Foreword F

Page Issue Levels P

Engine 1

Maintenance Hydraulic System 2

All Copyright and rights are the property of Johnston Sweepers Ltd.

Manual Electrical System 3

Optional Equipment 4
Servicing Procedures 5
Service Tools 6
Health and Safety 7

CN101
Suction Sweeper

Part No. 7032299

Revision Level A

E.C.N. Issue - 710570 Print date - August 2013

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 CN101 - Maintenance

All Copyright and rights are the property of Johnston Sweepers Ltd.

F:2 Foreword Page Issue A

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 CN101 - Maintenance

CHAPTER P
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Page Issue Levels

Page Issue A Chapter - Page Issue Levels P:1

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 CN101 - Maintenance

Page Issue Changed Page Issue Changed

Front Sheet A Foreword 1 A

P Chapter - Page Issue Levels

Page Issue Changed Page Issue Changed

P:1 A P:2 A
P:3 A P:4 A

All Copyright and rights are the property of Johnston Sweepers Ltd.
1 Chapter - Engine
Page Issue Changed Page Issue Changed

1:1 A 1:2 A
1:3 A 1:4 A

2 Chapter - Hydraulic System

Page Issue Changed Page Issue Changed

2:1 A 2:2 A
2:3 A 2:4 A

3 Chapter - Electrical System

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3:1 A 3:2 A
3:3 A 3:4 A
3:5 A 3:6 A
3:7 A 3:8 A
3:9 A 3:10 A
3:11 A 3:12 A
3:13 A 3:14 A
3:15 A 3:16 A
3:17 A 3:18 A
3:19 A 3:20 A
3:21 A 3:22 A

4 Chapter - Optional Equipment

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4:1 A 4:2 A
4:3 A 4:4 A

P:2 Chapter - Page Issue Levels Page Issue A

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5 Chapter - Servicing Procedures

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5:1 A 5:2 A
5:3 A 5:4 A
5:5 A 5:6 A
5:7 A 5:8 A
5:9 A 5:10 A
5:11 A 5:12 A
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6 Chapter - Service Tools

Page Issue Changed Page Issue Changed

6:1 A 6:2 A

7 Chapter - Health and Safety

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7:1 A 7:2 A
7:3 A 7:4 A
7:5 A 7:6 A
7:7 A 7:8 A

Page Issue A Chapter - Page Issue Levels P:3

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 CN101 - Maintenance

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P:4 Chapter - Page Issue Levels Page Issue A

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 CN101 - Maintenance

CHAPTER 1
All Copyright and rights are the property of Johnston Sweepers Ltd.

Engine

Table of Contents

Section Page

Engine Component Overview 1:2

Supplemental Engine Information Links 1 : 3

Page Issue A Chapter - Engine 1:1

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 F4L2011 Deutz D2011 L03i

1:2
Engine Component Overview
Einspritzventil
Injector
Injecteur
Inyector
Injector

Verbrennungsluftansaugleitung
Schmierkühler Air intake mainfold
Lube oil coooler Collecteur d'admission
Radiateur d'huile de graissage Colector de admisión
Air intake manifold
Refrigerador de aceite lubricante
Lubrication oil cooler

Ventil-Stößelstange
Integriertes Kühlgebläse mit Schutzgitter
Valve push rod
Integrated Colling Fan with Guard
Tige de culbuteur

Chapter - Engine
Ventilateur de refroidissement intégré
Varilla de empuje
Valve push rod avec grille de protection
Integrated cooling fan
Ventilador de refrigeración integrado,

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con rejilla de protección
with guard

Einzel-Einspritzpumpe
Single injection pump
Pompe d'injection individuelle Generator
Bomba individual de inyección
Single injection pump Alternator
Alternateur
Generador
Alternator

Schmieröl-Filter Kolben mit eingezogener Brennraum-Mulde

Oil filter Piston with re-entrant type bowl
Filtre à huile de graissage Piston avec alvéole omega
Oil de aceite lubricante
Filtrofilter Pistón con cámera de combustión
Piston with re-entrant type bowl

Drehzahlregler
Heizungsanschlüsse Speed governor
Cab heater
Cab connections
heater Régulateur de vitesse
Prise de chauffage Regulador de velocidad
Speed governor
Connexiones de calefacción
connections

Permanentspannrolle
Permanent tension pulley
Schwungrad Galet-tendeur permanent
Flywheel Polea tensora permanente
Permanent tension pulley
Volant
Flywheel
Volante

Zahnriemen für Motorsteuerung

Toothed belt for engine timing
Regelstange Courroie dentée pour la distribution
Control rod Correa dentada para distribución del motor
Engine timing belt
Crémaillère
Barra cremallera
Control rod

Best.-Nr. 0031 2008/VM-V/05/2002

Ölwanne Kraftstoff-Filter Nockenwelle mit Einspritzpumpennocke Schmieöl-Peilstab Ölpumpe für den Schmieröl- und Kühlkreislauf
Oil pan Fuel filter Camshaft with cams for injection pump
Camshaft with cams for Oil dipstick Oil pump for lubricating oil and cooling oil circuits
Carter d'huile Filtre à combustible Arbre à cames avec cames de pompes d'injection Jauge d'huile
Oil pump for lubricating oil and
Pompe à huile pour les circuits d'huile de graissage et de refroidissement
Cárter de aceite
Oil pan Filtro de combustible
Fuel filter Arbol de levas con levas para bombas de inyecci'on
injection pump Varilla medidora del nivel de aceite lubricante Bomba para aceite
cooling lubricante y refrigerante
oil circuits
Oil dipstick
CN101 - Maintenance

Page Issue A
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 CN101 - Maintenance

For engine operator’s manual please refer to the following document;

Deutz Operator’s Manual_English.pdf

For engine timing belt replacement information please refer to the following document;

Deutz Timing Belt Replacement.pdf

All Copyright and rights are the property of Johnston Sweepers Ltd.

Page Issue A Chapter - Engine 1:3

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 CN101 - Maintenance

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1:4 Chapter - Engine Page Issue A

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 CN101 - Maintenance

CHAPTER 2
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Hydraulic System

Table of Contents

Section Page

Hydraulic Block Location & Identification 2:2

Hydraulic Circuit 2:3
Vehicle Function Truth Table 2:4

Page Issue A Chapter - Hydraulic System 2:1

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 CN101 - Maintenance

Hydraulic Block Location & Identification

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3:2 Chapter - Electrical System Page Issue A

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 CN101 - Maintenance

Hydraulic Circuit
(drawing reference: 400-3-019483 - Issue A)

Transit = 59.8 l/min

Work = 72.4 l/min

Right
Wheel
0-250 min-1 4WS Block
Motor
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Vg = 300 ccm (Option)

Direction
of travel

Rear Axle
Front Axle

Left
Wheel
Motor

Transit = 59.8 l/min

Work = 72.4 l/min
Option

p dyn ca. 70 bar

Gritter p max. = 130 bar
working = 2400 r/min
Vg = 15 ccm

Blower Motor
Steering
Unit / Motor

Q = 0-12.5 l/min
pmax. = 110 bar
Brush Motors
8 l/min Brush
Transit = 36.1 l/min Nozzle Left Brush Right Brush
Speed / Balance Hopper
Work = 43.7 l/min
HP Water Raise / Lower Position Position Raise / Lower
Brush
System Reverse 0-120 r/min
(Option) (Option) Vg = 100 ccm
Electric
Oil Cooler
Transit = 20.9 l/min
Work = 25.3 l/min

Brush
Brush
Relief
Speed
Transit = 65 l/min
Work = 77 l/min
Cooler Block

Foot Pedal
Raise /
5-25 bar
Lower Position

Transit = 36.1 l/min Transit = 20.9 l/min

Work = 43.7 l/min
Transmission Pump Settings: Work = 25.3 l/min
Pressure cut-off = 300 bar
8 l/min
Secondary pressure = 350 bar
Feed pump = 25 bar

Snow

Option
Idle = 8-900 r/min
Priority Plough
Blower Transit = 1900 r/min Work
Pump Valve
Work = 2300 r/min Pump
Max. = 2800 r/min i=1:1

Transit = 119.7 l/min

Work = 144.9 l/min
Sweep Control Manifold Block
Transmission Pump

Hydraulic Tank

Page Issue A Chapter - Hydraulic System 2:3

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 CN101 - Maintenance

Vehicle Function Truth Table

Page Issue A Chapter - Hydraulic System 2:4 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

CHAPTER 3
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Electrical System

Table of Contents

Section Page

Electrical Circuit Key 3 : 3

Ignition Switch Circuit 3 : 4
Rear Lighting System Circuit 3 : 5
Indicators Circuit 3 : 6
Front Lighting System Circuit 3 : 7

Rear Camera Circuit 3 : 8

Windscreen Wiper Circuit 3 : 9
Heater & Air Conditioning Circuit 3 : 10
Water System 1 Circuit 3 : 11
Water System 2 Circuit 3 : 12

Engine Starter Circuit 3 : 13

Sensors Circuit 3 : 14
ECU Controller Circuit 3 : 15
Transmission Circuit 3 : 16
Side Brush Positioning Circuit 3 : 17

Suction Circuit 3 : 18
Side Brush Sweeping Control Circuit 3 : 19
Hydraulics & Water Recirculation Circuit 3 : 20
Hopper & Heating Circuit 3 : 21
4WS Circuit 3 : 22

Page Issue A Chapter - Electrical System 3:1

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 CN101 - Maintenance

All Copyright and rights are the property of Johnston Sweepers Ltd.

3:2 Chapter - Electrical System Page Issue A

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 CN101 - Maintenance

Electrical Circuit Key

(drawing reference: 7013052 - Issue D)
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Page Issue A Chapter - Electrical System 3:3

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 CN101 - Maintenance

Ignition Switch Circuit

(drawing reference: 7013052, Sheet 1 - Issue D)

Page Issue A Chapter - Electrical System 3:4 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

Rear Lighting System Circuit

(drawing reference: 7013052, Sheet 2 - Issue D)
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Page Issue A Chapter - Electrical System 3:5

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 CN101 - Maintenance

Indicators Circuit
(drawing reference: 7013052, Sheet 3 - Issue D)

Page Issue A Chapter - Electrical System 3:6 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

Front Lighting Circuit

(drawing reference: 7013052, Sheet 4 - Issue D)
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Page Issue A Chapter - Electrical System 3:7

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 CN101 - Maintenance

Reversing Camera Circuit

(drawing reference: 7013052, Sheet 5 - Issue D)

Page Issue A Chapter - Electrical System 3:8 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

Wipers Circuit
(drawing reference: 7013052, Sheet 6 - Issue D)
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Page Issue A Chapter - Electrical System 3:9

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 CN101 - Maintenance

Heater / Air Conditioning Circuit

(drawing reference: 7013052, Sheet 7 - Issue D)

Page Issue A Chapter - Electrical System 3:10 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

Water System 1 Circuit

(drawing reference: 7013052, Sheet 8 - Issue D)
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Page Issue A Chapter - Electrical System 3:11

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 CN101 - Maintenance

Water System 2 Circuit

(drawing reference: 7013052, Sheet 9 - Issue D)

Page Issue A Chapter - Electrical System 3:12 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

Engine Starter Circuit

(drawing reference: 7013052, Sheet 10 - Issue D)
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Page Issue A Chapter - Electrical System 3:13

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 CN101 - Maintenance

Sensors Circuit
(drawing reference: 7013052, Sheet 11 - Issue D)

Page Issue A Chapter - Electrical System 3:14 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

ECU Controller Circuit

(drawing reference: 7013052, Sheet 12 - Issue D)
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Page Issue A Chapter - Electrical System 3:15

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 CN101 - Maintenance

Transmission Circuit
(drawing reference: 7013052, Sheet 13 - Issue D)

Page Issue A Chapter - Electrical System 3:16 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

Side Brush Positioning Circuit

(drawing reference: 7013052, Sheet 14 - Issue D)
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Page Issue A Chapter - Electrical System 3:17

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 CN101 - Maintenance

Suction Circuit
(drawing reference: 7013052, Sheet 15 - Issue D)

Page Issue A Chapter - Electrical System 3:18 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

Side Brush Sweeping Control Circuit

(drawing reference: 7013052, Sheet 16 - Issue D)
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Page Issue A Chapter - Electrical System 3:19

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 CN101 - Maintenance

Hydraulics & Water Recirculation Circuit

(drawing reference: 7013052, Sheet 17 - Issue D)

Page Issue A Chapter - Electrical System 3:20 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

Hopper & Heating Circuit

(drawing reference: 7013052, Sheet 18 - Issue D)
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Page Issue A Chapter - Electrical System 3:21

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 CN101 - Maintenance

4WS Circuit
(drawing reference: 7013052, Sheet 19 - Issue D)

Page Issue A Chapter - Electrical System 3:22 All Copyright and rights are the property of Johnston Sweepers Ltd.

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 CN101 - Maintenance

CHAPTER 4
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Optional Equipment

Table of Contents

Section Page

4WS Bleeding 4:2

Page Issue A Chapter - Water System 4:1

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 CN101 - Maintenance

4WS Bleeding

The following outlines the correct procedure for the removal of air from the Johnston CN101 rear
hydraulic 4 wheel steering (4WS) cylinder.

Should for any reason air be introduced into the 4WS hydraulic system (hose replacement, etc.)
the following procedure must be undertaken to ensure that the 4WS system functions safely and
as intended.

Air in the rear steering cylinder may result in inconsistent control and poor centralisation of the rear

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wheels.

Procedure

Safe working practices should be adhered to throughout.

1. Start the engine, raise the hopper and support on the prop. Activate the 4WS and turn the
steering wheel fully to the left hand lock (rear wheels will point to the right hand side). Stop the
engine; the rear steering cylinder is now at its maximum stroke, see figure one.

2. Remove the cover panel above the hydraulic control located on the right hand side of the
machine (held by five 13mm headed fixings). Fit the tee piece and test point between the hose
and adaptor at the HB port on the 4WS hydraulic valve block and tighten securely with the test
point facing vertically, see figure two.

3. From the hydraulic test kit use one of the test hoses to connect between the test point at HB
on the 4WS hydraulic valve block, see figure three. and the test point at port PS on the charge
pressure connector of the driving pump, see figure four.

4. Start the engine.

Warning
Starting the engine will charge the 4WS hydraulic valve block output HB to a pressure of
25 bar. Any air trapped within the system will also be compressed to this pressure.

Suitable precautions must be applied when venting the circuit in the following steps.

5. Whilst taking all necessary precautions to protect the any personnel and the surrounding area
from any air and oil that is released. Slowly undo the banjo connector bolt on the rear steering
cylinder until any trapped air and oil is seen to be released from the connection. Repeat several
times or until no air is seen to be expelled and then retighten the connection bolt ensuring
correct orientation of the hose.
6. Stop the engine; disconnect the test hose from the 4WS hydraulic valve block and the charge
pressure connector of the driving pump. Refit the protective covers to both test points.

7. Start the engine, activate and operate the 4WS - check the circuit for leaks – Stop the engine.

4:2 Chapter - Optional Equipment Page Issue A

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 CN101 - Maintenance

8. Refit the cover panel over the hydraulic controls and top up the hydraulic oil as required – see
operator’s gu for further details.
9. Lower the hopper and test drive the vehicle to ensure correct operation.

Figure One

Rear steering cylinder extended to its

maximum stroke.
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Figure Two

Installation of tee piece and test point to

port HB of the 4WS hydraulic valve block.

Figure Three

Test hose connected to test point at port HB

on the 4WS hydraulic valve block.

Page Issue A Chapter - Optional Equipment 4:3

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 CN101 - Maintenance

Figure Four

Connection for test hose to test point at port PS on the

charge pressure connector of the driving pump.

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Figure Five

Banjo connector on the rear steering cylinder.

Figure Six

Whilst taking all necessary precautions, slowly release

the banjo connector bolt on the rear steering cylinder
until any trapped air is seen to be released from the
connection and then retighten.

4:4 Chapter - Optional Equipment Page Issue A

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 CN101 - Maintenance

CHAPTER 5
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Servicing Procedures

Table of Contents

Section Page
Adjustment of Steering Components (TB 1519) 5:2
Front Axle Steering Components (TB 1522) 5:7
Engine Oil Consumption (TB 1549) 5 : 11

Page Issue A Chapter - Servicing Procedures 5:1

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 CN101 - Maintenance

Adjustment of Steering Components (TB 1519)

Prior to a planned retrofit campaign an adjustment procedure for the front axle steering
components as well as on-going periodic inspections are being introduced.

Please refer to the following sections defined by the steering configuration of the vehicle of either
two wheel steer (2WS) or four wheel steer (4WS).

Once adjustment is affected, the periodic inspections must be carried out on a weekly basis
– Until the retrofit applied.

All Copyright and rights are the property of Johnston Sweepers Ltd.
Details for Identification

Steering Stop
Steering Cylinder
Locks

Steering Cylinder Ball

Joint
King Pin / Hub
Assembly
Steering Cylinder Ball
Joint & Split Pin
(Torque to 40 Nm)

Adjustment procedure for 4WS models

The front steering locks are adjusted in comparison to the factory adjusted rear stops and the
following procedures should be followed to ensure correct adjustment.

1. Check security of ball joint.

b) With the vehicle on a level surface, raise the front of the vehicle and support securely on
axle stands.

c) Remove both front wheels.

d) Remove the split pin from the steering cylinder ball joint nut (on the front of the right hub
assembly) and check the security of the ball joint by tightening the nut to 40Nm also check
for any movement between the ball joint and hub assembly.

e) Renew split pin and secure.

Note: Should any play exist between the ball joint and hub assembly following tightening of the
nut, further action will be required – Please contact the appropriate Johnston Sweepers
Ltd. service provider.

5:2 Chapter - Servicing Procedures Page Issue A

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 CN101 - Maintenance

2. Adjust steering lock stops

a) Check the steering cylinder ball joint locknut as this is paint marked at the factory – if the
paint mark is intact it would suggest no prior adjustment has been undertaken, so the lock
stops will not require adjustment – If this is the case, please proceed directly to item 3. If
the marks are disturbed continue as follows.

b) Slacken the lock nuts and adjust the steering lock stops (4 in total) to a minimum setting
(the head of the lock stop setscrew should contact the king pin/hub assembly in the
minimum setting).
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c) Start the vehicle engine and engage 4WS, ensuring the vehicle remains stable and fully
supported on the axle stands (It may be necessary to raise the rear of the vehicle as well
as the front due to ground conditions) steer the vehicle to the left until the rear steering just
contacts the appropriate rear steering lock stops – at this point no further steering wheel
movement should be undertaken and the vehicles engine switched off.

d) In this position the appropriate front axle steering locks can be adjusted until they contact
the axle beam and the lock nuts secured. (Rear adjuster on the left hand side and front
adjuster on the right hand side).

e) Start the vehicle engine, ensuring 4WS is engaged and the vehicle remains stable and fully
supported on the axle stands steer the vehicle to the right until the rear steering just
contacts the appropriate lock stops – at this point no further steering wheel movement
should be undertaken and the vehicles engine switched off.

f) In this position the appropriate front axle steering locks can be adjusted until they contact
the axle beam and the lock nuts secured. (Front adjuster on the left hand side and rear
adjuster on the right hand side).

g) Start the vehicle engine, ensure the vehicle remains stable and fully supported on the axle
stands, disengage 4WS and centralise the rear steering and turn off the engine.

3. Adjust cylinder ball joint

a) Steer the vehicle to the full right hand lock.

b) Release the steering cylinder ball joint lock nut.

c) Adjust the ball joint/cylinder length by rotating the cylinder rod until the cylinder is at its
maximum extension whilst the steering remains against the right hand steering lock stops.

d) Re-secure the steering cylinder ball joint lock nut and mark with paint pen to indicate the
unit has been adjusted.

e) Start the vehicle engine and engage 4WS, ensuring the vehicle remains stable and fully
supported on the axle stands (It may be necessary to raise the rear of the vehicle as well
as the front due to ground conditions) steer the vehicle to the left until the rear steering just
contacts the appropriate rear steering lock stops – at this point no further steering wheel
movement should be undertaken and the vehicles engine switched off.

Page Issue A Chapter - Servicing Procedures 5:3

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 CN101 - Maintenance

f) With the steering in this position, check the front axle steering locks are in contact with
the axle beam (Rear adjuster on the left hand side and front adjuster on the right hand
side). If clearance exists the steering locks should be adjusted until they contact the axle
beam ensuring the lock nuts are secured.

g) Start the vehicle engine, ensure the vehicle remains stable and fully supported on the axle
stands, disengage 4WS and centralise the rear steering and turn off the engine.

h) Refit the road wheels torqueing the bolts to 100Nm.

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i) Return the vehicle to the ground and road test to ensure full operation of steering.

Adjustment procedure for 2WS models only

The front axle lock stops are adjusted to allow a specified turning circle to be achieved; the
following procedure should be followed to ensure correct adjustment.

1. Check security of ball joint

a) With the vehicle on a level surface, raise the front of the vehicle and support securely on
axle stands.

b) Remove both front wheels.

c) Slacken the lock nuts and adjust the steering lock stops to a minimum setting (the head of
the lock stop setscrew should contact the king pin/hub assembly in the minimum setting).

d) Remove the split pin from the steering cylinder ball joint nut (on the front of the right hub
assembly) and check the security of the ball joint by tightening the nut to 40Nm also check
for any movement between the ball joint and hub assembly.

e) Renew split pin and secure.

Note: Should any play exist between the ball joint and hub assembly following tightening of
the nut, further action will be required – Please contact the appropriate Johnston
Sweepers Ltd. service provider.

2. Adjust cylinder ball joint

a) Release the steering cylinder ball joint lock nut.

b) Adjust the ball joint/cylinder length by rotating the cylinder rod until the dimension between
the ball joint centre and cylinder rod end is 40mm (figure one).

c) Re-secure the steering cylinder ball joint lock nut and mark with paint pen to indicate the
unit has been adjusted.

5:4 Chapter - Servicing Procedures Page Issue A

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 CN101 - Maintenance

3. Adjust steering lock stops

a) Steer the vehicle to the full right hand lock and adjust the appropriate front axle steering
locks until they contact the axle beam and secure the lock nuts (Front adjuster on the left
hand side and rear adjuster on the right hand side).

b) Now steer the vehicle to the left whilst measuring between the ball joint centre and the
cylinder end face until a measurement of 97mm is achieved (Fig 2.).

c) At this point adjust the appropriate front axle steering locks until they contact the axle beam
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and secure the lock nuts (Rear adjuster on the left hand side and front adjuster on the right
hand side).

d) Centralise the steering and refit the road wheels torqueing the bolts to 100Nm.

e) Return the vehicle to the ground and road test to ensure full operation of steering.

Periodic inspection – All Models (2WS and 4WS)

As prescribed, periodic inspection of the steering cylinder ball joint should be undertaken to ensure
that security of its fixing is maintained.

1. Check security of ball joint

a) With the vehicle on level ground with the handbrake applied rotate the steering to give full
right hand lock.

b) Remove the split pin from the steering cylinder ball joint nut (on the front of the right hub
assembly) and check the security of the ball joint by tightening the nut to 40Nm and
checking for any movement between the ball joint and hub assembly.

c) Renew split pin and secure.

Note: Should any play exist between the ball joint and hub assembly following tightening
of the nut further action will be required – Please contact the appropriate Johnston
Sweepers Ltd. service provider.

Page Issue A Chapter - Servicing Procedures 5:5

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 CN101 - Maintenance

Adjustment of Steering Components - Tools required

1 x Trolley jack (capable of safely lifting the vehicle to the required height).
2 x Axle stands (sufficient to support the vehicle safely at the required height)
1 x 22mm open ended spanner.
2 x 17mm spanner.
1 x 19mm socket.

1 x 17mm socket
1 x torque wrench (Suitable for above sockets and able to give 40Nm and 100Nm measurements).

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1 x Paint pen.

Parts required

Split pin 2mm x 30mm - as required.

Standard Repair Time

Adjustment of lock stops, steering and initial periodic inspection - 60 Minutes.

Periodic inspection - 15 Minutes.

5:6 Chapter - Servicing Procedures Page Issue A

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 CN101 - Maintenance

Front Axle Steering Components (TB 1522)

Further to TB1519 a retrofit campaign has been introduced to enhance the reliability of the front
axle steering components utilising a larger ball joint and associated components..

The components must be replaced by following the procedures outlined below:-

Replacement of Components

1. With the vehicle on a level surface, raise the front of the vehicle and support securely on axle
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stands.

2. Remove right hand front wheel.

3. Working on the right hand side front hub assembly, remove the clamp from the drive hoses
(item 1) – shown below.

Item 1
Drive Hose Clamp

4. Remove the four screws (Item 2) and the drive motor with the hoses still connected – support
until refitted to ensure hoses are not damaged.

5. Remove the split pins and nuts from the two steering ball joints (Item 3) and disconnect them
from the swivel housing using a ball joint separator.

Remove and discard the ball joint fitted to the steering cylinder.

6. Remove the swivel housing retaining screw (Item 4) (this can be achieved by working through
the spring) and withdraw the swivel housing.
Item 5
Steering Lock Stops

Item 2
Wheel Motor
Retaining Screws Item 3
Steering Ball Joints

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 CN101 - Maintenance

7. Remove the steering lock stops (Item 5) from the swivel housing and discard the original swivel
housing.

8. Using the revised swivel housing (Part number 7001770) re-assemble the components in
reverse order of removal with the exception of the steering cylinder ball joint. The swivel
housing retaining screw (Item 4) should be fitted using Loctite 243.

9. The revised steering cylinder ball joint (Part number 7022475) and adaptor (Part number
7021822) can now be fitted to the cylinder and tightened using Loctite 243 on both thread
faces – shown below.

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Apply Loctite 243

10. The ball joint should now be fitted to the swivel housing and tightened to 80Nm – shown
below.

Item 4
Swivel Housing
Retaining Screw

40 Nm

80 Nm

11. Refit the road wheel and torque to 100Nm and return the vehicle to the ground.

12. Carry out adjustment to the front wheel alignment using propriety “tracking” equipment to give
a figure of 0°40’ Toe in, by adjusting the length of the track rod located behind the axle.

13. Carry out adjustment to the steering lock stops as detailed below depending on steering
configuration – Four wheel steer or two wheel steer.

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Adjustment of Steering Lock Stops – 4WS Models Only

1. With the vehicle on a level surface, raise the front of the vehicle and support securely on axle
stands.

2. Remove both front wheels.

3. Start the vehicle engine and engage 4WS, ensuring the vehicle remains stable and fully
supported on the axle stands (It may be necessary to raise the rear of the vehicle as well
as the front due to ground conditions) steer the vehicle to the left until the rear steering just
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contacts the appropriate rear steering lock stops – at this point no further steering wheel
movement should be undertaken and the vehicles engine switched off.

4. In this position the appropriate front axle steering locks can be adjusted until they contact the
axle beam and the lock nuts secured. (Rear adjuster on the left hand side and front adjuster on
the right hand side).

5. Start the vehicle engine, ensuring 4WS is engaged and the vehicle remains stable and fully
supported on the axle stands steer the vehicle to the right until the rear steering just contacts
the appropriate lock stops – at this point no further steering wheel movement should be
undertaken and the vehicles engine switched off.

6. In this position the appropriate front axle steering locks can be adjusted until they contact the
axle beam and the lock nuts secured. (Front adjuster on the left hand side and rear adjuster on
the right hand side).

7. Start the vehicle engine, ensure the vehicle remains stable and fully supported on the axle
stands, disengage 4WS and centralise the rear steering and turn off the engine.

8. Refit the road wheels torqueing the bolts to 100Nm.

9. Return the vehicle to the ground and road test to ensure full operation of steering.

Adjustment of Steering Lock Stops – 2WS Models Only

1. With the vehicle on a level surface, raise the front of the vehicle and support securely on axle
stands.

2. Remove both front wheels.

3. Adjust the right and left hand rear most lock stops to 25mm protruding from the swivel housing.

Adjust rear most steering

lock stops to 25mm.

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 CN101 - Maintenance

4. Rotate the steering until full right hand lock is achieved and the right hand rear most steering
lock is in contact with the axle assembly. With the steering in this position adjust the left hand
front steering lock until it also contacts the axle assembly.

5. Rotate the steering until full left hand lock is achieved and the left hand rear most steering
lock is in contact with the axle assembly. With the steering in this position adjust the right hand
front steering lock until it also contacts the axle assembly.

6. Centralise steering.

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7. Refit the road wheels torqueing the bolts to 100Nm.

8. Return the vehicle to the ground and road test to ensure full operation of steering.

Tools Required

1 x Trolley jack (capable of safely lifting the vehicle to the required height).
2 x Axle stands (sufficient to support the vehicle safely at the required height)
1 x 27mm spanner.
1 x 22mm spanner.
2 x 17mm spanner.

1 x 13mm spanner.
1 x 13, 19, 17 and 22mm sockets with a ratchet.
1 x Torque wrench (Suitable for above sockets and able to give between 40Nm and 100Nm
measurements.
1 x Ball joint separator.
1 x Tracking gauges.

Parts Required

Kit part number - TB1522

Description Part Number Quantity

Ball Joint 7022475 1 Off

Adaptor 7021822 1 Off
Swivel Housing - RH 7001770 1 Off
Loctite 243 Reference

Standard Repair Time

120 minutes.

Note: This design improvement has been introduced in production from Manufacturing Sequence
Number 0175.

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 CN101 - Maintenance

Engine Oil Consumption (TB 1549)

The following instructions should be implemented for the Deutz engines fitted to the Johnston
CN101.

The instructions apply during the first 500 to 700 operating hours and are intended to prevent high
oil consumption:

• Higher than usual oil consumption during the first 500 to 700 operating hours of the running-in
period is quite normal.
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• In general and especially during the running-in period the engine should not be left to idle for
long periods.

• Only use the oil grade recommended in the operator manual.

Do not use a lower grade oil.
Using a lower grade oil will increase oil consumption.

• The oil level may be checked with the engine hot or cold with the engine switched off. If the
engine has been running it should be switched off for minimum of 5 minutes prior to checking
the level to allow the oil to settle.

If you want to compare oil levels ensure that the oil levels to be compared are checked under
similar conditions.

• When filling, only fill up to the halfway mark on the dipstick. If you fill to the upper mark, the
engine will use the excess oil until the level drops to the halfway mark. Often this is declared as
the normal oil consumption of the engine but this is not in effect the case.

• If engine oil consumption is exceptionally high despite implementation of the running-in

instructions, you should inform your local Johnston representative. You will also be asked to
record the consumption data over a period of 100 hours running time. You should record the oil
consumption and the fuel consumption for comparison.

The limit value for the maximum specific lubricant consumption is 0.75 % (max.) of fuel
consumption.

Recommended Oil Grade from Operators Manual.

Minimum Specification - ACEA E3-96/E5-02, API CH-4/CG-4, DHD-1

Viscosity - 10W-40

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CHAPTER 6
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Service Tools

Table of Contents

Section Page

Service Tools 6:2

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 CN101 - Maintenance

The following tools are available through our Spares Network

Tool No. Description Function

437/3 Pressure Gauge Set Used to measure hydraulic and water pressures.

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437/4 Optical Tachometer Used to measure fan rpm.

437/7 0.55 Litres/min Flow Gauge Used to measure hydraulic flows.

437/8 Impulse Adaptor Connects to 437/4 to measure engine speeds

from fuel injection pipes.

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CHAPTER 7
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Health and Safety

Introduction

The information presented in this chapter does not infer that there are
hazards associated with the Johnston sweepers. It is given as a guide
to general precautions that should be exercised in the course of their
maintenance work.

Whilst every effort has been made to ensure completeness of this

document, owners and operators of Johnston sweepers are reminded of
their responsibilities to comply with all relevant legislation including Risk/
COSHH Assessments and Approved Codes of Practice.

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 CN101 - Maintenance

Health and Safety Precautions

The information presented in this section does not infer there are any particular hazards
associated with these machines. It is given as a guide to the general precautions that
should be taken in any workshop environment when working on machines of this nature
in the course of their maintenance.

Safety symbol:
The universal symbol is used throughout this manual to indicate information which is
essential for health and safety of all operating personnel.

All Copyright and rights are the property of Johnston Sweepers Ltd.
Refer to all state, district/company, or council Health and Safety Regulations and follow
the procedures laid down.

The repair and maintenance of machinery such as this can involve physical hazards
or other risks to health. This section lists some of these hazards and the precautions
necessary to avoid them.

The list is only general but all other operations, procedures and the handling of materials
should be carried out in accordance with the requirement of health and safety laws, which
is the responsibility of the Owner/Operator/Maintainer.

Anti Freeze:
Anti-freeze may be absorbed though the skin in toxic or harmful quantities.
If swallowed, seek medical attention immediately.
Some types, i.e., isopropanol, ethylene glycol and methanol are flammable.

Batteries:
Gases released during charging are explosive. Never use naked flames or allow sparks
near charging or recently charged batteries.

Disconnection:
Disconnect the negative battery lead from battery first. The positive cable must always
be disconnected last.

Reconnection:
Always reconnect the positive battery cable first.

Jump-starting and use of auxiliary (booster) batteries:

Do not jump-start maintenance free batteries if in a deeply discharged state as internal
short circuits may occur.

If a maintenance free battery is found to be in a deeply discharged state, it is essential to

remove the battery and recharge off the vehicle. Jump-starting will not enable the vehicles
own charging system to initiate the charging process.

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Jump starting procedure:

Always follow this procedure when connecting a booster battery.

Take care not to cause sparking which could ignite hydrogen gas being given off by the
batteries.

1. Apply the park brake, turn off ignition, lights and other electrical loads.
2. If the slave battery is mounted on another vehicle, ensure that the vehicles are not
touching.
3. Ensure that the donor battery voltage is compatible with the vehicle battery.
4. Ensure that adequate ventilation is available to the vehicle and slave batteries.
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5. Connect positive terminal of the donor battery group to positive terminal of the
discharged 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 negative lead from the chassis and then
the slave battery.
9. Remove positive lead from discharged chassis and then the donor chassis.

If the vehicle will not start with a booster battery, contact your local Johnston Service
Network.

Chemical materials:
Chemical materials such as solvents, sealers, adhesive, paints, resin foams, battery
acids, anti-freezes, brake fluids, oils and grease should always be used with caution and
stored and handled with care.

Chemical materials may be toxic, harmful, corrosive, irritant or highly flammable and give
rise to hazardous fumes and dust.

Always consult the appropriate safety standards for handling such materials.

Typical biohazard symbol

Typical radioactive material symbol

Typical poison symbol

Always use appropriate protective clothing

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Reminders
Chemical materials

DO remove chemical materials from the skin and clothing as soon as practical after soiling.
Change heavily soiled clothing and have it cleaned.

DO carefully read and observe hazard and precaution warnings given on hazardous material
containers and in any accompanying leaflets, posters or other instructions. Hazardous
material health and safety data can be obtained from manufacturers.

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organise work practices and use protective clothing to avoid soiling of the skin and eyes;
DO
breathing vapours, aerosols, dust, and fumes; inadequate container labelling; fire and
explosive hazards.

wash before job breaks, before eating, smoking, drinking or using toilet facilities when
DO
handling chemical materials.

DO keep work areas clean, uncluttered and free of spills.

mix chemical materials except in accordance with the manufacturer’s instructions. Some
DO NOT
chemicals can form other toxic or harmful substances; give off toxic or harmful fumes; be
explosive when mixed together.

DO NOT spray chemical materials, particularly those based on solvents, in confined spaces; for
example, when people are inside a vehicle.

DO NOT apply heat or flame to chemical materials, except under the manufacturer’s instructions.
Some are highly flammable and some may release toxic or harmful fumes.

DO NOT leave containers open. Fumes given off can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than air and will accumulate in confined areas,
pits, etc.

DO NOT transfer chemical materials to unlabelled containers.

clean hands or clothing with chemical materials. Chemicals, particularly solvents and
DO NOT
fuels will dry the skin and may cause irritation with dermatitis. Some can be absorbed
through the skin in toxic or harmful quantities.

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Dusts:
Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from
powdery chemical materials or those arising from dry abrasion operations.
Wear respiratory protection in accordance with the requirement of the Health and Safety
Acts.

Electric shocks:
When working on electrical systems, remove watches, bracelets and rings as these can
conduct electricity and cause shorts and/or burns.
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Electric shocks can result from the use of faulty electrical equipment or from the misuse
of equipment even in good condition.

Ensure that electrical equipment is maintained in good condition and frequently inspected
and tested.

Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or
otherwise damaged.

Ensure that electrical equipment is protected by the correct rated fuse and if used outside
an earth-leakage circuit breaker is used.

Never misuse electrical equipment and never use equipment that is in any way faulty. The
results could be fatal.

Use reduced voltage equipment (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 operated mobile equipment where possible in preference to electrical equipment.

Exhaust fumes:
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon
oxides, nitrogen oxides, aldehydes, leads and aromatic hydrocarbons.
Engines should only be run under conditions of adequate extraction or general ventilation
and not in confined spaces.
NB : Catalyst exhausts/silencers can run at extremely high temperatures.

Fire and welding:

Observe strict fire safety when storing and handling flammable materials or solvents,
particularly near electrical equipment or welding processes.
Disconnect battery, microprocessors, etc. before commencing welding. Failure to observe
this could cause failure of components.
Ensure before using electrical or welding equipment that there is no fire hazard present.
Have a suitable fire extinguisher available when using welding or heating equipment.
Special precautions must be taken before any welding or cutting takes place on vessels
which have contained combustible materials, e.g. fuel tanks.
The sound insulation foam used on the equipment must be removed if any welding is to
be carried out in that area of the machine.

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First aid:
It is desirable for someone in the workshop to be trained in the first aid procedures.
Splashes or particles in the eye should be flushed with clean water for at least ten minutes
and medical attention sought.
Soiled skin should be washed with soap and water.
Inhalation affected individuals should be removed to fresh air immediately.
If hazardous material has been swallowed or if the effects of exposure to hazardous
materials persist, consult a doctor with information (label) on material used.
Do not induce vomiting (unless indicated by the manufacturer).

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High-pressure air and lubrication equipment:
Always keep high-pressure equipment in good condition and regularly maintained,
particularly at joints and unions.

Never direct a high (or low) pressure nozzle at the skin as the fluid may penetrate to the
underlying tissue, etc, and cause serious and potentially fatal injury.

Oils and greases:

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 used engine oil, which contains potentially
harmful contaminants, may cause skin cancer.

Where there is a risk of eye contact, e.g., by splashing, eye protection should be worn,
for example, chemical goggles or face shields; in addition, an eyewash facility should be
provided.

Adequate means of skin protection and washing facilities should be provided.

Repeated or prolonged skin contact should be avoided by wearing protective clothing,

including impervious gloves where practical. Particular care should be taken with used
oils and greases containing lead.

First Aid treatment should be obtained immediately for open cuts and wounds.

Apply barrier cream before each work period to help when removing oil from the skin.

Use proprietary hand cleaners only if they can be removed from the skin using water.

Overalls must be cleaned regularly. Discard clothing that cannot be cleaned and footwear
that has become impregnated.

In the event of a skin condition occurring consult a doctor and tell him/her that your work
involves using oil.

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Solvents:
Solvents such as acetone, white spirit, toluene, xylene and trichloroethane are flammable.

Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and
clothing.

When using solvents ensure good ventilation; avoid breathing fumes, vapours, spray-
mists and keep containers tightly sealed. Do not use in confined spaces. When spraying
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materials containing solvents, for example paints, adhesives or coatings, use extraction
ventilation or personal respiratory protection in the absence of adequate general
ventilation.

Do not apply heat or flame except under specific and detailed manufacturer’s instructions.

Suspended loads:
Never work under an unsupported, 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 suitable for the job, in good condition and regularly maintained.

NEVER improvise lifting tackle. ALWAYS ensure body props and/or axle stands are used
when working under bodies or chassis.

Workshop tools and equipment:

Only use tools and equipment for their intended purposes.

Never overload equipment such as hoists, jacks, axles stands or lifting slings. Damage
caused by overloading is not always immediately apparent and may result in a fatal failure
the next time the equipment is used.

Never use damaged or defective tools or equipment.

Always wear suitable eye protection when using grinding, chiselling or air guns.

Always wear a suitable breathing mask when using sand blasting equipment, working with
asbestos based materials (such as brake linings) or using spraying equipment.

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