (Hour Glass icon) from the base screen. See following illustrations for more details; F1 - Vehicle Logging 09:45 20.01.2016...
  • Page 50 1.4 Service Hours 20.01.2016 1.5 USB Download (Data Capture) 09:45 1.05 20.01.2016 Insert an Johnston approved USB stick into the USB port (located on front of the JVM - bottom left hand side). Press centre button on JVM to download.
  • Page 51 Capture” file. The “Data Capture” file can be downloaded from the JVM to a Johnston approved USB memory stick. The “Data Capture” file format is CSV (Comma Separated values), this is a common format which may be viewed on any PC.
  • Page 52 V Range 502 802 Maintenance Manual Index 01 - Sheet 01/65 Rev A MA3:16 Chapter - Electrical System...
  • Page 53 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Index 02 - Sheet 02/65 Rev A MA3:17 Chapter - Electrical System...
  • Page 54 V Range 502 802 Maintenance Manual Electrical Circuit Symbol 1 - Sheet 03/65 Rev A MA3:18 Chapter - Electrical System...
  • Page 55 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Electrical Circuit Symbol 2 - Sheet 04/65 Rev A MA3:19 Chapter - Electrical System...
  • Page 56 V Range 502 802 Maintenance Manual Electrical Circuit Symbol 3 - Sheet 05/65 Rev A MA3:20 Chapter - Electrical System...
  • Page 57 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Electrical Circuit Component - Sheet 06/65 Rev A MA3:21 Chapter - Electrical System...
  • Page 58 V Range 502 802 Maintenance Manual Electrical Circuit Model Map - Sheet 07/65 Rev A MA3:22 Chapter - Electrical System...
  • Page 59 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Fused Power and Ignition Distribution 01 - Sheet 08/65 Rev A MA3:23 Chapter - Electrical System...
  • Page 60 V Range 502 802 Maintenance Manual Fused Power and Ignition Distribution 02 - Sheet 09/65 Rev A MA3:24 Chapter - Electrical System...
  • Page 61 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Operating Panel Switch / PCB Node - Sheet 10/65 Rev A MA3:25 Chapter - Electrical System...
  • Page 62 V Range 502 802 Maintenance Manual Key Pad / PCB Node - Sheet 11/65 Rev A MA3:26 Chapter - Electrical System...
  • Page 63 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Discharge Pendant Controller / PCB Node - Sheet 12/65 Rev A MA3:27 Chapter - Electrical System...
  • Page 64 V Range 502 802 Maintenance Manual Flat Ribbon IDC PCB Connectors - Sheet 13/65 Rev A n/min MA3:28 Chapter - Electrical System...
  • Page 65 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Power/Ignition Feed I/O Nodes - Sheet 14/65 Rev A MA3:29 Chapter - Electrical System...
  • Page 66 V Range 502 802 Maintenance Manual Power/Ignition Feed Rotatilt Aux Engine and Nodes - Sheet 15/65 Rev A MA3:30 Chapter - Electrical System...
  • Page 67 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Power/Ignition Feed Beacon Cab and WSB Balance - Sheet 16/65 Rev A MA3:31 Chapter - Electrical System...
  • Page 68 V Range 502 802 Maintenance Manual Power/Ignition Feed Display Operating Panel/Pendant & Key Pad - Sheet 17/65 Rev A MA3:32 Chapter - Electrical System...
  • Page 69 V Range 502 802 Maintenance Manual Johnston Sweepers Limited PCB Fuse Lay-out - Sheet 18/65 Rev A MA3:33 Chapter - Electrical System...
  • Page 70 V Range 502 802 Maintenance Manual PCB Fuse and Relay Lay-out - Sheet 19/65 Rev A MA3:34 Chapter - Electrical System...
  • Page 71 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Can-Bus System Can-0, Aux Engine Can-1, and Chassis Can-2 - Sheet 20/65 Rev A MA3:35 Chapter - Electrical System...
  • Page 72 V Range 502 802 Maintenance Manual Can-Bus System Can-0 and Aux Engine Can-1 - Sheet 21/65 Rev A MA3:36 Chapter - Electrical System...
  • Page 73 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Can-Bus System Can-0 - Sheet 22/65 Rev A MA3:37 Chapter - Electrical System...
  • Page 74 V Range 502 802 Maintenance Manual Front Systems Interface Connection - Sheet 23/65 Rev A MA3:38 Chapter - Electrical System...
  • Page 75 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Front Sliding Brush - Sheet 24/65 Rev A MA3:39 Chapter - Electrical System...
  • Page 76 V Range 502 802 Maintenance Manual System Locker Node Hydraulic Valves - Sheet 25/65 Rev A MA3:40 Chapter - Electrical System...
  • Page 77 V Range 502 802 Maintenance Manual Johnston Sweepers Limited System Locker Node Electrical Water Valves - Sheet 26/65 Rev A MA3:41 Chapter - Electrical System...
  • Page 78 V Range 502 802 Maintenance Manual Powapak Node Engine Pack Sensors/Control and Work Lamps - Sheet 27/65 Rev A MA3:42 Chapter - Electrical System...
  • Page 79 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Powapak Node Engine Pack Sensors & Control (Generic Engine) - Sheet 28/65 Rev A MA3:43 Chapter - Electrical System...
  • Page 80 V Range 502 802 Maintenance Manual Subframe Node Discharge/Supawash and Powaboom Control - Sheet 29/65 Rev A MA3:44 Chapter - Electrical System...
  • Page 81 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Subframe Node Sensors/Switches and Weight Load Indicator - Sheet 30/65 Rev A MA3:45 Chapter - Electrical System...
  • Page 82 V Range 502 802 Maintenance Manual Work Lights Rear Beacons and Cowl Work Light - Sheet 31/65 Rev A MA3:46 Chapter - Electrical System...
  • Page 83 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Additional Rear Work Lights and Additional Warning Lights - Sheet 32/65 Rev A MA3:47 Chapter - Electrical System...
  • Page 84 V Range 502 802 Maintenance Manual Front Cab Beacons and Top/Side Marker Lights - Sheet 33/65 Rev A MA3:48 Chapter - Electrical System...
  • Page 85 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Aux Engine JCB 24 Volt Power Pod Box - Sheet 34/65 Rev A MA3:49 Chapter - Electrical System...
  • Page 86 V Range 502 802 Maintenance Manual Aux Engine JCB 12 Volt Power Pod Box - Sheet 35/65 Rev A MA3:50 Chapter - Electrical System...
  • Page 87 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Aux Engine JCB 55kW and 93kW 24 Volt - Sheet 36/65 Rev A MA3:51 Chapter - Electrical System...
  • Page 88 V Range 502 802 Maintenance Manual Aux Engine John Deere High Power 86kW - Sheet 37/65 Rev A MA3:52 Chapter - Electrical System...
  • Page 89 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Aux Engine John Deere Standard Power 63kW - Sheet 38/65 Rev A MA3:53 Chapter - Electrical System...
  • Page 90 V Range 502 802 Maintenance Manual Aux Engine JCB 55kW and 93kW 12 Volt - Sheet 39/65 Rev A MA3:54 Chapter - Electrical System...
  • Page 91 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Aux Engine JCB 85kW S3A 24 Volt - Sheet 40/65 Rev A MA3:55 Chapter - Electrical System...
  • Page 92 V Range 502 802 Maintenance Manual Spare - Sheet 41/65 Rev A MA3:56 Chapter - Electrical System...
  • Page 93 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Telescopic Dual Front Brush Options Rotatilt x2 01 - Sheet 42/65 Rev A MA3:57 Chapter - Electrical System...
  • Page 94 V Range 502 802 Maintenance Manual Telescopic Dual Front Brush Options Rotatilt x2 02 - Sheet 43/65 Rev A MA3:58 Chapter - Electrical System...
  • Page 95 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Telescopic Single Front Brush Options Rotatilt x1 01 - Sheet 44/65 Rev A MA3:59 Chapter - Electrical System...
  • Page 96 V Range 502 802 Maintenance Manual Telescopic Single Front Brush Options Rotatilt x1 02 - Sheet 45/65 Rev A MA3:60 Chapter - Electrical System...
  • Page 97 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Multi Camera System - Sheet 46/65 Rev A MA3:61 Chapter - Electrical System...
  • Page 98 V Range 502 802 Maintenance Manual Hydrostatic Front Cab Beacons and Top/Side Marker Lights - Sheet 47/65 Rev A MA3:62 Chapter - Electrical System...
  • Page 99 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Powapak Node Hydrostatic Drive Control - Sheet 48/65 Rev A MA3:63 Chapter - Electrical System...
  • Page 100 V Range 502 802 Maintenance Manual Powapak Node Hydrostatic Sensors/Control and Work Lamps - Sheet 49/65 Rev A MA3:64 Chapter - Electrical System...
  • Page 101 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Powapak Node Semi Hydrostatic Sensors and Work Lamps - Sheet 50/65 Rev A MA3:65 Chapter - Electrical System...
  • Page 102 V Range 502 802 Maintenance Manual Electrical Circuit Model Map Demount - Sheet 51/65 Rev A MA3:66 Chapter - Electrical System...
  • Page 103 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Demount Disconnection Power/Work Lamps - Sheet 52/65 Rev A MA3:67 Chapter - Electrical System...
  • Page 104 V Range 502 802 Maintenance Manual Demount Disconnection Front System Node - Sheet 53/65 Rev A MA3:68 Chapter - Electrical System...
  • Page 105 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Rotatilt Hydraulic/Electrical Control - Sheet 54/65 Rev A MA3:69 Chapter - Electrical System...
  • Page 106 V Range 502 802 Maintenance Manual Power Wander Hose and Engine Speed Control with Extension - Sheet 55/65 Rev A MA3:70 Chapter - Electrical System...
  • Page 107 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Combivak Controls - Sheet 56/65 Rev A MA3:71 Chapter - Electrical System...
  • Page 108 V Range 502 802 Maintenance Manual HGB2 Powapak Node Hydrostatic Drive Control - Sheet 57/65 Rev A MA3:72 Chapter - Electrical System...
  • Page 109 V Range 502 802 Maintenance Manual Johnston Sweepers Limited HGB2 Powapak Node Hydrostatic Sensors/Control & Work Lamps- Sheet 58/65 Rev A MA3:73 Chapter - Electrical System...
  • Page 110 V Range 502 802 Maintenance Manual Systems Locker LED Strip Light - Sheet 59/65 Rev A MA3:74 Chapter - Electrical System...
  • Page 111 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Wide Sweep Brush Balance - Sheet 60/65 Rev A MA3:75 Chapter - Electrical System...
  • Page 112 V Range 502 802 Maintenance Manual AUX Engine JCB 93kW T4 - Sheet 61/65 Rev A MA3:76 Chapter - Electrical System...
  • Page 113 V Range 502 802 Maintenance Manual Johnston Sweepers Limited AUX Engine JCB 93kW T4 CAN/Power Connections - Sheet 62/65 Rev A MA3:77 Chapter - Electrical System...
  • Page 114 V Range 502 802 Maintenance Manual AUX Engine JCB AdBlue after treatment system - Sheet 63/65 Rev A MA3:78 Chapter - Electrical System...
  • Page 115 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Spare - Sheet 64/65 Rev A MA3:79 Chapter - Electrical System...
  • Page 116 V Range 502 802 Maintenance Manual AUX Engine Cummins - Sheet 65/65 Rev A MA3:80 Chapter - Electrical System...
  • Page 117 V Range 502 802 Maintenance Manual Johnston Sweepers Limited CHAPTER Water System Table of Contents Section Page Introduction General Description 4 : 2 Circuit Pressures 4 : 2 Component Maintenance and Settings Water Pump 4 : 3 Relief Valve 4 : 4...

  • Page 118: General Description 4

    V Range 502 802 Maintenance Manual WATER SYSTEM - INTRODUCTION General Description The water systems can be categorised into three systems. Low pressure:- For dust suppression and lubrication of consumable components. High pressure:- (Supawash) For surface cleaning. Re-circulation:- For reducing the overall usage of water and extended on station work time Low Pressure Water Pressure for the water supply is provided by a twin diaphragm pump hydraulically driven from the auxiliary engine.

  • Page 119: Component Maintenance And Settings

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited COMPONENT MAINTENANCE AND SETTINGS Water Pump Manifold Suction Port Delivery Port Suction Valve Delivery Valve Valve Sealing Rings Pump Chamber Tension Pad Bolts Tension Pads Diaphragms Connecting Rods M02MA-029 The assembly of the twin diaphragm pump is quite simple and straightforward, but attention to the under mentioned points will afford economy by prolonging the life of the pump and, more especially, the expendable components.

  • Page 120: Relief Valve 4

    V Range 502 802 Maintenance Manual Relief Valve This valve is factory set and should not normally be touched, but should it be necessary to make adjustments, the pressure is set as follows. Pressure Setting Remove the cover (A) and loosen adjuster locknut (B).

  • Page 121: Recirculation Valves 4

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited Recirculation Valves CAUTION: The shut off valve must be used when servicing any item on the air system M02MA-048 There is no routine maintenance required on these valves. MA4:5 Chapter - Water System...

  • Page 122: Piping Diagram / Component Location 4

    V Range 502 802 Maintenance Manual Piping Diagram / Component Location W-1V1 W-5V1 Y.201 Y.205 W-2V1 W-6V1 Y.202 Y.206 W-3V1 W-7V1 Y.203 Y.207 W-4V1 W-8V1 Y.204 Y.208 W-1Z2 M02MA-007-3 MA4:6 Chapter - Water System...
  • Page 123 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Component Key Water tank Water pump - output 28 l/m Water tank primary filter Suction filter Tank flushing ports Tank filler port - hosepipe Tank drain/flushing valve Hydrant filler port for water tank * Hydrant filler port for Recirc water ‘Type A’...

  • Page 124: Supawash Pump

    V Range 502 802 Maintenance Manual SUPAWASH SUPAWASH PUMP Water Pump Repair Pump Repair Water pumps by their very nature are subject to erosion and wear from the process of pumping water. The life of the pump will depend on the quality of the water being used. The more particles that are in suspension in the water the sooner the seals and valves in the pump will wear and require replacing and are therefore considered as consumable items.
  • Page 125 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Seal and Valve Maintenance Instructions P22/34-100 Johnston Water pump 283701-1 Seal and Valve Maintenance Instructions P22/34-100 Johnston Water Pump 700803 The following shows the overhaul procedure for the valves and plunger seals 1.
  • Page 126 V Range 502 802 Maintenance Manual 9. Remove and inspect the 10. Turn over intermediate 11. Remove the seal case low pressure seal (50) and casting (48) Remove (39) from the valve casing replace if necessary. and inspect the high (29) and inspect both O pressure seal (31) and the Rings (40) for wear.
  • Page 127 V Range 502 802 Maintenance Manual Johnston Sweepers Limited 18. Replace the three 19. Install the pressure 20. Secure the intermediate spacer sleeves (26a) over rings (30) over the plungers casing (48) to the valve the plunger (24a) with the (24a).
  • Page 128 V Range 502 802 Maintenance Manual Exploded view of Pump Exploded View of Pump Item Number Quantity Part Number Description 283701-19 Woodruff Key 283701-20 Connecting Rod 283701-24A Ceramic Liner 31,32,40,49,50 1 Kit 283701-500 Plunger Seal kit - for 3 plungers 34,35,36,37,38 1 Kit 283701-501...
  • Page 129 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Low Pressure Water System - Sheet 1/8 Rev E MA4:13 Chapter - Water System...
  • Page 130 V Range 502 802 Maintenance Manual Low Pressure Water System - Sheet 2/8 Rev E MA4:14 Chapter - Water System...
  • Page 131 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Low Pressure Water System - Sheet 3/8 Rev E MA4:15 Chapter - Water System...
  • Page 132 V Range 502 802 Maintenance Manual High Pressure Water System - Sheet 4/8 Rev E MA4:16 Chapter - Water System...
  • Page 133 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Low Pressure Water System - Sheet 5/8 Rev E MA4:17 Chapter - Water System...
  • Page 134 V Range 502 802 Maintenance Manual Low Pressure Water System - Sheet 6/8 Rev E MA4:18 Chapter - Water System...
  • Page 135 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Low Pressure Water System - Sheet 7/8 Rev E MA4:19 Chapter - Water System...
  • Page 136 V Range 502 802 Maintenance Manual Low Pressure Water System - Sheet 8/8 Rev E MA4:20 Chapter - Water System...
  • Page 137 V Range 502 802 Maintenance Manual Johnston Sweepers Limited CHAPTER Pneumatic System Table of Contents Section Page Introduction General Description 5 : 2 Circuit Pressures 5 : 2 Pneumatic Pipe Colours 5 : 2 Valve Identification/Location 5 : 3 Component Removal...

  • Page 138: General Description

    V Range 502 802 Maintenance Manual PNEUMATIC SYSTEM - INTRODUCTION General Description The air supply for the pneumatic system is taken from the vehicle braking system via a safety regulating valve that ensures the braking system receives priority in the event of a failure to the sweeper air system. A filter regulator unit with integral shut off/drain facility and low air pressure warning buzzers are located within the systems locker, as are the electrical solenoid control valves for operation of channel brush/nozzle and wide sweep brush, and intake duct flap.

  • Page 139: Valve Identification/Location

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited Valve Identification/Location P-18V2 P-18V3 P-0S1 P-0Z1 P-12V2 P-18V1 MKI WSB Control P-1V1 P-3V1 P-5V1 P-7V1 P-12V1 P-14V1 P-16V1 P-10V1 P-11V1 P-9V1 P-2V1 P-4V1 P-6V1 P-8V1 P-13V1 P-15V1 P-17V1 SPARE P-0Z2 M02MA-009-3a...

  • Page 140: Component Removal

    V Range 502 802 Maintenance Manual COMPONENT REMOVAL Air Filtration and Regulator (FR) A filter regulator unit, located in the systems locker filters the air for the sweeper section of the pneumatic system to prolong the life of the components served by it. Before carrying out any major work on the unit it will be necessary to remove it from the locker by first draining the vehicle air system, then disconnecting the supply pipes and releasing the fixing bolts.
  • Page 141 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Pneumatic Valve Island - Status Indicators Status/Colour Indication Error (Red) Indicates the status of the CAN physical and indicates errors due to missing CAN messages (SYNC, GUARD or HEARTBEAT). Run (Red/Green) Indicates the status of the CANopen network state machine.
  • Page 142 V Range 502 802 Maintenance Manual Pneumatic Valve Island - Fault situation 1 Pneumatic Valve Island - Fault situation 2 ● Key on Chassis, JVM starts to boot up. ● Key on Chassis, JVM starts to boot up. ● VM10 LEDs ●...
  • Page 143 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Pneumatic Valve Island - Fault situation 3 Pneumatic Valve Island - Fault situation 4 ● Key on Chassis, JVM starts to boot up. ● Key on Chassis, JVM starts to boot up.

  • Page 144: Pneumatic Valve Island - Modus Operandi

    V Range 502 802 Maintenance Manual Pneumatic Valve Island - Modus Operandi Single Sweep Function Segment Valve MKI WSB Control MKII WSB Control P-1V1 [Port 4 / LED 14] Unlock [Autoloc Option] (NC) NA6U TA6U P-2V1 [Port 2 / LED 12] Water Purge (NC) P-3V1 [Port 4 / LED 14] Channel Brush Lower (NO)
  • Page 145 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Air Set Suits All Variants - Sheet 1/17 Rev K MA5:9 Chapter - Pneumatic System...
  • Page 146 V Range 502 802 Maintenance Manual Valve Island Dual - No Options 01 - Sheet 2/17 Rev K MA5:10 Chapter - Pneumatic System...
  • Page 147 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Valve Island Dual - No Options 02 - Sheet 3/17 Rev K MA5:11 Chapter - Pneumatic System...
  • Page 148 V Range 502 802 Maintenance Manual Valve Island Dual - No Options 03 - Sheet 4/17 Rev K MA5:12 Chapter - Pneumatic System...
  • Page 149 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Wide Sweep Brush Control MK2 - Sheet 5/17 Rev K MA5:13 Chapter - Pneumatic System...
  • Page 150 V Range 502 802 Maintenance Manual Valve Island Single - No Options 01 - Sheet 6/17 Rev K MA5:14 Chapter - Pneumatic System...
  • Page 151 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Valve Island Single - No Options 02 - Sheet 7/17 Rev K MA5:15 Chapter - Pneumatic System...
  • Page 152 V Range 502 802 Maintenance Manual Valve Island Single - No Options 03 - Sheet 8/17 Rev K MA5:16 Chapter - Pneumatic System...
  • Page 153 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Valve Island Auto Lock Option - Sheet 9/17 Rev K MA5:17 Chapter - Pneumatic System...
  • Page 154 V Range 502 802 Maintenance Manual Valve Island Powasave Option - Sheet 10/17 Rev K MA5:18 Chapter - Pneumatic System...
  • Page 155 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Valve Island Dual Varagap Option - Sheet 11/17 Rev K MA5:19 Chapter - Pneumatic System...
  • Page 156 V Range 502 802 Maintenance Manual Valve Island Single Varagap Option - Sheet 12/17 Rev K MA5:20 Chapter - Pneumatic System...
  • Page 157 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Valve Island Water Recirculation Option - Sheet 13/17 Rev K MA5:21 Chapter - Pneumatic System...
  • Page 158 V Range 502 802 Maintenance Manual Littasnatch Option - Sheet 14/17 Rev K MA5:22 Chapter - Pneumatic System...
  • Page 159 V Range 502 802 Maintenance Manual Johnston Sweepers Limited In-Cab Mesh Shakers Option - Sheet 15/17 Rev K MA5:23 Chapter - Pneumatic System...
  • Page 160 V Range 502 802 Maintenance Manual Hydrostatic Transmission Option - Sheet 16/17 Rev K MA5:24 Chapter - Pneumatic System...
  • Page 161 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Runway Magnet Option - Sheet 17/17 Rev K MA5:25 Chapter - Pneumatic System...
  • Page 162 V Range 502 802 Maintenance Manual MA5:26 Chapter - Pneumatic System...
  • Page 163 V Range 502 802 Maintenance Manual Johnston Sweepers Limited CHAPTER Wearing Items Table of Contents Section Page Replacement Instructions Fan Impeller 6 : 2 Intake Duct Flap 6 : 3 Wear Plate 6 : 3 Intake Duct 6 : 4...

  • Page 164: Fan Impeller

    V Range 502 802 Maintenance Manual WEARING PARTS - REPLACEMENT INSTRUCTIONS WARNING: 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 engaged at all times when working under the body. Ensure operators are fully conversant with the controls and operation.

  • Page 165: Intake Duct Flap

    The fan impeller is supplied complete with the hub. Do not remove the hub or replace it, as the balancing will be adversely affected. Strictly adhere to the regular checking routines as outlined in the Johnston Operator’s Guide. Refit fan case cover (B) using sealant part number 94-1, to the mating face having first removed the old sealant.

  • Page 166: Intake Duct

    V Range 502 802 Maintenance Manual Intake Duct These parts are also abraded by the material being conveyed from the suction nozzle and must be periodically inspected and replaced when worn or holed. The duct is 250 mm diameter. Removal Enter body after carrying out the same precautions as for intake flap replacement.

  • Page 167: Nozzle Wheel

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited Nozzle Wheel Removal Release nozzle wheel adjustment nut (A) on inner end of wheel spindle. Remove wheel complete. Refitting Reverse of removal procedure. Tyre - Suction Nozzle Wheel Removal Remove nozzle wheel as above. Remove five screws securing tyre plate (B) and prise off.

  • Page 168: Channel Brush

    V Range 502 802 Maintenance Manual Channel Brush and Wide Sweep Brush CAUTION: The use of needle stick gloves is recommended when working with this equipment. Ensure the auxiliary engine is not running and isolated before brush adjustment or replacement is attempted. Removal It is preferable to have brushes in working position with auxiliary engine stopped.
  • Page 169 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Removal Release and remove the retaining screws (F) securing the end plate / adaptor (A). Slide off the segments (B) and spacers (C) from the central core, or single Plastic Disposable Stock (H). Note : On earlier machines the driving pin (E) on the inner diameter of the segments must be aligned with a slot (D) on the core (G) where the two parts join.
  • Page 170 V Range 502 802 Maintenance Manual MA6:8 Chapter - Wearing Items...
  • Page 171 V Range 502 802 Maintenance Manual Johnston Sweepers Limited CHAPTER Remove and Refit Procedures Table of Contents Section Pages Removal and Refitting Instructions Water Pump VT & VS 7 : 2 Wide Sweep Brush Motor VT & VS 7 : 3 Channel Brush Motor VT &...
  • Page 172 V Range 502 802 Maintenance Manual REMOVAL AND REFITTING INSTRUCTIONS WARNING: 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 engaged at all times when working under the body. Ensure operators are fully conversant with the controls and operation.
  • Page 173 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Wide Sweep Brush Motor Removal Remove the brush stock as described in Chapter 6. Unscrew the four end plate securing setscrews and remove plate complete with motor assembly and drive shaft or drive dog.
  • Page 174 V Range 502 802 Maintenance Manual Channel Brush Cylinder Removal and refitting Disconnect the two hydraulic hoses from rear of the cylinder. Remove cylinder pin (B). Remove stop from pivot frame (D). Remove cylinder eye pivot (E) from pivot head lever (F). Lift out cylinder. Refitting is the reverse of removal, grease items (B) and (E) prior to refitting.
  • Page 175 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Hydrostatic Gearbox and Pumps WARNING: If the gearbox is to be removed, the truck will be immobile. The ignition keys should be removed to prevent inadvertent starting and consequential damage to the drive line and components.
  • Page 176 V Range 502 802 Maintenance Manual VT - Twin Engine Radiator WARNING: Insure the cooling system has adequately cooled before commencing Removal To remove the radiator it will first be necessary to remove the hydraulic oil cooler. Drain the hydraulic oil to a level below that of the cooler using the remote drain under the systems locker.
  • Page 177 V Range 502 802 Maintenance Manual Johnston Sweepers Limited VT - Twin Engine Gearbox Removal & Overha Removal 1. Carry out procedures 4 and 5. 2. Drain fluid drive coupling as described in Chapter 7. 3. Remove the six setscrews securing the gearbox to the bell housing and the four bolts holding the two cover plates to the flywheel housing.
  • Page 178 A more suitable tool for this application is a ‘segmental plug gauge’ (Johnston Part No. 437-321) Note: This measuring tool requires periodic calibration and should be included in your normal processes for the control...
  • Page 179 V Range 502 802 Maintenance Manual Johnston Sweepers Limited VT - Twin Engine Fluid Drive Coupling Removal 1. Carry out procedures for Fan Impeller, Fancase and Gearbox removal 2. Remove the twenty socket head screws securing the coupling to the flywheel.
  • Page 180 V Range 502 802 Maintenance Manual VS - Single Engine HYDROSTATIC GEARBOX ASSEMBLY HGB-1 (Formally identified as MKIII) Sealant INPUT INPUT HOUSING Apply sealant round removal holes as shown INPUT DRIVE MOTOR HOUSING FLANGE FAN PUMP Shims Shims FLANGE 29742-1 = 0.4mm 29742-1 = 0.4mm 29742-2 = 0.2mm 29742-2 = 0.2mm...
  • Page 181 V Range 502 802 Maintenance Manual Johnston Sweepers Limited VS - Single Engine MK III GEARBOX ASSEMBLY - SETTINGS AND ASSEMBLY DETAILS 2. FANDRIVE PUMP:- 4. TRANSMISSION PUMP:- c) ‘’Standby’’ differential pressure setting Charge Pump pre-set to 24 Bar d) Main relief valve maximum pressure setting...
  • Page 182 V Range 502 802 Maintenance Manual M02OG-050-3 MA7:12 Chapter - Remove and Refit Procedures...
  • Page 183 (H) Chassis PAS - Auto See Chassis 39661 Gearbox Handbook Grease Points 94-69 Battery Terminals Petroleum Jelly The above oils are those approved by Johnston Sweepers. Other manufacturer’s oils must be of equivalent grade. MA7:13 Chapter - Remove and Refit Procedures...
  • Page 184 V Range 502 802 Maintenance Manual GREASE M02OG-054-4 MA7:14 Chapter - Remove and Refit Procedures...
  • Page 185 See Chassis (H) Chassis PAS - Auto Gearbox 39661 Handbook Grease Points 94-69 Petroleum Battery Terminals Jelly The above oils are those approved by Johnston Sweepers. Other manufacturer’s oils must be of equivalent grade. MA7:15 Chapter - Remove and Refit Procedures...
  • Page 186 V Range 502 802 Maintenance Manual GREASE M02OG-054-4 MA7:16 Chapter - Remove and Refit Procedures...
  • Page 187 See Chassis (H) Chassis PAS - Auto Gearbox 39661 Handbook Grease Points 94-69 Petroleum Jelly Battery Terminals The above oils are those approved by Johnston Sweepers. Other manufacturer’s oils must be of equivalent grade. MA7:17 Chapter - Remove and Refit Procedures...
  • Page 188 V Range 502 802 Maintenance Manual MA7:18 Chapter - Remove and Refit Procedures...
  • Page 189 VT & VS 8 : 7 Discharge Body Tip VT & VS 8 : 8 Hydrodrive Gearbox System VS Only 8 : 9 Johnston Visual Module (JVM) Emergency Codes VT & VS 8 : 10 MA8:1 Chapter - Fault Diagnosis...

  • Page 190: Power Systems

    Relief valve stuck open. Relief valve worn. Audible Warning Fault Symptom Possible Cause Audible warning on continuously Air pressure switch faulty. Insufficient pressure in Johnston system. Low Hydraulic oil level. Body raised. Rear door open. MA8:2 Chapter - Fault Diagnosis...
  • Page 191 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Electrical System Fault Symptom Possible Cause Beacon not working Check vehicle ignition is on Check beacon bulb/motor Check feed to beacon Check earth wire Check fuse No. 1 for front. Fuse 2 for rear...
  • Page 192 V Range 502 802 Maintenance Manual SUCTION SYSTEMS Fault Symptom Possible Cause No pickup performance Hopper full, causing airflow to be throttled: - Discharge load. Nozzle or nozzle trunking blocked or restricted by debris. Check the nozzle water jets are not blocked, are working correctly and lubricating the intake duct.

  • Page 193: Power Pack

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited VT - Twin Engine POWER PACK Auxiliary Engine Fault Symptom Possible Cause Engine fails to turn over Check truck ignition is on. Check battery and connections. Check ignition switch. Check starter motor.

  • Page 194: Sweep Gear

    V Range 502 802 Maintenance Manual SWEEP GEAR Wide Sweep Brush Fault Symptom Possible Cause Not rotating Worn drive adaptor and plate. Bearings seized. Motor seized. Foreign matter jammed in brush. Check electrical feed to solenoid/Plug LED (see Modus Operandi). Check hydraulic pressure to aid fault diagnosis.

  • Page 195: Channel Brush

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited Channel Brush Fault Symptom Possible Cause Rotating slowly Motor worn. Hydraulic pump worn. Channel brush worn. Check hydraulic pressure to aid fault diagnosis. Works intermittently Check switch in Control Panel and looms for loose connections.

  • Page 196: Discharge

    V Range 502 802 Maintenance Manual DISCHARGE Body Tip Fault Symptom Possible Cause Rear door will not open Check handbrake is on. Check master switch V is illuminated. Check green safety run button is pressed on pedant unit. Check pendant unit has not become unplugged. Body will not tip Ensure handbrake is on.

  • Page 197: Hydrodrive Gearbox System

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited VS - Single Engine HYDRODRIVE GEARBOX SYSTEM Fault Symptom Possible Cause No forward/reverse drive Is the chassis in the correct gear EG 1:1. On dual sweep m/c has drive for power steering changeover been correctly selected.

  • Page 198: Johnston Visual Module (Jvm)

    V Range 502 802 Maintenance Manual JOHNSTON VISUAL MODULE (JVM) JVM Emergency Codes Should a fault occur in any of the equipment operating systems the fault icon (!) is displayed over soft key F2. Selecting F2 automatically opens Menu 4.2 (CANbus Network) which highlights the location of the affected Node.

  • Page 199: Emergency Codes

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited Menu 4.2.3.1 - Powapak IO Node Should a fault occur within the CANbus network it will be accompanied by one or more emergency codes (EMCY), which will be logged in the system.
  • Page 200 V Range 502 802 Maintenance Manual MA8:12 Chapter - Fault Diagnosis...
  • Page 201 V Range 502 802 Maintenance Manual Johnston Sweepers Limited MA8:13 Chapter - Fault Diagnosis...
  • Page 202 V Range 502 802 Maintenance Manual MA8:14 Chapter - Fault Diagnosis...
  • Page 203 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Truck Mounted Sweepers 85kW Engine Specific Revision 05 Release Date: 29.06.2016 Note: All of the Codes below are displayed on page 4.8 Code Type Description of Fault 4096 Engine Fault (85kW Engine only)
  • Page 204 V Range 502 802 Maintenance Manual MA8:16 Chapter - Fault Diagnosis...

  • Page 205: Vs Only

    V Range 502 802 Maintenance Manual Johnston Sweepers Limited CHAPTER Service Tools Table of Contents Section Page Service Tools Service Tools VT & VS 9 : 2 Hydrodrive Transmission VS Only 9 : 3 MA9:1 Chapter - Service Tools...
  • Page 206 V Range 502 802 Maintenance Manual SERVICE TOOLS The following tools are available through our Spares Network TOOL NO ITEM FUNCTION 7028665 ESU Unpacking Rear door control Control Unit 12v (502, 652 & 802) enables ESU’s to be unpacked 7021548 ESU Unpacking Rear door control Control Unit 24v (502, 652 &...
  • Page 207 V Range 502 802 Maintenance Manual Johnston Sweepers Limited VS - Single Engine HYDRODRIVE TRANSMISSION HydroDrive Transmission System Set-Up and Commissioning Procedure For Truck Mounted Units Incorporating CAN communications Via JVM control system Software Revision J Onwards Employing Sauer Sundstrand Hydrostatic...
  • Page 208 Introduction The purpose of this chapter is to provide guidance and set-up data for commissioning the hydrostatic transmission components associated with the Johnston HydroDrive system. The data is specific to truck mounted sweepers together with Sauer Sundstrand transmission equipment and the Johnston JVM control system.
  • Page 209 V Range 502 802 Maintenance Manual Johnston Sweepers Limited WARNING: When the HydroDrive is engaged if the chassis is in gear and the clutch is released the front prop shaft will be turning Note: On either new machines or after repairs the following checks should be carried out to ensure that the system is free of air.
  • Page 210 V Range 502 802 Maintenance Manual Pump Set Up continued: With the vehicle jacked-up and secured on axle stands and both front wheels fully chocked - engage the HydroDrive and select the 1:1 ratio. Release the clutch and increase the engine rpm to the maximum 1700. Keep handbrake applied, select forward using the drive select control, depress the accelerator pedal and read the pressure from test point T3.
  • Page 211 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Motor Set-Up - Pressure Control Adjustment The motor is equipped with two in-built pre-set control features: 1 Threshold Control. Instigates a decrease in the motor displacement resulting from a signal from the main control valve in the pump.
  • Page 212 V Range 502 802 Maintenance Manual MA9:8 Chapter - Service Tools...
  • Page 213 Introduction The information presented in this chapter does not infer that there are hazards associated with the Johnston Sweepers. It is given as a guide to general precautions that should be exercised in the course of their maintenance work. Whilst every effort has been made to ensure completeness of this document, owners...
  • Page 214 V Range 502 802 Maintenance Manual HEALTH AND SAFETY PRECAUTIONS The information presented in this section does not infer there are any particular hazards associated with these machines. It is given as a guide to the general precautions that should be taken in any workshop environment when working on machines of this nature in the course of their maintenance.
  • Page 215 Remove positive lead from discharged chassis and then the donor chassis. If the vehicle will not start with a booster battery, contact your local Johnston Service Network. Chemical materials: Chemical materials such as solvents, sealers, adhesive, paints, resin foams, battery acids, anti-freezes, brake fluids, oils and grease should always be used with caution and stored and handled with care.
  • Page 216 V Range 502 802 Maintenance Manual REMINDERS Chemical materials Remove chemical materials from the skin and clothing as soon as practical after soiling. Change heavily soiled clothing and have it cleaned. Carefully read and observe hazard and precaution warnings given on hazardous material containers and in any accompanying leaflets, posters or other instructions.
  • Page 217 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Dusts: Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection in accordance with the requirement of the Health and Safety Acts.
  • Page 218 V Range 502 802 Maintenance Manual First aid: It is desirable for someone in the workshop to be trained in the first aid procedures. Splashes or particles in the eye should be flushed with clean water for at least ten minutes and medical attention sought.
  • Page 219 V Range 502 802 Maintenance Manual Johnston Sweepers Limited Solvents: Solvents such as acetone, white spirit, toluene, xylene and trichloroethane are flammable. Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing. When using solvents ensure good ventilation; avoid breathing fumes, vapours, spray-mists and keep containers tightly sealed.
  • Page 220 V Range 502 802 Maintenance Manual MA10:8 Chapter - Health and Safety...

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