PI616 V Range What's Changed

Product Information PI616
Sheet 1 of 20
Subject Introducing the new V Range
Revision: A
Series V501, V651, V801
Release Date: 17.09.2012
ECM: 709328
The V500, V650 and V800 models are being replaced by the V501, V651 and V801. This
document highlights the main changes implemented, most of which are evolutionary improvements
suggested by our customers across the world.
Chassis
Feature Improvement / Benefit
Subframe height increased by 50mm to More robust and versatile without adding any
150mm additional weight.
It also increases the accessibility of parts mounted
within the subframe feature giving better access for
design packaging and maintenance.
Old New
Range of subframes has been reduced. Only one width available and length is selected
automatically by configuration. Mounting height still
needs to be selected. Reduces the possibility of
ordering errors.
Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Tel: +44 (0)1306 884722 Fax: +44 (0)1306 884151
www.johnstonsweepers.com E-mail: enquiries@johnstonsweepers.com
The Information in this bulletin should not be interpreted as the basis for any claims unless so designated by Johnston Sweepers Limited. Form No.404 Issue 009/09
Sheet 2 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Body rear pivot point has moved towards the This allows more clearance for the body to tip over
rear of the vehicle. rear mounted equipment – fuel tanks etc.
Discharge block Has been separated from the main sweeper block
and moved from the systems wafer to outside the
subframe. This gives better access for maintenance
and, in case of systems failure, the possibility of
manual override to lift the body.
New
Steel Hydraulic piping All hydraulic piping that does not need to flex has
been changed to steel; reducing the chance of
failure, tidying up the hydraulic plumbing and
ultimately reducing maintenance costs and making
the product more robust.
Old New

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Sheet 3 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Powerpack
Compliant Auxiliary Engines In many territories, legislation now requires Stage 3b
or Tier 4i auxiliary engines. We are now able to offer a
range of engines to suit both the legal requirement of
the market and our customers’ power requirements.
Old New
Engine Range: Engine Range:
Stage 3a 24V FPT 66kW Stage 4/Tier 4 12V/24V JCB 55kW/74hp
Stage 3a 24V FPT 104kW Stage 3b/Tier4i 12V/24V JCB 93kW/125hp
Tier 3 12V JD 86kW/115hp Tier 3 12V JD 86kW/115hp
Tier 3 12V JD 63kW/84hp Stage 3a 24V JCB 85kW/114hp
VS 12V/24V Hydrostatic VS 12V/24V Hydrostatic
New JCB Engines We have chosen JCB to be our primary auxiliary
engine supplier for the VT (twin engined) versions of
our new range with the following key benefits:
- Better fuel consumption than our competitors
- Emission compliance
- World wide support
- Reduced maintenance through simple design.
- No ‘Ad-blue’ tank
- No Diesel Particulate Filter.
- Rigid bedplate reduces vibration and noise
generation.
- There is no requirement for the size of our skid
units to increase to house the new engines.
All daily auxiliary engine checks (on JCB Reduces maintenance and the need to climb up onto
electronic engines 55kW & 93kW) can now be the power pack. Includes low oil level, low coolant level
carried out from inside the cab. and air filter blockage warnings.

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Sheet 4 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
JCB Aux Engine 55kw / 74hp The JCB 55kW engine is ahead of current emission
Stage 4/Tier 4 (12 & 24volt) standards being Stage 4 / Tier 4 compliant - making the
choice “future proof”.
Maximum Torque : 400Nm @ 1250 rpm
Fuel Usage : 208 g/kWh @ 1400 rpm
JCB Aux Engine 93kW / 125hp

Stage 3b/Tier 4 Interim (12 & 24volt) Maximum Torque : 550Nm @ 1500 rpm
JCB Aux Engine 85kW / 114hp Johnston will still be providing the option of a Stage 3a
Stage 3a (24volt only) engine for 24 volt territories not governed by the
emissions legislation above. In addition this engine is able
to tolerate poorer quality fuel.

John Deere Aux Engine 86kW / 115hp Johnston will still be providing the option of a Tier 3 JD
Tier 3 (12volt only) engine for 12 volt territories that are either covered by flex
rules or not governed by the more stringent emissions
legislation above. In addition this engine is able to tolerate
poorer quality fuel.

Eco Mode Econ Mode is provided and automatically activated as

standard.
All aux engines are initially limited to 1500rpm, reducing
noise emissions, fuel consumption. There is an easy
manual override button (circled) if more power is required.
This feature is designed to discourage operators
continually working at maximum power.
Remote fluid drains Remote drainage points are now provided as standard for
aux engine coolant, hydraulic oil tank, engine oil &
gearbox oil. Easier & cleaner maintenance.

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Sheet 5 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Body & Cowl

Moulded high strength plastic fuel tank Overall weight reduced, increasing potential payload.
The tank is still 190L.
Johnston have introduced a new anti-slosh plate
which in integrated into the fuel filler neck.
Old New
Newly designed systems locker Opening mechanism improved allowing better access
to the components stored within the systems locker.
LED light is now supplied as standard. All fuses have
been moved from the cab to the systems locker.
Old New
New “Garage door” style opening mechanism

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Sheet 6 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Flush fitting side lockers now available as standard This allows storage on the V501 and the V801 without
on V501, V651 & V801 machines. the need for additional storage boxes and does away
with the need to offer front or rear wanderhose
extension storage trays.
Old New
The external opening for the hydraulic oil filler has Allows easier filling if there is a hydraulic failure and
been increased the hopper is down.
Rear discharge chute has been redesigned giving Reduces the potential to ‘lose’ debris & water from the
side retainers as standard. side of the chute when discharging the load.
Old New

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Sheet 7 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Rear hopper screens changed to allow easier Cleaning of the hopper screens is now able to be
access and cleaning carried out with only one hand and is far more
efficient with less chance of injury to hands
Old New
Intake duct seals are now clamped, not glued Reduced chance of failure, more secure. Reduced
maintenance costs.
Old New
The rubber skirt seal on the cowl has now been This reduces potential noise pollution by creating a
changed to a three piece design and clamped rather better seal between cowl and subframe. It also
than glued. reduces potential maintenance costs by allowing the
operator to replace only one side instead of the whole
item.

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Sheet 8 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Make and break fan seal moved from the cowl to This reduces maintenance by making the seal easier
the fan casing. to fit and more accessible. This also increases the
health and safety aspect of the system reducing the
possible chance of injury.
Old New
No wafer pack in cowling. The airflow is directly exhausted through a protective

hood. Allows increased ease of access for servicing
and reduces ‘working at height’ concerns.
Old New
Air is directly exhausted through the top of the
cowl.

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Sheet 9 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Discharge pendant For tipping the hopper, opening/closing the door, also
controls wide sweep brush balancing. Now has a
status LED to show that it is OK to use, i.e. handbrake
is active, there is power available etc.
Old New
Body height The body height of all machines increases by 50mm

(due to the increase in the subframe height). In addition
the VT501 increases by 230mm to be the same height
as the VT651.The V605 model is discontinued.
The body sensors have been changed from This increases reliability and reduces maintenance by
contact sensors (micro switches) to ‘non-contact’ reducing the possibility of the sensors becoming
sensors damaged or clogged up with debris.

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Sheet 10 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Rear Door
New one piece rear door The new modular design builds from a standard flat
panel door, similar to the old “contractors door”.
- A perforated load dewatering panel is added to
the inside of the door when the Load
Dewatering” option is specified.
- A wedge wire screen with additional primary
screen is added when the “Water Recirculation”
option is specified.
All are designed to be easy clean.
Old standard door with water recirculation screens: New standard door:
New Water Recirculation screens:

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Sheet 11 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Rear door hinge bushes have been improved. Bushes have been changed from plastic to molybdenum
and a grease nipple added.
This avoids the potential ‘binding’ of the pins to the rear
door, ripping the door flaps off and other potential
damage.
Old New
Some older machines have suffered from a rust

build up on the hinges and subsequent binding..
Closing mechanism is now single cylinder with This is a simplified design, eliminating the need for
‘non-contact sensors’. contact sensors offering reduced maintenance and
replacement costs.
Old mechanism New
Screens on rear door are now secured with linch Aids access and cleaning and reduces hand injury.
pins, not ‘R’ clips.
Old New

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Sheet 12 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Sweepgear
New channel brush motors A sleeve has been added to eliminate potential
corrosion and offer added protection against binding.
A labyrinth has also been added to further protect the
shaft seal.
The same motor is used for the 500mm and 650mm
brush and is common to both the Wide Sweep Brush
and the C201 range reducing the number of parts
needing to be held in stock.
Old New
Some older machines have suffered from binding

breaking the seals of the units.
New sweepgear legs and mounts Has been updated and modernised providing a
positive fixing and a more robust design without any
additional weight being added. The old system used
‘U’ bolts.
Old New

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Sheet 13 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
New manual nozzle adjustment mechanism Due to the update in design there is now no possibility
for the nozzle adjustment mechanism to ‘jump off’ the
setting when going over bumps.
Old New
New wide sweep brush balancing mechanism The wide sweep brush balance is now set
electronically with the pendant control together with the
JVM panel.
The complexity surrounding the old adjustment
regulators has been replaced.
Old New
Intake duct flaps are now fully automated There is no longer a button for intake duct flaps, as the
controls are now fully automated. This reduces the
drivers need to manually manage the intake duct flaps
and increases the efficiency of the machine.

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Sheet 14 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Wanderhose
V501 Rear Wanderhose As the V501 is taller, it allows us to offer the rear
mounted wanderhose previously only available on the
V650 & V800 models.
Hose trays not supplied on VT501 or VT801. Hose trays are no longer required due to the
introduction of side lockers on all vehicles allowing
stowage in the side lockers.
Water Systems
New low pressure water jets at Gutter and Flow reduced from 3 l/min to 1.5 l/m per pair of jets.
Channel Brush. Changed to use less water allowing for longer ‘on-
station’ time before refilling. Higher flow jets can still
be fitted as a retrofit if required
Old New
Water connectors now have quick ‘push in’ This reduces maintenance time allowing quicker
fittings serviceability.

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Sheet 15 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Unique self-cleaning nozzle jets introduced Johnston has introduced new ‘self-cleaning’ nozzle
jets as standard reducing maintenance and potential
downtime.
Old New
Water capacities have increased on all models. Longer on station time without refilling allowing
V501 increased 360L to 1360L. increased efficiency.
V651 increased 272L to 1572L.
V801 increased 173L to 2023L
Body water tank outlet and high pressure This gives better water usage when the hopper is
pump water sensor has been relocated further raised. Allowing for more water capacity to the water
to the rear of the body. system at the end of the shift when the body needs to
be cleaned out with the Supawash option
Old New

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Sheet 16 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
The ‘Pressadrain’ water purging system is now A menu on the JVM allows the machine to
automated. automatically purge the water from the lines, reducing
the potential of damage from frozen pipes or frost in
cold environments. Simple step by step instructions
are provided on screen.
Old New
There is no longer an external sight ‘pea’ to view There is now a visual display on the JVM displaying
water levels. the water levels.
Old New
In-Cab
All new sweeping controls Ergonomically positioned giving the operator a better
sweeping position.
The number of sweep gear controls have been reduced
by half and moved to a pod mounted on the driver’s door;
perfectly placed to continuous operation.

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Sheet 17 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Can-Bus control system Easy fault diagnostics, lighter/simpler looms, Intuitive

display, key information recorded.
Old New

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Sheet 18 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Data Capture facility Due to the move to Canbus, it is now possible to record
various items of data for better control and analysis of
sweeping operations – just like the C201.
Information available:
Total auxiliary engine hours; Engine hours today; Total
engine hours in work mode; Engine hours in work mode
today; Average workmode RPM; Average workmode
RPM today; Avg Fuel consumption to date; Avg fuel
consumption today; Avg workmode fuel consumption to
date; Avg workmode fuel consumption today; Hours at
last service; Hours until next service.
A Johnston USB stick can be inserted to the bottom left
hand corner of the screen and the data downloaded.
Transfer the USB stick to a computer and all the data is
provided in an excel table – perfect for easy analysis.
One button “Pause” (programme/ergo) The machine now remembers the previous settings used
operation in the prior workmode. Therefore in the morning, if all
settings are to be kept the same as the day before, it is
possible to engage the unit with identical settings at the
push of one button. In addition, to reduce fuel
consumption and general emissions, the auxiliary engine
rpm reduces to 1200 after ~20 seconds but will resume
the original rpms when the pause (programme) button is
reactivated.
New

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Sheet 19 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Electrical Systems
Electrical connectors and looms have been re- Improves reliability and durability by reducing the risk of
routed and given protected locations. water ingress at vulnerable locations.
New discharge pump operation The electrical discharge pump (previously used when
hydraulics have failed), will now lift the hopper even when
the engine is not running allowing alternative operation
with reduced emissions.
Old New
In Cab Channel Brush Controls In-cab controls allow the operator to set channel brush
speeds via a simple switch rather than a separately
mounted regulator. This also simplifies the interface
between the chassis and the body allowing for easier
body mounting.
Old New
Options control panel no longer required Reduces parts requirements

Systems control panel Now only needed for Water Recirculation and Variagap.
Beacon & Lighting

Rear work lights option, mounted to the rear of Have been changed to LED increasing durability and
the hopper reducing maintenance

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Sheet 20 of 20
Revision: A
Series V501, V651, V801
ECM: 709328
Cowl work light option has been changed to Has been changed to LED increasing durability and
LED when the option is selected. reducing maintenance
Optional LED Channel Brush Worklights Increasing durability and reducing maintenance
New Beacons Strobe beacons have been discontinued and replaced

with R65 compliant LED. Rotating beacons remain the
standard.
Miscellaneous Changes
New wider aluminium folding inspection ladder & Offers a more comfortable “3 points of contact” when
grab handle working or climbing to the aux engine
Old New
Higher commonality of pneumatic cylinders used Inlet flap, Wide Sweep Brush and Nozzle lift cylinders are
now all common..
For more information on the technical aspects of this product or any other questions that may
arise, please contact sales administration on : enquiries@johnstonsweepers.com
Due to continuous product development, Johnston Sweepers Ltd reserves the right to alter specifications without prior notice.

Tel: +44 (0)1306 884722 Fax: +44 (0)1306 884151

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Product Information PI616

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

JCB Aux Engine 93kW / 125hp

Maximum Torque : 440Nm @ 1300 rpm

Maximum Torque : 480Nm @ 1600 rpm

Eco Mode Econ Mode is provided and automatically activated as

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Body & Cowl

New “Garage door” style opening mechanism

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

No wafer pack in cowling. The airflow is directly exhausted through a protective

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Body height The body height of all machines increases by 50mm

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

New Water Recirculation screens:

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Some older machines have suffered from a rust

Old mechanism New

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Some older machines have suffered from binding

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Can-Bus control system Easy fault diagnostics, lighter/simpler looms, Intuitive

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

Options control panel no longer required Reduces parts requirements

Beacon & Lighting

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

New Beacons Strobe beacons have been discontinued and replaced

Johnston Sweepers Limited, Curtis Road, Dorking, Surrey RH4 1XF

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PI616 V Range What's Changed

PI616 V Range What's Changed