Johnston VT551 Maintenance Section Download

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Section Revision Level 02

VT551 - Maintenance

All Copyright

and rights are the property of Johnston Sweepers

Ltd

Summary of Contents for VT551

Page 1: ...e Part No 02634 1 M Revision Level 02 Pneumatic System Page Issue Levels Scheduled Maintenance Hydraulic System Electrical System Water System 11 Wearing Items Remove and Refit Procedures Fault Diagno...

Page 2: ...VT551 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 3: ...ance section it s issue level and whether it has changed since the previous revision level Changed pages are indicated by the letter C in the changed column and new pages by the letter N P1 VT551 Main...

Page 4: ...ge Issue Changed Page Issue Changed 8 1 01 8 2 01 8 3 02 C 8 4 01 8 5 01 8 6 01 8 7 01 8 8 01 8 9 01 8 10 01 8 11 01 8 12 01 9 Chapter Electrical System Page Issue Changed Page Issue Changed 9 1 01 9...

Page 5: ...2 Chapter Wearing Items Page Issue Changed Page Issue Changed 12 1 01 12 2 01 12 3 01 12 4 01 12 5 01 12 6 01 12 7 01 12 8 01 13 Chapter Remove and Refit Procedures Page Issue Changed Page Issue Chang...

Page 6: ...sue Changed 15 1 01 15 2 01 16 Chapter Warranty Page Issue Changed Page Issue Changed 16 1 01 16 2 01 16 3 01 16 4 01 17 Chapter Health and Safety Page Issue Changed Page Issue Changed 17 1 01 17 2 01...

Page 7: ...aintenance 7 2 Security of Sweeping Equipment 7 3 Circuit Diagrams Fluid Finder 7 4 Diagram Index 7 5 Auxiliary Engine Fuel System Bleeding 7 6 Hydraulics Hydraulic Oil Reservoir 7 7 Pneumatics Filter...

Page 8: ...d when working on the machine 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 used at all times...

Page 9: ...35 Nm M14 Grade 10 9 215 Nm 160 lbf ft 100 lbf ft Standard 150 lbf ft C C C C C A A D D D D C C A A SECURITY OF SWEEPING EQUIPMENT It is necessary to check every six months the security of various com...

Page 10: ...Page Issue 01 Chapter Scheduled Maintenance 7 4 VT551 Maintenance Fluid Finder Diagram SF300z03 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 11: ...Page Issue 02 Chapter Scheduled Maintenance 7 5 VT551 Maintenance Diagram Index SE300z01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 12: ...he Auxiliary Engine Handbook for information THROTTLE SETTINGS The engine tick over speed is adjustable and is set by the tick over screw on the injector pump The engine maximum speed is controlled by...

Page 13: ...able spanner and lift out the cartridge element B Refit cartridge and screw on the cover some force will be required to compress the carriage retaining spring SYSTEM DRAINING The oil can be drained by...

Page 14: ...is fitted to illuminate the low air pressure warning lamp on the cab switch panel PNEUMATIC CYLINDER MAINTENANCE Periodically inspect the cylinder rods for damage blemishes or build up of material suc...

Page 15: ...er 8 3 Fan Pump Set Up 8 4 Hydraulic System Initial Operation 8 5 Valve Identification 8 5 Circuit Diagrams Hydraulic Tank Connections 8 6 Single Sweep 8 7 Dual Sweep 8 8 Suction Fan Load Discharge 8...

Page 16: ...essures select menu 4 Set pressures from the main CANview screen and choose sub menu 11 NB There is a default setting on this menu 4 11 6 to input default figures in order for you to be able to initia...

Page 17: ...ng HOPPER RAISE MENU 4 11 4 Connect a suitable 250 bar gauge to Test Point T8 Follow the on screen CANview instructions This pressure should be 175 bar If necessary press or to adjust the pressure to...

Page 18: ...pressure should be set at 20 bar 2 Main Operating Pressure 150 bar To check this setting enter the suction fan pressure menu 4 11 3 follow on screen instructions and increase RP output until the pres...

Page 19: ...N Start the auxiliary engine and open and close the rear door three times to ensure all air is purged from the system Failure to carry out this procedure may cause the rear door lock to function incor...

Page 20: ...Page Issue 01 Chapter Hydraulic System 8 6 VT551 Maintenance Hydraulic Tank Connections Diagram SH301a02 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 21: ...Page Issue 01 Chapter Hydraulic System 8 7 VT551 Maintenance Single Sweep Diagram SH302z02 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 22: ...Page Issue 01 Chapter Hydraulic System 8 8 VT551 Maintenance Dual Sweep Diagram SH303z02 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 23: ...Page Issue 01 Chapter Hydraulic System 8 9 VT551 Maintenance Suction Fan Load Discharge Diagram SH304a01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 24: ...Page Issue 01 Chapter Hydraulic System 8 10 VT551 Maintenance Pump Services Diagram SH306a02 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 25: ...Page Issue 01 Chapter Hydraulic System 8 11 VT551 Maintenance Emergency Hand Pump Diagram SH307z01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 26: ...Page Issue 01 Chapter Hydraulic System 8 12 VT551 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 27: ...tion Page Introduction General Description 9 2 System Description 9 2 Component Identification Relay Box 9 3 Relays Fuses and Connector Refs 9 4 Electrical Components Diagrams 9 9 Page Issue 01 VT551...

Page 28: ...there is only one design variation thought there could be other variations identified by the seventh and eighth digits To assist fault finding and troubleshooting the solenoids have an LED in the ele...

Page 29: ...rators Guide Chapter 2 The main feed from the battery to the electrical system is protected by a circuit breaker MCB which is also mounted in the relay box The button A will pop out when activated and...

Page 30: ...Power Active with Worklamp Additional Worklamp switch and Sweep Select Switch in LH or Dual mode SE302 Relay Box R10 RH Worklamp Power Active with Worklamp Additional Worklamp switch and Sweep Select...

Page 31: ...Crank Solenoid 15 15 SE304 Relay Box F03 Spare F04 Spare F05 Spare F06 Additional Beacon 15 10 SE304 Relay Box Option F07 Spare F08 Node 2 20 20 SE304 Relay Box F09 Spare F10 Node 5 5 5 SE304 Relay Bo...

Page 32: ...716 1 293714 1 P2 31 Relay Box 293714 1 293717 1 P03 P04 P05 P06 P07 P08 12 Engine Bay 293719 1 293717 1 P09 4 Engine Bay 293719 1 293717 1 P10 8 Subframe Rear 293718 2 293717 1 P11 8 Subframe Rear 29...

Page 33: ...1 CVC 12 Switch Panel CANView C 293716 1 CVD 17 Switch Panel 293716 1 293713 1 DAW 2 Front Valance Discharge Buzzer 293726 1 DS1 2 Cowl Door Limit Switch 293718 3 DS2 2 Cowl Door Limit Switch 293718 3...

Page 34: ...16 1 283440 1 RH AWL 2 Body Additional Worklight 293774 1 RMML 2 RH Cowl Door Marker Light 293718 3 RRML 2 Rear of Body RH Marker Light 293718 2 RT 5 Auxiliary Engine Heat Start Relay 293719 1 RWL 2 R...

Page 35: ...Electrical Components Diagram SE300z02 Page Issue 02 Chapter Electrical System 9 9 VT551 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 36: ...Page Issue 02 Chapter Electrical System 9 10 VT551 Maintenance Electrical Components Diagram SE300z03 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 37: ...Page Issue 02 Chapter Electrical System 9 11 VT551 Maintenance System Map Diagram SE301z01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 38: ...Page Issue 02 Chapter Electrical System 9 12 VT551 Maintenance Relay and Fuse Box Diagram 24 Volt SE302z01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 39: ...Page Issue 02 Chapter Electrical System 9 13 VT551 Maintenance Relay and Fuse Box Diagram 12 Volt SE302z02 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 40: ...Chapter Electrical System Page Issue 02 9 14 VT551 Maintenance Node 1 Diagram SE303z01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 41: ...Page Issue 02 Chapter Electrical System 9 15 VT551 Maintenance Node 2 Diagram SE304z01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 42: ...Page Issue 02 Chapter Electrical System 9 16 VT551 Maintenance P1 CANview Diagram SE305z03 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 43: ...Page Issue 02 Chapter Electrical System 9 17 VT551 Maintenance P2 Subframe Diagram SE306z02 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 44: ...Page Issue 02 Chapter Electrical System 9 18 VT551 Maintenance Body Rear Beacon Marker Lamp Diagram SE307z01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 45: ...Page Issue 02 Chapter Electrical System 9 19 VT551 Maintenance Switch Panel Diagram SE308z01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 46: ...Page Issue 02 Chapter Electrical System 9 20 VT551 Maintenance VM Engine Diagram SE309z01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 47: ...f Valve 10 3 Solenoid Valves 10 3 Hydrant Filter 10 3 Circuit Diagrams Piping Diagram 10 4 Single Sweep Low Pressure Water 10 6 Dual Sweep Low Pressure Water 10 7 Supawash Pump Pump Repair 10 9 Seal a...

Page 48: ...a hydraulic test gauge to the Supawash manifold T13 3 Disconnect the 3 8 bypass pipe at the unloader valve and plug the hose end 4 Turn on the front spraybar tap 5 Activate the Supawash and increase t...

Page 49: ...ticlockwise opens the valve clockwise closes it This manual lift facility can be used when draining the water system in winter see Operator s Guide Chapter 3 and for actuating the valve should it for...

Page 50: ...1 4 DUAL SWEEP D S SHOWN 7 1 3 4 14 5 6 6 13 12 8 11 BLOCK 3 W1 W4 W3 WTP W8 W9 W10 WTP W1 W4 W3 W10 LH SINGLE DUAL WTP W10 W3 W4 W1 RH SINGLE WTP 16a 16b 2 2 10 9 Piping Diagram Low Pressure System A...

Page 51: ...nk 11 Type A anti syphon water break 12 Relief valve 13 Washdown hose 14 Additional wide sweep brush spraybar Water valve manifold see table below 16a LH Water valve manifold 16b RH Water valve manifo...

Page 52: ...Page Issue 01 Chapter Water System 10 6 VT551 Maintenance Single Sweep Low Pressure Water Diagram SW301a02 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 53: ...Page Issue 01 Chapter Water System 10 7 VT551 Maintenance Water System Low Pressure Dual Sweep Diagram SW302a01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 54: ...Page Issue 01 VT551 Maintenance Chapter Water System 10 8 LP HP Valve Location All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 55: ...er 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 continuous drip from under...

Page 56: ...sion 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 replace as necessa...

Page 57: ...ng 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 and replace as necessary 14 Install the...

Page 58: ...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 plungers 24a Secure with inner hexagon screws 45 Torque...

Page 59: ...Part Number Description 19 1 283701 13 Woodruff Key 20 3 283701 14 Connecting Rod 24A 3 283701 12 Ceramic Liner 31 32 40 49 50 1 Kit 283701 10 Plunger Seal kit for 3 plungers 34 35 36 37 38 1 Kit 283...

Page 60: ...Page Issue 01 Chapter Water System 10 14 VT551 Maintenance High Pressure Water Diagram SW303z02 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 61: ...1 2 Component Valve Identification 11 3 Component Removal Air Filtration and Regulator FR 11 4 Pneumatic Valve Island 11 4 Wide Sweep Brush Regulator Maintenance 11 6 Circuit Diagrams Maxigap Single S...

Page 62: ...set at 2 bar 1 First ensure truck air system is up to pressure and sweepgear is lifted 2 Fit a 25 bar minimum pressure gauge to test point PTP If pressure is incorrect adjustment is carried out by tur...

Page 63: ...20 V 22 V 24 B2 A1 A2 B1 R1 Regulators A1 B2 Wide Sweep Brush Balance adjustable R1 Channel brush Powasave adjustable R2 Wide sweep brush Powascrub fixed R3 Channel brush Powathrust yellow fixed R4 Le...

Page 64: ...manual override button B for ports 2 or 4 on each segment The segments are identified by a code and are not all the same see following tables B 3 0 0 N B 6 U N G 6 U N B 6 U N A 6 U N G 6 U N B 6 U N...

Page 65: ...03 V19 V20 REMOVED FROM 12 24 V23 24 ADDED TO 12 24 ED22500 RD 05 06 2006 REMOVE ALL BURRS AND SHARP EDGES DEV293 CANOpen TITLE SIMILAR TO MATERIAL 930911 USED ON ASSEMBLIES 283305 MASS kg FINISH SEE...

Page 66: ...adjusting screw 12 with upper and lower piston assemblies Items 13 through 20 Remove spring 21 Unscew the adjusting screw 12 then separate upper and lower piston assemblies Item 13 through 20 The adju...

Page 67: ...Page Issue 01 Chapter Pneumatic System 11 7 VT551 Maintenance Maxigap Single Sweep Diagram SP301z02 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 68: ...Page Issue 01 Chapter Pneumatic System 11 8 VT551 Maintenance Maxigap Dual Sweep Diagram SP302z03 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 69: ...Page Issue 01 Chapter Pneumatic System 11 9 VT551 Maintenance Mesh Shakers and Littasnatch Option Diagram SP305z01 All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 70: ...Page Issue 01 Chapter Pneumatic System 11 10 VT551 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 71: ...ent Instructions Fan Impeller 12 2 Intake Duct Flap 12 3 Wear Plate 12 3 Intake Duct 12 4 Intake Trunking 12 4 Intake Seat 12 5 Suction Nozzle Wheel 12 5 Nozzle Wheel Bearings 12 6 Suction Nozzle Rubb...

Page 72: ...tructions 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 73: ...lve plate which is secured to 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 f...

Page 74: ...duct a new trunking seat seal should be used and secured using a contact adhesive Part No 9903 Fit two bolts in diagonal holes the duct B has two holes with keyhole slots Align slots over the bolt he...

Page 75: ...rect length of intake seat is determined by measuring dimension A as shown below from ground to underside of the subframe i e top of chassis SUCTION NOZZLE WHEEL REMOVAL Release nozzle wheel adjustmen...

Page 76: ...g bump bar at kerb end of nozzle Release securing nuts retaining the rubbers Pull away the two short end rubbers then remove the front and rear side rubbers REFITTING Reverse of removal procedure reme...

Page 77: ...and also clamp them tightly The peg E on the segment B to be alternatively located round the core clock face at 12 2 4 o clock and so on until the core is filled failure to observe this could cause th...

Page 78: ...Page Issue 01 Chapter Wearing Items 12 8 VT551 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 79: ...ons Water Pump 13 2 Wide Sweep Brush Motor 13 2 Channel Brush Motor 13 3 Channel Brush Cylinder 13 3 Body and Body Tip Ram 13 4 Radiator 13 5 Hydraulic Pump 13 5 Fan Impeller 13 5 Fan Case and Fan Mot...

Page 80: ...NB It is possible to replace the pump suction and discharge valves in situ 2 WIDE SWEEP BRUSH MOTOR REMOVAL AND REFITTING 1 Remove the brush stock as described in Chapter 6 2 Unscrew the four end pla...

Page 81: ...r this purpose 3 Disconnect the two hydraulic hoses from the motor 4 Unscrew the two bolts securing the motor to mounting bracket and lift off motor 5 Refitting is the reverse of removal 4 CHANNEL BRU...

Page 82: ...t brackets 293909 1 to the subframe crossmember and the front of the body Secure each with two M12 x 30 bolts plus washers and nuts 3 Raise the body a little and get an assistant to place the special...

Page 83: ...r 3 Loosen the hydraulic pipe at the bottom of the radiator to drain the remaining oil and disconnect the hoses 4 Remove the kick plate at the bottom of the radiator 5 Remove the 6 securing bolts 6 Re...

Page 84: ...move the 4 bolts holding the fan case to the engine mounting frame 2 each side 9 Lift off fan assembly in one unit 10 Once on the ground the fan impeller and fan can be removed as required 11 FAN DRIV...

Page 85: ...n fuel tank 2 Remove right hand worklamp 3 Loosen the 2 tank securing bolts Slide tank out part way 4 Remove fuel sender and fuel pipes 5 Remove the tank completely 6 The refit procedure is the revers...

Page 86: ...Page Issue 01 Chapter Remove and Refit Procedures 13 8 VT551 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 87: ...14 2 Pneumatic 14 2 Water 14 2 Electrical 14 3 Suction System Suction System 14 4 Power Pack Auxiliary Engine 14 5 Sweepgear Wide Sweep Brush 14 6 Channel Brush 14 7 Maxigap Nozzle 14 7 Discharge Bod...

Page 88: ...YSTEMS FAULT SYMPTOM POSSIBLE CAUSE Low pressure warning 1 Air pressure switch faulty buzzer on continuously 2 Insufficient pressure in Johnston system Constant air leak from 1 Cylinder seals leaking...

Page 89: ...solenoid plug LED V5 LH or V11 RH 2 Check solenoid 3 Check earth wire on pin 13 plug VM 4 Check fuse No 10 5 Check switch using J plex screen Channel Brush fails to rotate 1 Check feed to solenoids pl...

Page 90: ...the duct 3 Channel brush curtain incorrectly set not directing debris in line with nozzle 4 Intake flap not fully opened dual m c s 5 Rear body meshes blocked or restricted 6 Fan case transition ring...

Page 91: ...e starts 1 Check feed to actuator but will not accelerate 2 Check fuse 3 Check switch using J plex screen Auxiliary engine turns 1 Check fuel tank over but will not start 2 Check electric feed to engi...

Page 92: ...ock bent 3 Linkage pins brackets worn damaged 4 Air damping system not working Not dropping 1 Check feed to solenoid Plug LED V23 and V24 2 Solenoid faulty use man override 3 Switch on control box fau...

Page 93: ...g J plex 2 Check hydraulic valves Y1 LH or Z1 RH Brush fails to lift 1 Check for electrical power at solenoid plug LED V5 LH or V10 RH if a dual 2 Check pneumatic solenoid for correct operation 3 Seal...

Page 94: ...ndant unit 4 Check pendant unit has not become unplugged 5 Check feed to solenoids DA door open and DB door close Body will not tip 1 Ensure handbrake is on and feed at plug PC1A pin 2 2 Ensure master...

Page 95: ...Service Tools CHAPTER 15 Service Tools 15 1 Table of Contents Section Page Service Tools Service Tools 15 2 Page Issue 01 VT551 Maintenance All Copyright and rights are the property of Johnston Sweep...

Page 96: ...ater pressures 437 4 Optical Tachometer Measure fan rpm 437 7 0 55 Litres Min Flow Gauge Hydraulic flows 437 8 Impulse Adaptor Connects to 437 4 to measure engine speeds from fuel injection pipes 437...

Page 97: ...Chapter Warranty CHAPTER 16 Warranty 16 1 Table of Contents Section Page Warranty Warranty 16 2 Page Issue 01 VT551 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd...

Page 98: ...rges e The defect has not been caused by carelessness vandalism accident incorrect maintenance improper operation abnormal working conditions tampering with sealed settings failure to follow JSL s ins...

Page 99: ...t Bulbs and Fuses Nozzles Nozzle Wheels and or Skids Guards Rubbers and Retaining Strips Nozzle and Wanderhose Trunkings Seals and Rubbers Tyres and Friction Materials Wanderhose Turrets Ducts and Bea...

Page 100: ...k as appropriate This form registers the Standard Silver Gold warranty for the following vehicle To register the date into service please complete and return Model Delivery Date EQ No Registration No...

Page 101: ...that should be exercised in the course of their maintenance work Whilst every effort has been made to ensure completeness of this document owners and operators of Johnston Sweepers are reminded of th...

Page 102: ...er Sharp objects warning There can be a risk of injury from sharp objects such as discarded hypodermic needles becoming lodged in the sweeping system The use of needle stick gloves is recommended when...

Page 103: ...rth of the discharged battery group 7 Attempt to start the casualty vehicle 8 Once the vehicle has started remove the negative lead from the chassis and then the slave battery 9 Remove positive lead f...

Page 104: ...erials except in accordance with the manufacturer s instructions Some chemicals can form other toxic or harmful substances give off toxic or harmful fumes be explosive when mixed together spray chemic...

Page 105: ...cables of mobile electrical equipment cannot be trapped and damaged such as in a vehicle hoist trolley jacks etc Use air operated mobile equipment where possible in preference to electrical equipment...

Page 106: ...n the removal of natural fats from the skin leading to dryness irritation and dermatitis Gross and prolonged contact especially with used engine oil which contains potentially harmful contaminants may...

Page 107: ...ine 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 regularly maintained NEVER improvise lifting tackle ALW...

Page 108: ...Page Issue 01 Chapter Health and Safety 17 8 VT551 Maintenance All Copyright and rights are the property of Johnston Sweepers Ltd...

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