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Johnston VS501, Maintenance Section

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All Copyright and rights are the property of Johnston Sweepers Ltd

MA7:11

V Range 501 

l

 651 

l

 801 Maintenance Manual

Johnston Sweepers Limited

Chapter - Remove and Refit Procedures

JOHNSTON

HYDR

O

DRIVE

(d) (c)

(b)

(a)

(e)

30

2

4

4

6

6

2

2. FANDRIVE PUMP:-

c) ‘’Standby’’ differential pressure setting

d) Main relief valve maximum pressure setting

e) Set displacement limiter 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 assembly for leaks

Test ‘free movement’ of sliding gears at 1.0 bar maximum air pressure

Test switches for on/off operation/engagement

M02HT-002a

Apply Kluberpaste (46 MR 401) Part number 94-24 to 

all splines on assembly

MK III GEARBOX ASSEMBLY - SETTINGS AND ASSEMBLY DETAILS

Page Issue B

VS - Single Engine

Summary of Contents for VS501

Page 1: ...and Refit Procedures Fault Diagnosis Service Tools Health and Safety Maintenance Section P 1 2 3 4 5 6 7 8 9 10 ECN 712655 Print date 10 02 2016 VT Twin Engine Specific to Twin engine sweepers VS Sing...

Page 2: ...1 18 B N 2 Chapter Hydraulic System Page Issue Changed Page Issue Changed 2 1 A 2 2 A 2 3 B C 2 4 B C 2 5 B C 2 6 B C 2 7 B C 2 8 B C 2 9 B C 2 10 B C 2 11 B C 2 12 B C 2 12 B C 2 13 B C 2 14 B C 2 15...

Page 3: ...3 65 B C 3 66 B C 3 67 B C 3 68 B C 3 69 B C 3 70 B C 3 71 B C 3 72 B C 3 73 B C 3 74 B C 3 75 B C 3 76 B C 3 77 B N 3 78 B N 3 79 B N 3 80 B N 4 Chapter Water System Page Issue Changed Page Issue Cha...

Page 4: ...ge Issue Changed 7 1 A 7 2 B C 7 3 A 7 4 A 7 5 B C 7 6 B C 7 7 B C 7 8 B C 7 9 B C 7 10 B C 7 11 B C 7 12 A 8 Chapter Fault Diagnosis Page Issue Changed Page Issue Changed 8 1 A 8 2 A 8 3 A 8 4 A 8 5...

Page 5: ...ty of Sweeping Equipment 1 4 Standard Repair Times 1 5 Auxiliary Engine Throttle Settings 1 10 Auxiliary Engine and Gearbox Drain Plugs 1 10 Fluid Flywheel VT Maintenance 1 11 Draining and Filling Ins...

Page 6: ...tial that more frequent attention is given to 1 Air cleaner servicing 2 Engine oil changes 3 Fluid oil changes 4 Gearbox oil changes 5 Hydraulic oil changes Attention to the servicing of air cleaners...

Page 7: ...he engine is switched off once the channel brush has been lowered for adjustment l Be aware of the safety instructions relative to the suction fan given in the equipment maintenance notes l Keep hands...

Page 8: ...Nm 2700 Nm Property Class Thread 4 8 5 6 Steel 8 8 Steel A1 50 S S 10 9 Steel A2 70 S S 12 9 Steel A4 80 S S 0 13 Nm 0 35 Nm 0 5 Nm 0 6 Nm M 2 0 1 Nm 0 23 Nm 0 3 Nm 0 60 Nm 1 3 Nm 1 8 Nm 2 1 Nm M 3 0...

Page 9: ...Hopper Rear Door Cylinder 35 none 1 Hopper Rear Door Seal 30 none 1 Hopper Fan Case Seal 20 none 1 Hopper Cowl Seal 45 none 1 Hopper Cowl NAF 90 none 1 Hopper Intake duct flap air cylinder 15 80 bar P...

Page 10: ...ne 1 Sweepgear Nozzle tow bar With tow eye removed 25 None 1 Sweepgear Nozzle tow eye 10 None 1 Sweepgear Nozzle box lift cylinder each 15 None 1 Sweepgear Maxi gap cylinder 15 None 1 Sweepgear Carria...

Page 11: ...1 Wander Hose Turret bearing Boom and turret removed 15 None 1 Wander Hose Boom gaiter Boom removed 15 None 1 Mesh Shaker Shaker cylinder each 25 None 1 Mesh Shaker Push button 10 None 1 Hydraulics H...

Page 12: ...draulic oil level 60 None 1 Water System Water solenoids Includes cleaning seal and valve each 15 None 1 Water System High pressure water tap Front high pressure spray bar and suction box high pressur...

Page 13: ...trical System Pneumatic Valve Island Including software update and test each 30 None 1 Electrical System Emergency hydraulic pump Including test 45 None 1 Electrical System Rear beacon each 15 None 1...

Page 14: ...lowering the body ENGINE TYPE JOHNSTON PART NO IDLE SPEED Rev Min Max Off Load Rev Min JCB Ecomax 444 Standard Power Engine 24V 55kW S3b 7017176 850 2000 JCB Ecomax 444 Standard Power Engine 12V 55kW...

Page 15: ...000 hours operation Draining Instructions Ensure the flywheel is cool before removing the level filler plug Using a propriety vacuum pump or oil extractor syringe drain the oil from the flywheel Fill...

Page 16: ...drain plug C located under the systems locker or by using a propriety vacuum pump or oil extractor syringe The filters D should be changed whilst the system is empty System Refilling The system capac...

Page 17: ...s The oil can be drained by removing the drain plug C located under the systems locker or by using a propriety vacuum pump or oil extractor syringe The filters D should be changed whilst the system is...

Page 18: ...ply is isolated by the shut off valve C Pressure switch is fitted to illuminate the low air pressure warning lamp on the JVM D Service connection enabling the system to be charged using a workshop air...

Page 19: ...ndition and regularly maintained particularly at joints and unions The use of safety goggles is recommended in case of deflected spray debris NEVER direct a high pressure nozzle at the skin as the flu...

Page 20: ...ommendation in the Chassis Handbook relating to the post delivery check over Engine Management ECU Please note that the chassis manufacturers Engine Management System has been set in accordance with o...

Page 21: ...ble to minimise the loss of 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...

Page 22: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA1 18 Chapter Scheduled Maintenance Page Issue B...

Page 23: ...m 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 Circuit Dia...

Page 24: ...entification Function Machine Type H 15Z6 Boost pressure Reverse pressure and Antiskid VS H 15Z7 Pump control pressure VS H 15Z3 Boost pressure Forward pressure VS H 15Z2 Boost pressure VS H 15Z5 Moto...

Page 25: ...rom menu 4 12 and follow the on screen prompts Connect a suitable 250 bar gauge to test point H 12Z2 on the Supawash block Once connected acknowledge this by pressing the rotary encoder on the display...

Page 26: ...f the fancase in the Powapack 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 re...

Page 27: ...y cause the rear door locks to function incorrectly VALVE IDENTIFICATION Page Issue B 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...

Page 28: ...ight and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA2 6 Chapter Hydraulic System Page Issue B Hydraulic Tank Connections Twin Engine Machine Sheet 1...

Page 29: ...ts are the property of Johnston Sweepers Ltd MA2 7 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Hydraulic System Page Issue B Hydraulic Tank Connections Hydrostatic Mac...

Page 30: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA2 8 Chapter Hydraulic System Page Issue B Discharge System Controls Sheet 3 11 Rev Q...

Page 31: ...ight and rights are the property of Johnston Sweepers Ltd MA2 9 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Hydraulic System Page Issue B Single Sweep Controls Sheet 4...

Page 32: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA2 10 Chapter Hydraulic System Page Issue B Dual Sweep Controls Sheet 5 11 Rev Q...

Page 33: ...ht and rights are the property of Johnston Sweepers Ltd MA2 11 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Hydraulic System Page Issue B Suction Fan Hydrostatic Sheet...

Page 34: ...ll Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA2 12 Chapter Hydraulic System Page Issue B Hydrostatic Transmission HGB 1 Sheet 7 11 Rev...

Page 35: ...ight and rights are the property of Johnston Sweepers Ltd MA2 13 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Hydraulic System Page Issue B Tandem Pump Controls Sheet 8...

Page 36: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA2 14 Chapter Hydraulic System Combivak Nozzle Controls Sheet 9 11 Rev Q Page Issue B...

Page 37: ...d rights are the property of Johnston Sweepers Ltd MA2 15 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Hydraulic System Page Issue B Powaboom Rear Wanderhose Controls S...

Page 38: ...l Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA2 16 Chapter Hydraulic System Page Issue B Hydrostatic Transmission HGB 2 Sheet 11 11 Rev...

Page 39: ...weepers 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 Control 3 4...

Page 40: ...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 etc All circuit diagrams a...

Page 41: ...1 4 3 6 1 4 3 6 1 4 3 6 20A F120 20A F100 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 SY...

Page 42: ...uction in the number of conductors and the 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...

Page 43: ...ystem Page Issue A Powerpack Node Systems Locker Node Subframe Node Door Controller Node High Power Nodes CANbus System VDB Vehicle Data Bus Commuication Line Schematic Engine Management Control Unit...

Page 44: ...ton Customer Service 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_Soft...

Page 45: ...pears start operating system in STOP mode 2 7 Software 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 NEV...

Page 46: ...try 3 1 Press button F3 to access the Main 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 comple...

Page 47: ...4 11 Service and select option 2 OS Downloads Figure Five Menu 4 11 Service 4 2 Move the blue halo and select for example the machine cab area Figure Six Menu 4 11 2 Cab Area Selection 4 2 Move the bl...

Page 48: ...and back on 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 M...

Page 49: ...ncoder to highlight sub menu 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 ser...

Page 50: ...ta capture features are Total engine hours Engine hours today Total distance travelled sweeping Optional Distance travelled sweeping today Optional Avg Fuel Consumption to Date Avg fuel consumption to...

Page 51: ...r more details F1 Vehicle Logging F1 F2 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 P...

Page 52: ...5 20 01 2016 1 05 1 5 USB Download Data 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...

Page 53: ...ch may be viewed on any PC 1 Go to the logging 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 Pre...

Page 54: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 16 Chapter Electrical System Page Issue B Index 01 Sheet 01 64 Rev D...

Page 55: ...Copyright and rights are the property of Johnston Sweepers Ltd MA3 17 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Index 02 Sheet 02 64 R...

Page 56: ...ll Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 18 Chapter Electrical System Page Issue B Electrical Circuit Symbol 1 Sheet 03 64 Rev D...

Page 57: ...and rights are the property of Johnston Sweepers Ltd MA3 19 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Electrical Circuit Symbol 2 Shee...

Page 58: ...ll Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 20 Chapter Electrical System Page Issue B Electrical Circuit Symbol 3 Sheet 05 64 Rev D...

Page 59: ...and rights are the property of Johnston Sweepers Ltd MA3 21 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Electrical Circuit Component She...

Page 60: ...ll Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 22 Chapter Electrical System Page Issue B Electrical Circuit Model Map Sheet 07 64 Rev...

Page 61: ...ghts are the property of Johnston Sweepers Ltd MA3 23 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Fused Power and Ignition Distribution...

Page 62: ...yright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 24 Chapter Electrical System Page Issue B Fused Power and Ignition Distribution 02 Sheet 09 6...

Page 63: ...d rights are the property of Johnston Sweepers Ltd MA3 25 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Operating Panel Switch PCB Node Sh...

Page 64: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 26 Chapter Electrical System Page Issue B Key Pad PCB Node Sheet 11 64 Rev D...

Page 65: ...ights are the property of Johnston Sweepers Ltd MA3 27 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Discharge Pendant Controller PCB Node...

Page 66: ...l Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 28 Chapter Electrical System Page Issue B Flat Ribbon IDC PCB Connectors Sheet 13 64 Rev...

Page 67: ...nd rights are the property of Johnston Sweepers Ltd MA3 29 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Power Ignition Feed I O Nodes She...

Page 68: ...t and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 30 Chapter Electrical System Page Issue B Power Ignition Feed Rotatilt Aux Engine and Nodes Sheet...

Page 69: ...s are the property of Johnston Sweepers Ltd MA3 31 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Power Ignition Feed Beacon Cab and WSB Ba...

Page 70: ...rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 32 Chapter Electrical System Page Issue B Power Ignition Feed Display Operating Panel Pendant Key Pad S...

Page 71: ...right and rights are the property of Johnston Sweepers Ltd MA3 33 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B PCB Fuse Lay out Sheet 18...

Page 72: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 34 Chapter Electrical System Page Issue B PCB Fuse and Relay Lay out Sheet 19 64 Rev D...

Page 73: ...the property of Johnston Sweepers Ltd MA3 35 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Can Bus System Can 0 Aux Engine Can 1 and Chas...

Page 74: ...right and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 36 Chapter Electrical System Can Bus System Can 0 and Aux Engine Can 1 Sheet 21 64 Rev D Page...

Page 75: ...ght and rights are the property of Johnston Sweepers Ltd MA3 37 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Can Bus System Can 0 Sheet 22 64 Rev D Pa...

Page 76: ...Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 38 Chapter Electrical System Front Systems Interface Connection Sheet 23 64 Rev D Page Iss...

Page 77: ...yright and rights are the property of Johnston Sweepers Ltd MA3 39 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Spare Options Sheet 24 64 Rev D Page I...

Page 78: ...opyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 40 Chapter Electrical System System Locker Node Hydraulic Valves Sheet 25 64 Rev D Page Iss...

Page 79: ...hts are the property of Johnston Sweepers Ltd MA3 41 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System System Locker Node Electrical Water Valves Sheet 26...

Page 80: ...nd rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 42 Chapter Electrical System Powapak Node Engine Pack Sensors Control and Work Lamps Sheet 27 64 Rev...

Page 81: ...the property of Johnston Sweepers Ltd MA3 43 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Powapak Node Engine Pack Sensors Control Generic Engine She...

Page 82: ...and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 44 Chapter Electrical System Subframe Node Discharge Supawash and Powaboom Control Sheet 29 64 Rev D...

Page 83: ...the property of Johnston Sweepers Ltd MA3 45 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Subframe Node Sensors Switches and Weight Load Indicator Sh...

Page 84: ...ight and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 46 Chapter Electrical System Page Issue B Work Lights Rear Beacons and Cowl Work Light Sheet 31...

Page 85: ...the property of Johnston Sweepers Ltd MA3 47 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Additional Rear Work Lights and Additional Warn...

Page 86: ...ight and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 48 Chapter Electrical System Page Issue B Front Cab Beacons and Top Side Marker Lights Sheet 33...

Page 87: ...rights are the property of Johnston Sweepers Ltd MA3 49 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Aux Engine JCB 24 Volt Power Pod Box...

Page 88: ...opyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 50 Chapter Electrical System Page Issue B Aux Engine JCB 12 Volt Power Pod Box Sheet 35 64...

Page 89: ...rights are the property of Johnston Sweepers Ltd MA3 51 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Aux Engine JCB 55kW and 93kW 24 Volt...

Page 90: ...pyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 52 Chapter Electrical System Page Issue B Aux Engine John Deere High Power 86kW Sheet 37 64...

Page 91: ...hts are the property of Johnston Sweepers Ltd MA3 53 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Aux Engine John Deere Standard Power 63...

Page 92: ...opyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 54 Chapter Electrical System Page Issue B Aux Engine JCB 55kW and 93kW 12 Volt Sheet 39 64...

Page 93: ...d rights are the property of Johnston Sweepers Ltd MA3 55 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Aux Engine JCB 85kW S3A 24 Volt Sh...

Page 94: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 56 Chapter Electrical System Page Issue B Spare Sheet 41 64 Rev D...

Page 95: ...are the property of Johnston Sweepers Ltd MA3 57 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Telescopic Dual Front Brush Options Rotatil...

Page 96: ...t and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 58 Chapter Electrical System Page Issue B Telescopic Dual Front Brush Options Rotatilt x2 02 Sheet...

Page 97: ...re the property of Johnston Sweepers Ltd MA3 59 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Telescopic Single Front Brush Options Rotati...

Page 98: ...and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 60 Chapter Electrical System Page Issue B Telescopic Single Front Brush Options Rotatilt x1 02 Shee...

Page 99: ...ght and rights are the property of Johnston Sweepers Ltd MA3 61 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Multi Camera System Sheet 46...

Page 100: ...nd rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 62 Chapter Electrical System Page Issue B Hydrostatic Front Cab Beacons and Top Side Marker Lights Sh...

Page 101: ...ights are the property of Johnston Sweepers Ltd MA3 63 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Powapak Node Hydrostatic Drive Contro...

Page 102: ...nd rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 64 Chapter Electrical System Page Issue B Powapak Node Hydrostatic Sensors Control and Work Lamps She...

Page 103: ...re the property of Johnston Sweepers Ltd MA3 65 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Powapak Node Semi Hydrostatic Sensors and Wo...

Page 104: ...opyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 66 Chapter Electrical System Page Issue B Electrical Circuit Model Map Demount Sheet 51 64...

Page 105: ...ights are the property of Johnston Sweepers Ltd MA3 67 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Demount Disconnection Power Work Lamp...

Page 106: ...yright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 68 Chapter Electrical System Page Issue B Demount Disconnection Front System Node Sheet 53 64...

Page 107: ...ights are the property of Johnston Sweepers Ltd MA3 69 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Rotatilt Hydraulic Electrical Control...

Page 108: ...d rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 70 Chapter Electrical System Page Issue B Power Wander Hose and Engine Speed Control with Extension Sh...

Page 109: ...ight and rights are the property of Johnston Sweepers Ltd MA3 71 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Combivak Controls Sheet 56...

Page 110: ...ight and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 72 Chapter Electrical System Page Issue B HGB2 Powapak Node Hydrostatic Drive Control Sheet 57...

Page 111: ...the property of Johnston Sweepers Ltd MA3 73 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B HGB2 Powapak Node Hydrostatic Sensors Control...

Page 112: ...l Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 74 Chapter Electrical System Page Issue B Systems Locker LED Strip Light Sheet 59 64 Rev...

Page 113: ...t and rights are the property of Johnston Sweepers Ltd MA3 75 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Page Issue B Wide Sweep Brush Balance Sheet...

Page 114: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 76 Chapter Electrical System AUX Engine JCB 93kW T4 Sheet 61 64 Rev D Page Issue B...

Page 115: ...ts are the property of Johnston Sweepers Ltd MA3 77 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System AUX Engine JCB 93kW T4 CAN Power Connections Sheet 62...

Page 116: ...ight and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 78 Chapter Electrical System AUX Engine JCB AdBlue after treatment system Sheet 63 64 Rev D Pag...

Page 117: ...yright and rights are the property of Johnston Sweepers Ltd MA3 79 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Electrical System Spare Options Sheet 64 64 Rev D Page I...

Page 118: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA3 80 Chapter Electrical System Page Issue B...

Page 119: ...d 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 4 4 Re...

Page 120: ...as additional options Recriculating Water 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 Supawas...

Page 121: ...r face of the chamber is correctly located 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...

Page 122: ...sprays switched off turn adjuster 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 valv...

Page 123: ...ange 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Water System M02MA 048 Recirculation Valves There is no routine maintenance required on these valves The shut off valve must b...

Page 124: ...Range 501 l 651 l 801 Maintenance 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...

Page 125: ...water tank 8b Hydrant filler 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 valv...

Page 126: ...correctly will normally not have any water 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...

Page 127: ...th a pair of needle nose pliers remove the 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 f...

Page 128: ...g tensioning caps 34 valve spring 35 valve 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...

Page 129: ...lungers 24a Make sure that the small o ring 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...

Page 130: ...ater System Page Issue B Exploded view of 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 Ki...

Page 131: ...ight and rights are the property of Johnston Sweepers Ltd MA4 13 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Water System Page Issue B Low Pressure Water System Sheet...

Page 132: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA4 14 Chapter Water System Page Issue B Low Pressure Water System Sheet 2 8 Rev C...

Page 133: ...ight and rights are the property of Johnston Sweepers Ltd MA4 15 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Water System Page Issue B Low Pressure Water System Sheet...

Page 134: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA4 16 Chapter Water System Page Issue B Low Pressure Water System Sheet 4 8 Rev C...

Page 135: ...ight and rights are the property of Johnston Sweepers Ltd MA4 17 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Water System Page Issue B Low Pressure Water System Sheet...

Page 136: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA4 18 Chapter Water System Page Issue B Low Pressure Water System Sheet 6 8 Rev C...

Page 137: ...ight and rights are the property of Johnston Sweepers Ltd MA4 19 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Water System Page Issue B Low Pressure Water System Sheet...

Page 138: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA4 20 Chapter Water System Page Issue B Low Pressure Water System Sheet 8 8 Rev C...

Page 139: ...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 140: ...ly severs the pneumatic supply it also exhausts the air from the system causing the nozzle and wide sweep brush to lower Wait approximately 15 seconds to allow air to completely exhaust before carryin...

Page 141: ...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 SPARE P 1V1 Page Issue B M02MA 009 4 P 0Z1 P...

Page 142: ...and releasing the fixing bolts Pneumatic Valve Island The pneumatic valve island is a modular unit comprising various valve segments Each valve segment has an indicator light that illuminates when en...

Page 143: ...alve power terminal of the power supply connector Page Issue A Indicator status during powering up and commissioning Condition 24v 5v Error LED Run LED Power up On On Single flash Single flash green r...

Page 144: ...16V1 Port 4 LED 14 Water Recirculation 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...

Page 145: ...t and rights are the property of Johnston Sweepers Ltd MA5 7 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Page Issue B Air Set Suits All Variants Sheet...

Page 146: ...ll Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA5 8 Chapter Pneumatic System Page Issue B Valve Island Dual No Options 01 Sheet 2 17 Rev...

Page 147: ...and rights are the property of Johnston Sweepers Ltd MA5 9 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Page Issue B Valve Island Dual No Options 02 Sh...

Page 148: ...l Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA5 10 Chapter Pneumatic System Page Issue B Valve Island Dual No Options 03 Sheet 4 17 Rev...

Page 149: ...and rights are the property of Johnston Sweepers Ltd MA5 11 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Page Issue B Wide Sweep Brush Control MK2 She...

Page 150: ...Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA5 12 Chapter Pneumatic System Valve Island Single No Options 01 Sheet 6 17 Rev I Page Issue...

Page 151: ...d rights are the property of Johnston Sweepers Ltd MA5 13 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Valve Island Single No Options 02 Sheet 7 17 Rev...

Page 152: ...Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA5 14 Chapter Pneumatic System Valve Island Single No Options 03 Sheet 8 17 Rev I Page Issue...

Page 153: ...and rights are the property of Johnston Sweepers Ltd MA5 15 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Valve Island Auto Lock Option Sheet 9 17 Rev I...

Page 154: ...ll Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA5 16 Chapter Pneumatic System Valve Island Powasave Option Sheet 10 17 Rev I Page Issue B...

Page 155: ...d rights are the property of Johnston Sweepers Ltd MA5 17 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Valve Island Dual Varagap Option Sheet 11 17 Rev...

Page 156: ...Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA5 18 Chapter Pneumatic System Valve Island Single Varagap Option Sheet 12 17 Rev I Page Issu...

Page 157: ...ights are the property of Johnston Sweepers Ltd MA5 19 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Valve Island Water Recirculation Option Sheet 13 17...

Page 158: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA5 20 Chapter Pneumatic System Littasnatch Option Sheet 14 17 Rev I Page Issue B...

Page 159: ...and rights are the property of Johnston Sweepers Ltd MA5 21 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System In Cab Mesh Shakers Option Sheet 15 17 Rev I...

Page 160: ...l Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA5 22 Chapter Pneumatic System Hydrostatic Transmission Option Sheet 16 17 Rev I Page Issue...

Page 161: ...ght and rights are the property of Johnston Sweepers Ltd MA5 23 V Range 501 l 651 l 801 Maintenance Manual Johnston Sweepers Limited Chapter Pneumatic System Runway Magnet Option Sheet 17 17 Rev I Pag...

Page 162: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA5 24 Chapter Pneumatic System Page Issue B...

Page 163: ...Copyright and rights are the property of Johnston Sweepers Ltd Page Issue A 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: ...ore raising the body l Ensure the safety prop is engaged at all times when working under the body l Ensure operators are fully conversant with the controls and operation l Isolate the air in the syste...

Page 165: ...inspection cover D is provided to measure the fan speed by optical tachometer if required Intake Duct Flap When the flap plate is in the open position it is abraded by the material discharging from th...

Page 166: ...yhole and remove the duct Refitting 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 s...

Page 167: ...three setscrews from the retaining 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...

Page 168: ...ines 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 Refitting First slide on a segment then alternately a spacer and a seg...

Page 169: ...itting Instructions Water Pump VT VS 7 2 Wide Sweep Brush Motor VT VS 7 3 Channel Brush Motor VT VS 7 3 Channel Brush Cylinder VT VS 7 4 Body Lifting or Removal VT VS 7 4 Hydrodrive Gearbox Pumps VS O...

Page 170: ...e coupling Note It is possible to replace the pump diaphragms and valves with the pump in situ The hinged prop stowed beneath the body SHOULD BE USED AT ALL TIMES to prop the body when carrying out an...

Page 171: ...g 3 Refitting is the reverse 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 Chann...

Page 172: ...socket Removing the body If it is necessary 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 distribute...

Page 173: ...nd oil loss from the hoses Hydrodrive 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 d...

Page 174: ...refill the hydraulic oil tank 6 Run the engine to circulate 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 an...

Page 175: ...rbox supporting its weight so as not to 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...

Page 176: ...asuring 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 require a degree of familiarity or exper...

Page 177: ...trap and damage the large O ring 4 Refit fluid 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...

Page 178: ...as shown Apply sealant round 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...

Page 179: ...ng e Set displacement limiter 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 TRA...

Page 180: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA7 12 Chapter Remove and Refit Procedures Page Issue A...

Page 181: ...ulic 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 Shut Do...

Page 182: ...ng broken 3 Relief valve stuck 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...

Page 183: ...eck earth wires 4 Check fuse 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...

Page 184: ...rtially restricted by debris 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...

Page 185: ...l system Engine runs but stops 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...

Page 186: ...wly 1 Motor worn 2 Hydraulic 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 wor...

Page 187: ...2 Pneumatic solenoid valve 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 p...

Page 188: ...t open 1 Check handbrake is on 2 Check master 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...

Page 189: ...c has drive for power steering changeover 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 b...

Page 190: ...icon is displayed over soft key F2 Selecting 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 hig...

Page 191: ...the inactive fault memory press the encoder 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 N...

Page 192: ...mbivak Nozzle 1 Not Used Used as Input 8981 Digital Output 14 Over Current Nozzle 2 Water Combivak Nozzle 2 Fan Control Used as Input 8982 Digital Output 15 Over Current Body Discharge Work Lamp RH Wo...

Page 193: ...Used 20481 Safety Feed Power Input Safety Switch Failure 20482 General Internal Comms Failure 20992 H Bridge Output Lock Out Rear Warning Work Lights Not Used Not Used Powaboom Raise Lower 21248 Lock...

Page 194: ...t to ground CB 2 Water Used as Input Hydrostatic Reverse Output Used as Input 36883 Digital Output 12 Short to ground Gutter Spray 2 Ignition Output Aux engine Gearbox Sensors Output Used as Input 368...

Page 195: ...TER 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 VT VS...

Page 196: ...030357 ESU Unpacking Rear door and body control Control Unit 12v 501 651 801 enables ESU s to be unpacked 7030309 ESU Unpacking Rear door and body control Control Unit 24v 501 651 801 enables ESU s to...

Page 197: ...smission 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 Tr...

Page 198: ...arbox for the first time from a dry start 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...

Page 199: ...cated on the centre console Selecting 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 t...

Page 200: ...y turning the valves clockwise to increase the pressure and counterclockwise to reduce it Pump Control System Checks The pump is equipped with an electronically controlled proportional control valve w...

Page 201: ...and held PPU on position C2 slowly increase 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...

Page 202: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA9 8 Chapter Service Tools Page Issue A...

Page 203: ...s 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 eff...

Page 204: ...ility of the Owner Operator 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 nee...

Page 205: ...d battery 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 ne...

Page 206: ...ep work areas clean uncluttered 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 t...

Page 207: ...110 or 24 volt for inspection 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...

Page 208: ...reases Prolonged and repeated 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...

Page 209: ...orted suspended or raised load For example 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 suita...

Page 210: ...All Copyright and rights are the property of Johnston Sweepers Ltd V Range 501 l 651 l 801 Maintenance Manual MA10 8 Chapter Health and Safety Page Issue A...

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