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Johnston VM502, Maintenance Manual

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Johnston Sweepers Limited

Pneumatic System

Scheduled Maintenance

Hydraulic System

Electrical System

Water System

Wearing Items

Remove and Refit Procedures

Fault Diagnosis

Service Tools

Health and Safety

Maintenance

Section

 

1

 

2

 

3

 

4

 

5

 

6

 

7

 

8

 

9

 

10

 

VT - Twin Engine 

 

Specific to Twin engine sweepers.

 

VS - Single Engine   

Specific to Single engine sweepers.

 

VM - Single Engine   

Specific to Single engine sweepers.

ECN - 718631

Print date - 25/10/2018

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

Summary of Contents for VM502

Page 1: ...ion 1 2 3 4 5 6 7 8 9 10 VT Twin Engine Specific to Twin engine sweepers VS Single Engine Specific to Single engine sweepers VM Single Engine Specific to Single engine sweepers ECN 718631 Print date 2...

Page 2: ...V Range 502 l 652 l 802 Maintenance Manual...

Page 3: ...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 V...

Page 4: ...en 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 eng...

Page 5: ...ith a medium level of risk Indicates an imminently hazardous situation which if not avoided could result in serious injury or death DANGER Indicates an imminently hazardous situation with a high level...

Page 6: ...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...

Page 7: ...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 flap air cylinder 15 80 bar Pressure 1 Hopper Intake duct...

Page 8: ...r 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...

Page 9: ...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...

Page 10: ...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 W...

Page 11: ...e 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...

Page 12: ...ngine 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 1...

Page 13: ...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 fl...

Page 14: ...der 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 Rai...

Page 15: ...rain 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 capacit...

Page 16: ...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 Pneumatic Cylinder Maintenanc...

Page 17: ...at the skin as the fluid may penetrate the underlying tissue etc and cause serious injury NOTICE Care MUST be taken not to damage sign written areas when cleaning See special notes for cleaning vehicl...

Page 18: ...elating 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 t...

Page 19: ...any hydraulic oil Note This is a high pressure filter Ensure the correct filter is fitted Pattern Parts may not be suitable Start engine and engage Hydrodrive Allow system to tick over for a few minu...

Page 20: ...V Range 502 l 652 l 802 Maintenance Manual MA1 18 Chapter Scheduled Maintenance...

Page 21: ...System VT VS 2 2 Supawash Option Sweeping System VT VS 2 3 Powaboom Rear Wanderhose Option VT VS 2 3 Fan Drive System VS Only 2 4 Hydraulic System Initial Operation 2 5 Valve Identification 2 5 Circu...

Page 22: ...sure VS H 1Z2 Sweep system VT VS H 13Z5 Fan drive system VS H 12Z2 Options system i e Supawash VT VS H 8Z2 Discharge functions VT VS H 1472 Rear Wanderhose Powaboom VT VS Body Discharge System To set...

Page 23: ...otary encoder on the display Start the engine and run at the appropriate speed and acknowledge by pressing the rotary encoder on the display Check Hydraulic Pressure Powaboom Check and adjust if requi...

Page 24: ...ck tub Open rear door open inlet flap Run the truck engine and engage Hydrodrive engage work mode and raise the engine speed to maximum 1700 rpm There should be a nominal reading of 20 bar which is th...

Page 25: ...to function incorrectly VALVE IDENTIFICATION H 8Z2 BODY TIP BLOCK Attached to Sub frame H 9V1 Y 011 H 8V3 H 9V2 H 8V2 H 8V1 H 8Z1 Y 012 H 8Z2 Y 022 H 4V1 H 4Z2 H 4V2 SUPAWASH FRONT BRUSH BLOCK Locate...

Page 26: ...T N E M U C O D S E C N A R E L O T L A R E N E G 3 4 Y T I L A U Q G I D L E W T C U D O R P T C E J O R P S E C N A R E L O T G N I D L E W 5 6 T N E M T R A P E D E L I S N O P S E R E P Y T C O D...

Page 27: ...U N T N E M U C O D S E C N A R E L O T L A R E N E G 3 4 Y T I L A U Q G N I D L E W T C U D O R P T C E J O R P S E C N A R E L O T G N I D L E W 5 6 T N E M T R A P E D E L B I S N O P S E R E P Y...

Page 28: ...N T N E M U C O D S E C N A R E L O T L A R E N E G 3 4 Y T I L A U Q G N I D L E W T C U D O R P T C E J O R P S E C N A R E L O T G N I D L E W 5 6 T N E M T R A P E D E L B I S N O P S E R E P Y T...

Page 29: ...L E R R E B M U N T N E M U C O D S E C N A R E L O T L A R E N E G 3 4 Y T I L A U Q G N I D L E W T C U D O R P T C E J O R P S E C N A R E L O T G N I D L E W 5 6 T N E M T R A P E D E L B I S N O...

Page 30: ...M U N T N E M U C O D S E C N A R E L O T L A R E N E G 3 4 Y T I L A U Q G N I D L E W T C U D O R P T C E J O R P S E C N A R E L O T G N I D L E W 5 6 T N E M T R A P E D E L B I S N O P S E R E P...

Page 31: ...E R R E B M U N T N E M U C O D S E C N A R E L O T L A R E N E G 3 4 Y T I L A U Q G N I D L E W T C U D O R P T C E J O R P S E C N A R E L O T G N I D L E W 5 6 T N E M T R A P E D E L B I S N O P...

Page 32: ...T N E M U C O D S E C N A R E L O T L A R E N E G 3 4 Y T I L A U Q G N I D L E W T C U D O R P T C E J O R P S E C N A R E L O T G N I D L E W 5 6 T N E M T R A P E D E L B I S N O P S E R E P Y T C...

Page 33: ...L E R R E B M U N T N E M U C O D S E C N A R E L O T L A R E N E G 3 4 Y T I L A U Q G N I D L E W T C U D O R P T C E J O R P S E C N A R E L O T G N I D L E W 5 6 T N E M T R A P E D E L B I S N O...

Page 34: ...D 2 1 C B A 2 Y B D E S A E L E R R E B M U N T N E M U C O D S E C N A R E L O T L A R E N E G 3 4 Y T I L A U Q G N I D L E W T C U D O R P T C E J O R P S E C N A R E L O T G N I D L E W 5 6 T N E...

Page 35: ...R E B M U N T N E M U C O D S E C N A R E L O T L A R E N E G 3 4 Y T I L A U Q G N I D L E W T C U D O R P T C E J O R P S E C N A R E L O T G N I D L E W 5 6 T N E M T R A P E D E L B I S N O P S E...

Page 36: ...V Range 502 l 652 l 802 Maintenance Manual MA2 16 Chapter Hydraulic System...

Page 37: ...nston Sweepers Ltd Table of Contents Section Page Introduction General Description 3 2 System Description 3 2 Component Identification Systems Locker 3 3 Johnston Visual Module JVM Engine Chassis Cont...

Page 38: ...machine System Description The electrical system circuit diagrams are sub divided into modular sub circuits all of which use the same identification number ending with a revision alpha code i e A B C...

Page 39: ...0 20A F121 20A F101 20A F122 20A F102 20A F104 15A F106 15A F108 10A F109 5A F110 F103 20A 20A F123 20A F124 20A F125 POWAPAK NODE SUBFRAME NODE FRONT BEACON SYSTEMS LOCKER NODE WIDE SWEEP BALANCE CAB...

Page 40: ...amount of interference System CAN CANOPEN CANopen is also a CAN based higher layer protocol as is J1939 It provides a standardized network which can be fully customised with off the shelf controllers...

Page 41: ...pack Node Systems Locker Node Subframe Node Door Controller Node Power PCB CANbus System Engine Management Control Unit Johnston Visual Module M02OG118a CANbus Chassis Engine J1939 CANbus Auxiliary En...

Page 42: ...re_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 1 2 Unzip the file TMS_SoftwareSe...

Page 43: ...oftware will now download from the USB flash drive automatically Note Software download can take up to 10 minutes depending on the size of the update F1 F2 F3 F4 M02OG 112a NOTICE Never switch off the...

Page 44: ...in Menu 4 0 Menu 4 0 Main Menu 3 2 Select Menu 4 14 Security Menu 4 14 System Security 3 3 Enter the Service passcode 88335 3 4 Press the enter key F4 to complete the passcode entry 3 5 Press F1 to Ex...

Page 45: ...t option 2 OS Downloads Menu 4 11 Service 4 2 Move the blue halo and select for example the machine cab area Menu 4 11 2 Cab Area Selection 4 2 Move the blue halo and select the Centre Console cab Nod...

Page 46: ...s the centre button on the JVM to start the OS update The blue bar will indicate the progress of the download F1 F2 F3 F4 F4 09 45 20 01 2016 4 11 2 1 2 NOTICE When a fault is repeated 4 consecutive t...

Page 47: ...u 4 11 Service and press to select 4 Rotate the Encoder to highlight sub menu 4 11 1 Service Acknowledgment and press to select 5 The JVM will automatically select which service requires acknowledgmen...

Page 48: ...rs Engine hours today Total distance travelled sweeping Optional Distance travelled sweeping today Optional Avg Fuel Consumption to Date Avg fuel consumption today Hours at last service Hours until ne...

Page 49: ...F3 F4 F4 1 1 km h 0 0 09 45 20 01 2016 1 1 Part Totals The icon top right shows the current screen The icon bottom centre shows the next page E G Grand Totals Press the encoder to select the next page...

Page 50: ...Capture 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 Key to Logging Screen Icons Vehicle Logging con...

Page 51: ...ogging screens press hour glass icon 2 Press F4 in any of the sub menus 1 1 1 2 1 3 download icon Menu 1 5 will be displayed 3 Insert the USB Memory stick 4 Press the middle button on the display The...

Page 52: ...ECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C B 8 A REVISION INFORMATION...

Page 53: ...ERANCES 3 4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E...

Page 54: ...ELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C...

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Page 56: ...LDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C...

Page 57: ...ANCES 3 4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D...

Page 58: ...DING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C B...

Page 59: ...ERANCES 3 4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E...

Page 60: ...ELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C...

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Page 63: ...ANCES 3 4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D...

Page 64: ...WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7...

Page 65: ...ANCES 3 4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D...

Page 66: ...DING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C B...

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Page 68: ...NG QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C B 8...

Page 69: ...3 4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5...

Page 70: ...UALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C B 8 A R...

Page 71: ...ANCES 3 4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D...

Page 72: ...DING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C B...

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Page 74: ...DING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C B...

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Page 77: ...NCES 3 4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3...

Page 78: ...DING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C B...

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Page 80: ...ES 3 4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4...

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Page 112: ...4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6...

Page 113: ...ANCES 3 4 WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D...

Page 114: ...WELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7...

Page 115: ...G QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C B 8...

Page 116: ...ELDING QUALITY PRODUCT PROJECT WELDING TOLERANCES 5 6 RESPONSIBLE DEPARTMENT DOC TYPE FIRST ANGLE TITLE SUPPLEMENTARY TITLE CREATED BY VERSION 7 SHEET SCALE DATE A3 REVISION DATE ECN F E D 3 4 5 6 7 C...

Page 117: ...pers Ltd 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 Solenoid Valves 4 4 Hydrant Filler...

Page 118: ...er This option enables the water held within the body to be drained to the suction nozzle enabling it to be re used for lubrication and dust suppression Supawash Unloader Valve Pressure Setting 1 Ensu...

Page 119: ...ed against the crankcase 3 Manifolds and Valves Fit the valve sealing rings onto the valve seat Place the delivery valve stem upwards over the delivery orifice of the pump chamber and push the sealing...

Page 120: ...juster screw C until gauge reads 3 5 bar 50 psi Tighten locknut and replace cover Solenoid valves control the water spray jets and are located in the systems locker The valve is easily dismantled for...

Page 121: ...ntenance Manual Johnston Sweepers Limited Chapter Water System M02MA 048 Recirculation Valves There is no routine maintenance required on these valves CAUTION The shut off valve must be used when serv...

Page 122: ...enance Manual MA4 6 Chapter Water System M02MA 007 3 14 15 9 7 8a 8b 13 12 W 1V1 Y 201 W 2V1 Y 202 W 3V1 Y 203 W 4V1 Y 204 W 6V1 Y 206 W 7V1 Y 207 W 8V1 Y 208 W 5V1 Y 205 W 1Z2 6 5 2 4 3 16 10 11 Pipi...

Page 123: ...r port for Recirc water 9 Type A anti syphon water break 10 Cowl overflow 11 Breather 12 Relief valve 13 Washdown hose 14 Wanderhose valve 15 Littasnatch valve 16 Water valve manifold see table below...

Page 124: ...ter leaks If the plunger seals wear water will leak from the underside of the pump as shown below A drip ever 5 10 seconds is an indication that the seals need replacing in the very near future A cont...

Page 125: ...he spring tension cap 34 spring 35 and plate 36 3 Use a valve extractor tool 99 061 to remove the valve seats 37 4 Inspect the valve seat 37 and valve seat 36 for signs of wear or cavitation and repla...

Page 126: ...ve plate 36 from the valve casing 29 Using a valve extractor 99 061 to remove the valve seat 37 from the valve casing 29 13 Inspect the valve seat 37 and valve seat 36 for signs of wear or cavitation...

Page 127: ...ing 49 is in place in the intermediate casing 49 20 Secure the intermediate casing 48 to the valve casing 29 with the inner hexagon screws 46 Torque to 12 NM 21 Place the valve casing 29 over the plun...

Page 128: ...f Pump Item Number Quantity Part Number Description 19 1 283701 19 Woodruff Key 20 3 283701 20 Connecting Rod 24A 3 283701 24A Ceramic Liner 31 32 40 49 50 1 Kit 283701 500 Plunger Seal kit for 3 plun...

Page 129: ...T N E M T R A P E D E L B I S N O P S E R E P Y T C O D T S R I F E L G N A E L T I T Y R A T N E M E L P P U S E L T I T Y B D E T A E R C N O I S R E V 7 T E E H S E L A C S E T A D 3 A N O I S I V...

Page 130: ...P E D E L B I S N O P S E R E P Y T C O D T S R I F E L G N A E L T I T Y R A T N E M E L P P U S E L T I T Y B D E T A E R C N O I S R E V 7 T E E H S E L A C S E T A D 3 A N O I S I V E R E T A D N...

Page 131: ...T N E M T R A P E D E L B I S N O P S E R E P Y T C O D T S R I F E L G N A E L T I T Y R A T N E M E L P P U S E L T I T Y B D E T A E R C N O I S R E V 7 T E E H S E L A C S E T A D 3 A N O I S I V...

Page 132: ...P E D E L B I S N O P S E R E P Y T C O D T S R I F E L G N A E L T I T Y R A T N E M E L P P U S E L T I T Y B D E T A E R C N O I S R E V 7 T E E H S E L A C S E T A D 3 A N O I S I V E R E T A D N...

Page 133: ...T N E M T R A P E D E L B I S N O P S E R E P Y T C O D T S R I F E L G N A E L T I T Y R A T N E M E L P P U S E L T I T Y B D E T A E R C N O I S R E V 7 T E E H S E L A C S E T A D 3 A N O I S I V...

Page 134: ...P E D E L B I S N O P S E R E P Y T C O D T S R I F E L G N A E L T I T Y R A T N E M E L P P U S E L T I T Y B D E T A E R C N O I S R E V 7 T E E H S E L A C S E T A D 3 A N O I S I V E R E T A D N...

Page 135: ...T N E M T R A P E D E L B I S N O P S E R E P Y T C O D T S R I F E L G N A E L T I T Y R A T N E M E L P P U S E L T I T Y B D E T A E R C N O I S R E V 7 T E E H S E L A C S E T A D 3 A N O I S I V...

Page 136: ...P E D E L B I S N O P S E R E P Y T C O D T S R I F E L G N A E L T I T Y R A T N E M E L P P U S E L T I T Y B D E T A E R C N O I S R E V 7 T E E H S E L A C S E T A D 3 A N O I S I V E R E T A D N...

Page 137: ...roperty of Johnston Sweepers Ltd 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 Remova...

Page 138: ...up to pressure and sweepgear is lifted 2 If pressure is incorrect adjustment is carried out by turning the regulator control on the filter regulator unit Note Provided in the systems locker is an air...

Page 139: ...0V1 M02MA 009 4a P 0Z1 P 0S1 P 12V2 P 18V1 P 18V2 P 18V3 A B C D E F G H I J P 17V1 P 15V1 P 8V1 P 6V1 P 4V1 P 2V1 P 16V1 P 14V1 P 9V1 P 7V1 P 5V1 P 3V1 P 12V1 P 11V1 P 10V1 P 13V1 X X P 0Z2 P 1V1 P 1...

Page 140: ...sing various segments Each segment has an indicator LED that illuminates when energised A and a manual override button B for ports 2 or 4 on each segment Each segment is identified by a unique code th...

Page 141: ...s powered 4 24V Green Indicates when chassis voltage is applied to the power terminal of the supply connector 4 1 2 3 Pneumatic Valve Island Status Indicators Normal Operation Key on Chassis JVM start...

Page 142: ...sis JVM starts to boot up VM10 LEDs For 1 2 seconds after ignition on Quick flashing of Red Error Quick flashing of Green Run Solid Green 5V Solid Green 12 24V After 2 seconds and until the JVM shows...

Page 143: ...ing off VM10 will not be shown on CAN loss of ignition feed to X10 connector Check continuity between X608 Pin 3 and X10 pin 2 X10 Front M12 Connector Pneumatic Valve Island Fault situation 4 Key on C...

Page 144: ...ecirculation NC P 17V1 Port 2 LED 12 Plugged Dual Sweep Function Segment 24v 12v Valve Function 1 NA6U TA6U P 1V1 Port 4 LED 14 Unlock Autoloc Option NC P 2V1 Port 2 LED 12 Water Purge NC 2 NB6U TB6U...

Page 145: ...MA5 9 V Range 502 l 652 l 802 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Air Set Suits All Variants Sheet 1 17 Rev K...

Page 146: ...V Range 502 l 652 l 802 Maintenance Manual MA5 10 Chapter Pneumatic System Valve Island Dual No Options 01 Sheet 2 17 Rev K...

Page 147: ...MA5 11 V Range 502 l 652 l 802 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Valve Island Dual No Options 02 Sheet 3 17 Rev K...

Page 148: ...V Range 502 l 652 l 802 Maintenance Manual MA5 12 Chapter Pneumatic System Valve Island Dual No Options 03 Sheet 4 17 Rev K...

Page 149: ...MA5 13 V Range 502 l 652 l 802 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Wide Sweep Brush Control MK2 Sheet 5 17 Rev K...

Page 150: ...V Range 502 l 652 l 802 Maintenance Manual MA5 14 Chapter Pneumatic System Valve Island Single No Options 01 Sheet 6 17 Rev K...

Page 151: ...MA5 15 V Range 502 l 652 l 802 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Valve Island Single No Options 02 Sheet 7 17 Rev K...

Page 152: ...V Range 502 l 652 l 802 Maintenance Manual MA5 16 Chapter Pneumatic System Valve Island Single No Options 03 Sheet 8 17 Rev K...

Page 153: ...MA5 17 V Range 502 l 652 l 802 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Valve Island Auto Lock Option Sheet 9 17 Rev K...

Page 154: ...V Range 502 l 652 l 802 Maintenance Manual MA5 18 Chapter Pneumatic System Valve Island Powasave Option Sheet 10 17 Rev K...

Page 155: ...MA5 19 V Range 502 l 652 l 802 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Valve Island Dual Varagap Option Sheet 11 17 Rev K...

Page 156: ...V Range 502 l 652 l 802 Maintenance Manual MA5 20 Chapter Pneumatic System Valve Island Single Varagap Option Sheet 12 17 Rev K...

Page 157: ...MA5 21 V Range 502 l 652 l 802 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Valve Island Water Recirculation Option Sheet 13 17 Rev K...

Page 158: ...V Range 502 l 652 l 802 Maintenance Manual MA5 22 Chapter Pneumatic System Littasnatch Option Sheet 14 17 Rev K...

Page 159: ...MA5 23 V Range 502 l 652 l 802 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System In Cab Mesh Shakers Option Sheet 15 17 Rev K...

Page 160: ...V Range 502 l 652 l 802 Maintenance Manual MA5 24 Chapter Pneumatic System Hydrostatic Transmission Option Sheet 16 17 Rev K...

Page 161: ...MA5 25 V Range 502 l 652 l 802 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Runway Magnet Option Sheet 17 17 Rev K...

Page 162: ...V Range 502 l 652 l 802 Maintenance Manual MA5 26 Chapter Pneumatic System...

Page 163: ...s All Copyright and rights are the property of Johnston Sweepers Ltd Table of Contents Section Page Replacement Instructions Fan Impeller 6 2 Intake Duct Flap 6 3 Wear Plate 6 3 Intake Duct 6 4 Intake...

Page 164: ...NING 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 th...

Page 165: ...o actuating fingers by a pair of spring clips Removal To remove a flap plate the springs must be withdrawn using a suitable tool or bar Notice how the springs were fitted from each side of the finger...

Page 166: ...efitting Reverse of removal procedure Align slots in the intake duct flange with the released screws and twist Fit the other two bolts and tighten Re fasten the make break seal assembly to the intake...

Page 167: ...etaining plate Refit washer and nut insert M6c x 50mm setscrews in the three unused tapped holes Tighten each bolt half a turn at a time to extract the bearing Remove drift bearing from shaft Refittin...

Page 168: ...offering up brush stock assembly to driving plate Wide Sweep Brush Wide Sweep Core Assembly Brush Fills There are two types of brush fills Menu 4 1 11 Channel and W S B Removal Channel Brush and Wide...

Page 169: ...alternately a spacer and a segment Sufficient spacers and segments must be fitted to allow the end plate to nearly abut with the core and also clamp them tightly The peg E on the segment B to be alter...

Page 170: ...V Range 502 l 652 l 802 Maintenance Manual MA6 8 Chapter Wearing Items...

Page 171: ...7 4 Body Lifting or Removal VT VS 7 4 Hydrodrive Gearbox Pumps VS Only 7 5 Fan Drive Motor VS Only 7 5 Radiator VT Only 7 6 Fan Impeller VT Only 7 6 Fan Case VT Only 7 6 Gearbox Removal Overhaul VT O...

Page 172: ...nd 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...

Page 173: ...e of removal 1 End plate securing screws 2 Drive shaft retaining screws 3 Drive shaft drive dog 4 Drive adaptor retaining screw 5 Drive adaptor 6 Motor securing screws Channel Brush Motor Removal 1 Un...

Page 174: ...sary to remove the body use the two lifting eyes B together with a suitable chain at point C Care should be taken to ensure that the weight is evenly distributed so that the body lifts squarely M02MA...

Page 175: ...gearbox The Hydrodrive gearbox assembly can be removed as a complete unit by using a lifting jig Part No 93828 1 Removal 1 Remove fan case cover and impeller as described earlier 2 Loosen cap on hydr...

Page 176: ...te the hydraulic oil through the system Turn off the engine and top up the hydraulic oil to the correct level 7 Check also the coolant level and top up if necessary 4 Fan Impeller see also Chapter 6 R...

Page 177: ...damage the input shaft fluid drive coupling Repair Overhaul If it is proposed to carry out a repair or overhaul of the gearbox then it is important to check the following dimensions in respect to the...

Page 178: ...re are different kinds of gauges for measuring the inside cylinder or bore A bore gauge is a popular choice or a telescopic gauge used in conjunction with an outside micrometer both of these however r...

Page 179: ...luid coupling securing screws Note For JCB engine torque the 20 x M8 screws to 26Nm For John Deere engine torque the 20 x M6 screws to 19Nm Gearbox Refitting 1 Lightly grease splines on the input shaf...

Page 180: ...nd removal holes as shown Bearings 13 and 22 MUST be assembled back to back as shown Torque to 110 Nm Sealant 29742 1 0 4mm 29742 2 0 2mm 29742 3 0 1mm Shims Torque to 30 Nm Sealant See note above Tor...

Page 181: ...er dimension to 30mm DISPLACEMENT LIMITER 4 TRANSMISSION PUMP 24 Bar 420 Bar Charge Pump pre set to a Forward drive relief setting b Reverse drive relief setting 350 Bar TRANSMISSION MOTOR Test assemb...

Page 182: ...V Range 502 l 652 l 802 Maintenance Manual MA7 12 Chapter Remove and Refit Procedures 2 M02OG 050 3 4 i A G 1 7 5 6 3 9 10 11 D B F C H H H E 8...

Page 183: ...istribute grease around bearing 8 Hopper tip pivot 9 Rear door 10 Nozzle wheel 11 Body raise cylinder VT Twin Engine Approved Lubricants Capacity ISO Oil Grade Johnston Part No Fuchs A Hydraulic Syste...

Page 184: ...V Range 502 l 652 l 802 Maintenance Manual MA7 14 Chapter Remove and Refit Procedures GREASE 3 4 i 1 F F B F A C H F M02OG 054 4 5 H 2 6 F i 8 11 10 7 9...

Page 185: ...e 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 VS Single Engine 1 Body Prop Ensure autopr...

Page 186: ...V Range 502 l 652 l 802 Maintenance Manual MA7 16 Chapter Remove and Refit Procedures GREASE 3 4 i 1 F F B F A C H F M02OG 054 4 5 H 2 6 F i 8 11 10 7 9...

Page 187: ...nts 94 69 Battery Terminals Petroleum Jelly The above oils are those approved by Johnston Sweepers Other manufacturer s oils must be of equivalent grade VM Single Engine 1 Body Prop Ensure autoprop ha...

Page 188: ...V Range 502 l 652 l 802 Maintenance Manual MA7 18 Chapter Remove and Refit Procedures...

Page 189: ...Hydraulic VT VS 8 2 Pneumatic VT VS 8 2 Water VT VS 8 2 Audible Warnings VT VS 8 2 Electrical VT VS 8 3 Suction System Suction System VT VS 8 4 Power Pack Auxiliary Engine VT Only 8 5 Electrics and S...

Page 190: ...uck open 4 Relief valve worn Pneumatic Systems Fault Symptom Possible Cause Air leak from solenoid block 1 Cylinder seals leaking internally 2 Air solenoid faulty Hydraulic Systems Fault Symptom Possi...

Page 191: ...e No 4 5 Check switch Channel brush fails to lower 1 Check feed to solenoid Plug LED V4 or V10 2 Check solenoid 3 Check earth wires 4 Check fuse No 4 5 Check switch Channel brush fails to rotate 1 Che...

Page 192: ...s Check nozzle water jets are working correctly and so lubricating the duct 3 Channel brush incorrectly set not directing debris in line with nozzle 4 Intake flap not fully opened dual m c s 5 Rear bo...

Page 193: ...ops after 8 seconds 1 Check engine oil pressure is above 0 5 bar 2 Oil pressure switch faulty RPM will not increase 1 Check throttle cable is not broken jammed 2 Check feed to actuator 3 Check fuse 8...

Page 194: ...c pump worn 3 Brush end bearing seized Bouncing 1 Spring regulation adjustment incorrect 2 Brush stock bent 3 Linkage pins brackets worn damaged 4 Air damping system not working Not dropping 1 Check f...

Page 195: ...faulty 3 Cylinder pivot linkage seized Channel Brush Fault Symptom Possible Cause Rotating slowly 1 Motor worn 2 Hydraulic pump worn 4 Channel brush worn 3 Check hydraulic pressure to aid fault diagno...

Page 196: ...aster switch V is illuminated 3 Check green safety run button is pressed on pedant unit 4 Check pendant unit has not become unplugged Body will not tip 1 Ensure handbrake is on 2 Ensure master switch...

Page 197: ...r been correctly selected 3 Is master switch V1 illuminated 4 Has engine increased from tickover to 1100 rpm 5 Check boost pressure on transmission pump is 24 bar 6 If fan sweep gear operates check fe...

Page 198: ...cting F2 automatically opens Menu 4 2 CANbus Network which highlights the location of the affected Node Menu 4 2 CANbus Network Faults Rotate the encoder to highlight the indicated area Powapak Press...

Page 199: ...oder F4 when viewing the node F1 F2 F3 F4 F4 09 45 20 01 2016 4 2 3 1 0 0 8960 21248 0 0 0 0 0 0 0 0 22 3 16 0 00 1 4 2 3 Emergency Code s 6 7 5 8 10 1 1 9 12 Node ID O S Version See pages 8 12 for co...

Page 200: ...trol Used as Input 8982 Digital Output 15 Over Current Body Discharge Work Lamp RH Work Lamp RH Auto Lube Power 8983 Digital Output 16 Over Current Additional Water Work Lamp LH Work Lamp LH External...

Page 201: ...d Not Used Fan Speed Not Used 9169 PWM Output 2 Over Current WSB Motor Speed Not Used Mill Connector 1 Forward Not Used 9170 PWM Output 3 Over Current Not Used Not Used Mill Connector 2 Reverse Not Us...

Page 202: ...2 Cowl Worklight 36880 Digital Output 9 Short to ground CB 1 Water Rotatilt 2 Rotatilt 2 Rear Beacons 36881 Digital Output 10 Short to ground Gutter Spray 1 Not Used Used as Input Supawash 36882 Digit...

Page 203: ...Low Oil Level 4098 Engine Fault 85kW Engine only Coolant Temp High 4099 Engine Fault 85kW Engine only Loss of Speed Signal 4100 Engine Fault 85kW Engine only Water in Fuel 4101 Engine Fault 85kW Engi...

Page 204: ...V Range 502 l 652 l 802 Maintenance Manual MA8 16 Chapter Fault Diagnosis...

Page 205: ...al CHAPTER 9 Johnston Sweepers Limited Service Tools Chapter Service Tools All Copyright and rights are the property of Johnston Sweepers Ltd Table of Contents Section Page Service Tools Service Tools...

Page 206: ...oor and body control Control Unit 12v 502 652 802 enables ESU s to be unpacked 7030309 ESU Unpacking Rear door and body control Control Unit 24v 502 652 802 enables ESU s to be unpacked 437 2 Bearing...

Page 207: ...Commissioning Procedure For Truck Mounted Units Incorporating CAN communications Via JVM control system Software Revision J Onwards Employing Sauer Sundstrand Hydrostatic Transmission Components Note...

Page 208: ...tart for commissioning and set up the following procedures must be adhered to 1 Jack up the rear wheels and secure on axle stands and fully chock both front wheels 2 Fill hydraulic reservoir to the mi...

Page 209: ...the ignition switch will automatically increase the chassis rpm to its preset Minimum limit of 1100 on condition that the correct gear has been selected Note If the incorrect gear has been selected t...

Page 210: ...the pressure and counterclockwise to reduce it Pump Control System Checks The pump is equipped with an electronically controlled proportional control valve which acts to convert an electrical current...

Page 211: ...ease its value until a road speed of between 8 10 km h is reached at the same time observing the reading on pressure gauge it should be 24 bar until 8 10 km h is reached At this point the pressure sho...

Page 212: ...V Range 502 l 652 l 802 Maintenance Manual MA9 8 Chapter Service Tools...

Page 213: ...ter 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 ev...

Page 214: ...Maintainer 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 recomme...

Page 215: ...group 6 Connect negative terminal or slave battery group to chassis earth of the discharged battery group 7 Attempt to start the casualty vehicle 8 Once the vehicle has started remove the negative le...

Page 216: ...ered and free of spills Mix chemical materials except in accordance with the manufacturer s instructions Some chemicals can form other toxic or harmful substances give off toxic or harmful fumes be ex...

Page 217: ...on and working lights where possible Ensure that the cables of mobile electrical equipment cannot be trapped and damaged such as in a vehicle hoist trolley jacks etc Use air operated mobile equipment...

Page 218: ...ed contact with mineral oil may result in the removal of natural fats from the skin leading to dryness irritation and dermatitis Gross and prolonged contact especially with used engine oil which conta...

Page 219: ...le jacked up vehicle raised tipper body suspended engine etc Always ensure that lifting equipment e g jacks hoists axle stands slings etc are adequate and suitable for the job in good condition and re...

Page 220: ...V Range 502 l 652 l 802 Maintenance Manual MA10 8 Chapter Health and Safety...

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