Johnston RT655 Operator's Manual
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Johnston RT655 Operator's Manual

Mk iii regenerative air twin engine suction sweeper
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Operator's
Guide
RT655 Mk III
Regenerative Air
Twin Engine
Suction Sweeper
From Manufacture Sequence No. 7458
Part No 01288-1(GB)
Revision Level A
E.C.N. 712675
Johnston Sweepers Limited
General Arrangement
Controls
Operation
Optional Equipment
Chapter not used
Routine Maintenance
Conformity Certificates
Print date - 16/11/2015
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Summary of Contents for Johnston RT655

  • Page 1 Johnston Sweepers Limited Operator’s Guide General Arrangement Controls Operation RT655 Mk III Optional Equipment Regenerative Air Chapter not used Twin Engine Suction Sweeper Routine Maintenance From Manufacture Sequence No. 7458 Part No 01288-1(GB) Conformity Certificates Revision Level A Print date - 16/11/2015...
  • Page 2 RT655 Operator’s Guide Foreword The Johnston RT655 Air Regen Sweeper represents the highest grade of craftsmanship and reliability that makes Johnston probably the world leader in sweeping technology. This machine is designed for the removal of spoil on traffic or pedestrian areas, and litter collection using the Wanderhose [EN 13019 refers], and should only be driven by trained operatives.
  • Page 3 The universal safety symbol is used throughout this manual to indicate information which is essential for health and safety for all operating personnel. Ear defenders are recommended when working around the machine Eye protection is recommended when working around the machine are registered trade marks of Johnston Sweepers Limited. ® ® ®...
  • Page 4 RT655 Operator’s Guide Page Issue Levels Page Issue Changed Page Issue Changed Front Page Foreword 1 Foreword 2 Foreword 3 Foreword 4 Foreword 5 OG1:1 OG1:2 OG1:3 OG1:4 OG2:1 OG2:2 OG2:3 OG2:4 OG2:5 OG2:6 OG2:7 OG2:8 OG3:1 OG3:2 OG3:3 OG3:4...
  • Page 5 Hose Pipe 1b = Hydrant Hydraulic oil tank filler Fuel tank (diesel) filler Engine air cleaner instructions, i.e. use only genuine Johnston replacement air cleaner elements and refer to Chapter 6 of this guide for servicing instructions Foreword Page Issue A...
  • Page 6 RT655 Operator’s Guide Safety Symbol Descriptions Safety alert symbol Read Operator’s Guide Ensure body prop is engaged in rack before working under raised body Body prop NOT engaged in rack Body prop correctly engaged in rack Keep clear of brushes...
  • Page 7 RT655 Operator’s Guide Johnston Sweepers Limited CHAPTER General Arrangements Table of Contents Subject Page General Arrangement General Arrangement Drawing OG1 : 2 OG1:1 Chapter - General Arrangement Page Issue A...
  • Page 8 RT655 Operator’s Guide GENERAL ARRANGEMENT Figure 1 36 33 25 27 Cold Weather Drains 31 30 RTOG.051 RH Sweep machine shown OG1:2 Chapter - General Arrangement Page Issue A...
  • Page 9 RT655 Operator’s Guide Johnston Sweepers Limited Item Component See Chapter Hopper/load compartment Auxiliary engine cowl Body (hopper and cowl) prop Auxiliary engine Fuel tank Fuel tank filler access flap Hydraulic oil reservoir Suction fan case Variable exhaust gate (VEG) Pick-up head (hood)
  • Page 10 RT655 Operator’s Guide OG1:4 Chapter - General Arrangement Page Issue A...
  • Page 11 RT655 Operator’s Guide Johnston Sweepers Limited CHAPTER Controls Table of Contents Subject Page Operating Controls - In Cab Switch Panel OG2 : 2 Cab Mounted Controls OG2 : 6 Operating Controls - External Load Discharge Control Pendant OG2 : 7...
  • Page 12 RT655 Operator’s Guide Sweeping Controls - Switch Panel 15hrs RTOG.042 *Denotes Optional Equipment OG2:2 Chapter - Controls Page Issue A...
  • Page 13 RT655 Operator’s Guide Johnston Sweepers Limited Sweeping Controls Symbol Description Programme Button; ON/OFF switch illuminates when pressed and suspends all sweeping and parks brushes. Pressing again reactivates previous settings. ‘Hopper Raise’ - red warning lamp and buzzer. ‘Low Air Pressure’ - amber warning lamp and buzzer.
  • Page 14 RT655 Operator’s Guide Sweeping Controls - Switch Panel 15hrs RTOG.042 OG2:4 Chapter - Controls Page Issue A...
  • Page 15 RT655 Operator’s Guide Johnston Sweepers Limited Sweeping Controls Symbol Description Supawash option; 2 position switch - OFF/ON illuminated when selected. Hood reverse pick-up select switch; 2 position switch - OFF/ON. Rear Worklamp; 2 position switch OFF/ON illuminated when selected. Water tank low level indicator - illuminated when tank empty.
  • Page 16 RT655 Operator’s Guide Cab Mounted Controls AA BB RTOG. 010-2 Symbol Switch Description Channel brush speed control; clockwise rotation increases brush speed. Pressure control for each gutter broom Powasave; clockwise rotation reduces brush pressure. Fuse box is mounted inside relay box. Fuse functions - see page OG2:8.
  • Page 17 RT655 Operator’s Guide Johnston Sweepers Limited Load Discharge Control Pendant (Located beside the driver’s seat) M02OG-005 Function Hand brake off - Pendant not ready for operation Hand brake on - Pendant ready for operation Switch Function Raises body Closes rear door...
  • Page 18 RT655 Operator’s Guide Fuse Functions RTOG.011-2 Fuse No. Function Amps Beacons Marker Lights Power I/O Node Water/Supawash/Rotatilt Work Lights/Water Switches Power VEG Gate Aux Engine Ignition Chassis Ignition Chassis Ignition/Supawash Controls/VEG Sensors Aux Engine ECU Power Aux Engine Crank Fuse colour key...

  • Page 19: Table Of Contents

    RT655 Operator’s Guide Johnston Sweepers Limited CHAPTER Operation Table of Contents Subject Page Towing and Craning Towing the Vehicle OG3 : 2 Craning the Vehicle OG3 : 2 Engine Engine Starting and Operation Procedures - John Deere OG3 : 3...

  • Page 20: Towing The Vehicle

    RT655 Operator’s Guide Craning the Vehicle The vehicle may be lifted using conventional lifting systems that are slung from the vehicle road wheels. However, it is necessary to ascertain the centre of gravity as it can be up to 20% from the mid point of the wheelbase.

  • Page 21: Engine Starting And Operation Procedures - John Deere

    RT655 Operator’s Guide Johnston Sweepers Limited ENGINE STARTING AND OPERATION PROCEDURES - JOHN DEERE Before driving the sweeper, it is advisable to have the chassis engine running as it is necessary to ensure there is adequate air pressure to raise the sweepgear from the ground.
  • Page 22 RT655 Operator’s Guide ENGINE STARTING AND OPERATION PROCEDURES. Engine Operation Warning System The engine will automatically be shut down in the event of loss of lubrication oil pressure or coolant overheat. Illumination of the relative warning lamps occurs if these conditions prevail.

  • Page 23: Commence Sweeping

    RT655 Operator’s Guide Johnston Sweepers Limited To Commence Sweeping Start vehicle engine. Ensure the intake blanking plate is not blanking the tube and is stowed on the body underside. Start auxiliary engine. Ensure warning beacons are operating - switch (R).

  • Page 24: Hood Hop

    RT655 Operator’s Guide Hood Hop The Hood Hop feature is a versatile way to overcome bulky debris when sweeping. The pick-up head hop switch is instant. It reacts to lift the hood for as long as the button is pressed.

  • Page 25: Blocked Pick-Up Head /Suction Duct

    RT655 Operator’s Guide Johnston Sweepers Limited Blocked Pick-up Head or Suction Duct If it is apparent that the pick-up head is not lifting debris it may be that it is blocked or that the body is full. 1. With the machine stationary and the suction still operative on the pick-up head, raise and lower the pick-up head and see if the blockage clears.

  • Page 26: Load Discharge And Auto Body Prop

    RT655 Operator’s Guide Safety Notice Before carrying out the load discharge operations ensure the following safety aspects are observed ● E nsure the machine is standing on firm, level ground and there are no obstructions above or to the rear before raising the body. ● The rear door must be fully open before raising a loaded body. ● E nsure no-one is near the load discharge area when opening or closing the rear door. ● E nsure the body rests on the auto prop when the body is left in the raised position, or when working under the body or cowl.
  • Page 27 RT655 Operator’s Guide Johnston Sweepers Limited To Tip the Load Open the rear door by pressing DD-A and F. Raise the body by pressing switch DD-C and F, this will cause the body prop ‘A’ (painted red) to index into the locking step ‘B’ on the subframe. Ensure the prop has located against the step.

  • Page 28: Emergency Discharge Pump

    RT655 Operator’s Guide Emergency Discharge Pump In the event of an auxiliary or electrical system malfunction , the body can be raised by:- Turning on the chassis engine Turn on the sweepger ignition Check the green light on the discharge pendant Push buttons DD-C and F to raise the body so that the body prop can clear the locking steps NB: This system can also be used to open the rear door.

  • Page 29: Sweeping In Cold Temperatures

    RT655 Operator’s Guide Johnston Sweepers Limited SWEEPING IN COLD TEMPERATURES Operating Temperature 0°C to +5°C For sweeping in cold conditions above freezing, it is possible to use the water system providing the machine has been left in a warm garage overnight.

  • Page 30: Cold Weather Precautions

    RT655 Operator’s Guide COLD WEATHER PRECAUTIONS To avoid the possibility of frost damage to the water system when the machine is left during cold weather, it is essential to drain the system adequately. Open the drain taps Items 26 & 27, Fig.
  • Page 31 RT655 Operator’s Guide Johnston Sweepers Limited CHAPTER Optional Equipment Table of Contents Subject Page Options Supawash OG4 : 2 Wanderhose OG4 : 4 Emergency Discharge OG4 : 6 Emergency Hood Lift OG4 : 6 OG4:1 Chapter - Optional Equipment Page Issue A...
  • Page 32 RT655 Operator’s Guide SUPAWASH OPTION Safety Precautions ● Care MUST be taken not to damage sign written areas when cleaning. See special notes for cleaning vehicles with vinyl livery below. ● ALWAYS keep pressure equipment in good condition and regularly maintained, particularly at joints and unions.

  • Page 33: Operation

    RT655 Operator’s Guide Johnston Sweepers Limited DESCRIPTION RTOG. 014-4 The equipment comprises a hydraulically driven high pressure water pump (A) and unloader valve (B) fitted to the subframe centre crossmember. A hand lance with 15 metres of hose on a recoiling reel (C) mounted to the subframe rear crossmember and a manifold (D) attached to the nearside water tank.
  • Page 34 RT655 Operator’s Guide Safety Notice 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 changing brushes, using the Wanderhose/Littasnatch and when cleaning out the machine.
  • Page 35 RT655 Operator’s Guide Johnston Sweepers Limited The hose and boom are hydraulically lifted and can be used to the left or right hand side of a stationary vehicle with a single operator. With a second operator, the hose can be used whilst the vehicle is moving slowly along.
  • Page 36 RT655 Operator’s Guide EMERGENCY DISCHARGE In the event of an auxiliary engine malfunction, or discharging a load, tipping can be achieved as follows. Apply vehicle brake and leave the chassis engine running. Push sweeper ignition Use discharge pendant to raise body or open rear door...
  • Page 37 RT655 Operator’s Guide Johnston Sweepers Limited CHAPTER Routine Maintenance Table of Contents Subject Page Safety Precautions Safety Precautions OG6 : 2 Maintenance Schedules Maintenance Schedules OG6 : 3 Equipment Adjustment / Maintenance Gutter Broom Adjustment OG6 : 6 Gutter Broom Replacement...

  • Page 38: Safety Precautions

    RT655 Operator’s Guide Safety Precautions DO NOT ● Work on or around the engine whilst it is running except to adjust idle settings. ● Remove engine radiator cap when the engine is hot, without first covering the cap with a cloth. Release it slowly, otherwise there is a risk of being scalded by escaping coolant.
  • Page 39 RT655 Operator’s Guide Johnston Sweepers Limited MAINTENANCE SCHEDULE (OG6:4 - OG6:5) D = Daily W = Weekly A = 500 Hours B = 1000 Hours C = 12 Monthly Attention is drawn to the recommendations for servicing in the Auxiliary Engine Handbook.
  • Page 40 RT655 Operator’s Guide MAINTENANCE SCHEDULE DAILY MAINTENANCE - These can be carried out by a trained operator. Check the following items: Oil level in hydraulic reservoir - top up if required. Auxiliary engine oil level - top up if required.
  • Page 41 RT655 Operator’s Guide Johnston Sweepers Limited MAINTENANCE SCHEDULE ( Continued ♠ Service A - every 500 hours Change auxiliary engine oil and renew filter. Clean fuel pre-filter bowl (John Deere). Renew the fuel filter element. Renew auxiliary engine air cleaner elements Check auxiliary engine throttle control and engine idle for correct operation.

  • Page 42: Equipment Adjustment / Maintenance

    RT655 Operator’s Guide EQUIPMENT ADJUSTMENT / MAINTENANCE Introduction This chapter highlights some of the basic adjustment and maintenance procedures required to keep the machine performing efficiently. Gutter Broom Adjustment This section highlights the Gutter Broom adjustment. The machine can sweep with single brush, kerb (nearside) or offside (road side) or simultaneously brushes working.
  • Page 43 RT655 Operator’s Guide Johnston Sweepers Limited The brush angle should be set using adjustment (C) and (D) so that only about 120 of the circumference towards the front kerb is in contact with the road. If a ‘light sweep’ brush pressure is set, then the brush may not position itself outwards. In this case reset the ‘light sweep’...

  • Page 44: Pick-Up Hood

    RT655 Operator’s Guide Pick-up Hood The pick-up hood is towed by 4 chains positioned at the front and rear. This allows the machine to sweep forwards and backwards, as the pick-up hood will be guided during the travel mode. The pick-up hood is lifted by two hydraulic cylinders, one either side that connect directly to the head.

  • Page 45: Spring Adjustments

    RT655 Operator’s Guide Johnston Sweepers Limited Spring Adjustments The springs locate to the hood via chains which allow for adjustment by resetting the chain length. The chains length can be set longer by locating the spring into a longer chain loop to create a heavier force to the ground where needed.

  • Page 46: Suction Fan Impeller And Casing

    RT655 Operator’s Guide Suction Fan Impeller and Casing In operation the impeller and casing can be subjected to wear in the form of erosion Ensure the auxiliary engine is not running and isolated before fan maintenance resulting from dust or small abrasive particles passing through the fan system and must or replacement is attempted.

  • Page 47: Water Filter - Cleaning

    RT655 Operator’s Guide Johnston Sweepers Limited Ensure the screen is lowered slowly. If the mesh is allowed to ‘free fall’ and bounce off of the baffle, there is a possibility of it being dislodged from the hinge point. With the screen removed and the body raised and resting on its prop, clean out all debris from the roof duct which runs along the top of the body, using a hose and broom.

  • Page 48: Auxiliary Engine

    RT655 Operator’s Guide AUXILIARY ENGINE Safety Notice Ensure the auxiliary engine is not running and isolated before fan maintenance or replacement is attempted. RTOG. 043 Engine Oil OIL LEVEL CHECKING Check daily. The level can be checked with the body raised. Ensure the body prop is in place.

  • Page 49: Filter Regulator Unit

    RT655 Operator’s Guide Johnston Sweepers Limited Filter Regulator Unit (E) The filter regulator unit comprises a combined air filter/pressure regulator. The air filter can be manually drained by pushing up the bowl drain tube. The air is isolated and drained by pressing the red gate valve on the unit.

  • Page 50: Alternator And Water Pump Belt Tensioning

    RT655 Operator’s Guide Alternator and Water Pump Belt Tensioning The John Deere engines have an automatic belt tensioner so should not require adjustment unless the belt is replaced - see engine manufacturers handbook for setting information. ‘Z’ DRIVE GEARBOX OIL LEVEL CHECKING The level plug (B) should be removed and filled to the bottom of the thread.

  • Page 51: Supawash Pump

    RT655 Operator’s Guide Johnston Sweepers Limited SUPAWASH PUMP The oil level in the Supawash pump should be checked weekly. There is a sight level glass and dipstick at the front end of the pump. It is recommended that the oil is changed after the first 50 hours of operation and then changed at every C Service.
  • Page 52 RT655 Operator’s Guide LUBRICATION DIAGRAM - RH SWEEP MACHINE SHOWN LUBRICATION DIAGRAM Refer to Maintenance Schedules for lubrication intervals GREASE ( i ) RTOG. 054 Body prop - Ensure autoprop has engaged when body is raised. Filter regulator unit (FR) - (i) Isolation valve.
  • Page 53 E Chassis PAS 94-67-1 F Auto Gearbox G Antifreeze 39664 Grease Nipple 94-69 PETROLEUM JELLY Battery Terminals The above oils are those approved by Johnston Sweepers. Other manufacturer’s oils must be of equivalent grade. OG6:17 Chapter - Routine Maintenance Page Issue A...
  • Page 54 RT655 Operator’s Guide OG6:18 Chapter - Routine Maintenance Page Issue A...
  • Page 55 RT655 Operator’s Guide Johnston Sweepers Limited CHAPTER Conformity Certificates Table of Contents Subject Page EC Declaration of Conformity Certificates Safety Requirements OG7 : 2 Noise - Engines OG7 : 3 Noise and Vibration Levels OG7 : 4 OG7:1 Chapter - Conformity Certificates...
  • Page 56 RT655 Operator’s Guide TMS RANGE ALL MODELS - (SAFETY) - ENGLISH EC DECLARATION OF CONFORMITY Manufacturer’s Name: Johnston Sweepers Limited Manufacturer’s Address: Curtis Road, Dorking, Surrey, England, RH4 1XF Declares that: Product Name: Johnston Road Surface Cleaner Product Type(s): VT501, VT651, VT801...
  • Page 57 Johnston Sweepers Limited, Curtis Road, Dorking, Surrey, RH4 1XF, England. Johnston Sweepers Ltd. hereby declares that the following equipment conforms to the requirements of EC Directive 2000/14/EC: Description of Equipment: EC Directive 2000/14/EC, Annex 1, Item 46: Power sweeper...
  • Page 58 RT655 Operator’s Guide NOISE AND VIBRATION Safety Notice ● Ear defenders are recommended when working around the machine Noise Levels All noise levels are given at maximum engine operating speeds, but in normal operation are likely to be lower than the figures quoted.

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