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  5. Original Instructions Manual

NC HT1.0 Original Instructions Manual

Manual is about: Site Dumper

Summary of HT1.0

  • Page 1

    Ht1.0 site dumper ht1.0 site dumper ht1.0 site dumper ht1.0 site dumper maintenance maintenance maintenance maintenance instruction instruction instruction instruction manual manual manual manual nc engineering (hamiltonsbawn) ltd 2 killyrudden road, hamiltonsbawn, co armagh, bt61 9sf tel: 028 38871...

  • Page 2

    2 dear customer even if you have operated this type of equipment before, it is very important that your new equipment operations and instructions are explained to you by a dealer representative following delivery of your equipment. This will explain the operating controls and enable you to gain maxi...

  • Page 3: Foreword

    3 foreword this manual has been produced to provide information on the correct operating and maintenance procedures for the nc dumper the procedures in this publication relate specifically to the nc dumper all information, specifications and illustrations used in this manual are correct at the time ...

  • Page 4: Contents

    4 contents page no. Declaration of conformity 6 noise level declaration 7 vibration declaration 8 technical specifications 9 maintenance decals descriptions 10 safety decals descriptions 12 introduction 14 technical specification 15 service record 23 service schedules 24 torque settings 27 fluids & ...

  • Page 5: Contents

    5 contents page no. Fault finding 54 dumper will not start or difficult to start (no exhaust smoke) 55 dumper will not start or difficult to start (exhaust smoke) 56 engine will not crank or cranks slowly 57 engine starts then stops 58 engine poor running 59 engine poor running at idle 60 engine exc...

  • Page 6: Engineering

    6 engineering (hamiltonsbawn) ltd. Manufacturers of agricultural and industrial equ i pment 2 killyrudden road, hamiltonsbawn, tel: 028 38871970 richhill, co. Armagh. Fax: 028 3887 0362 northern ireland. E.Mail: info@nc engineering.Com 8t619sf www.Nc-engineering.Com ec – declaration of conformity ma...

  • Page 7: Noise Level Declaration

    7 noise level declaration the noise levels are measured according to iso6395:1998 the noise level of this machine is l wa 99db ( a ) l pa 82db ( a ) l wa :- a - weighted sound power level. L pa :- a - weighted sound pressure level..

  • Page 8: Vibration Declaration.

    8 vibration declaration. The absence of a harmonised test code together with variable conditions under which this equipment may be used allows only representative figures to be quotes. Whole body vibration level : a w (m/s²) = 0.1 hand / arm : a ha ( m/s² ) ≤ 3.98 the above figures are for reference...

  • Page 9: Technical Specifications

    9 technical specifications.

  • Page 10

    10 maintenance decal descriptions the machine is fitted with a maintenance decal. It is important that before using the ma- chine the decal is understood and all the checks have been carried out. The decal must be clean and readable at all times. If the decal needs to be replaced it can be obtained ...

  • Page 11

    11 maintenance decal descriptions ref no. Symbols description. 15 grease point - hi lift rams. 16 grease point - centre point articulation casting. 17 grease point - steering ram. 18 fuel filter. 19 hydraulic oil. 20 engine checks. 21 engine coolant..

  • Page 12: Safety Decals

    12 safety decals and descriptions safety decals the machine is fitted with a number of safety decals placed in areas to draw the attention of the users. It is important that before using the machine theses decals are read and un- derstood. The decals must be clean and readable at all times, if they ...

  • Page 13

    13 safety decals and descriptions part no. Symbol. Descriptions. Dec~1920-033 sound levels. Dec~1920-034 skip controls. Dec~1920-035 do not operate controls without reading manual. Dec~1920-036 safe gradients / lower skip before moving / visibility / transport / no passengers / towing procedures / r...

  • Page 14: Introduction

    14 introduction the following maintenance sections are provided to ensure safe working practices. The procedures in this booklet should be followed. No attempt should be made to shortcut any of the steps. You or others could be killed or seriously injured if the machine is not correctly prepared and...

  • Page 15: Technical Specifications.

    15 technical specifications. Item factory specification allowable limit valve clearance (cold) 0.145 to 0.185mm 0.00571 to 0.00728in. - compression pressure difference among cylinders d1105-e2b 539 to 596 psi - 327 psi 10% or less top clearance 0.55 to 0.70mm 0.0217 to 0.0276 in. - cylinder head sur...

  • Page 16: Technical Specifications.

    16 technical specifications. Item factory specification allowable limit rocker arm shaft to rocker arm rocker arm shaft rocker arm clearance o.D. I.D. 0.016 to 0.045mm 0.00063 to 0.00177in. 11.973 to 11.984mm 0.4714 to 0.4718in. 12.000 to 12.018mm 0.4724 to 0.4731in. 0.10mm 0.0039in. - - push rod al...

  • Page 17: Technical Specifications.

    17 technical specifications. Engine body (continued) item factory specification allowable limit idle gear shaft to gear bushing idle gear 1 idle gear bushing idle gear shaft 1 idle gear 2 idle gear bushing idle gear shaft 2 clearance 0.020 to 0.054mm 0.0008 to 0.0021in. 26.000 to 26.021mm 1.0236 to ...

  • Page 18: Technical Specifications.

    18 technical specifications. Engine body (continued) item factory specifications allowable limit piston ring to piston ring groove second ring oil ring clearance clearance 0.085 to 0.112mm 0.0033 to 0.0044in. 0.020 to 0.055mm 0.0008 to 0.0021in. 0.2mm 0.0079in. 0.15mm 0.0059in. Connecting rod alignm...

  • Page 19: Technical Specifications.

    19 technical specifications. Engine body (continued) item factory specification allowable limit crankshaft to crankshaft bearing 2 crankshaft journal crankshaft bearing 2 oil clearance o.D. I.D. 0.034 to 0.095mm 0.0013 to 0.0037in. 47.934 to 47.950mm 1.8872 to 1.8878in. 47.984 to 48.029mm 1.8891 to ...

  • Page 20: Technical Specifications.

    20 technical specifications. Lubricating system item factory specifications allowable limit engine oil pressure at idle speed at rated speed more than 49kpa 0.5kgf/cm² 7psi 196 to 441kpa 2.0 to 4.5kgf/cm² 28 to 64psi - 147kpa 1.5kgf/cm² 21psi inner rotor to outer rotor clearance 0.06 to 0.18mm 0.002...

  • Page 21: Technical Specifications.

    21 technical specifications. Fuel system item factory specifications allowable limit injection pump injection timing (3000min -1 (rpm)) injection timing (3600min -1 (rpm)) 0.30 to 0.33rad (17 to 19°) before t.D.C. 0.35 to 0.31rad (15.5 to 17.5°) before t.D.C. - - injection pump (bg type) injection t...

  • Page 22: Technical Specifications.

    22 technical specifications. Fuel system item factory specifications allowable limit glow plug resistance approx 0.9Ω - starter (planetary gear reduction type) commutator difference mica brush o.D. O.D. Undercut length 30.0mm 1.181in. Less than 0.02mm 0.0008in. 0.50 to 0.80mm 0.0197 to 0.0315in. 16....

  • Page 23: Service Record Sheet

    23 service record sheet first 50 hr. Date……………………. Hour reading………….. First 100 hr. Date……………………. Hour reading………….. First 500 hr. Date……………………. Hour reading………….. First 1000 hr. Date……………………. Hour reading………….. First 1500 hr. Date……………………. Hour reading………….. First 2000 hr. Date……………………. Hour readin...

  • Page 24: Service Schedules

    24 service schedules calendar equilivants 10hours = daily 50 hours = weekly 100 hours = fortnightly 500 hours = six months 1000 hours = yearly 2000 hours = 2 years engine service points & fluid levels operation 10 hr 50 hr 200 hr 500 hr 800 hr 1000 hr 1500 hr 2000 hr 3000 hr oil level (1) check ● co...

  • Page 25: Wheel Motors

    25 wheel motors service points & fluid levels operation 10 hr 50 hr 100 hr 500 hr 1000 hr hubs check for leaks ● ● ● tightness of axle mounting bolts (torque to 244nm /180lbf ft) ● ● tightness of motor mounting bolts (torque to 135nm /100lbf ft) ● ● tightness of wheel rim nuts (torque to 170nm /125...

  • Page 26: Service Schedules

    26 service schedules dumper chassis grease points operation 10 hr 50 hr 100 hr 500 hr 1000 hr skip pivot pins (1 pin, 2 no points) ● hi lift arm pins (4 no points) ● parallel link arm pins (2 no points) ● tipping ram pins (2 no pins) ● hi lift rams (4 no points) ● centre point articulation casting (...

  • Page 27: Torque Settings

    27 torque settings use these torque settings only where no torque setting has been specified in the text. Values are for dry threads and may be within 3% of the figures stated. For lubricated threads the values should be reduced by one third. Unf grade “s” bolts bolt size hexagon (a/f) torque settin...

  • Page 28: Kubota Torque Settings

    28 kubota torque settings tightening torques for general use screws, bolts and nuts. Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening, be sure to check out the numbers as shown below. Punched number screw and bolt material grade none or 4 s...

  • Page 29: Engine Torque Settings

    29 engine torque settings tightening torques for special use screws, bolts and nuts. Note • for “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening • the letter “m” in size x pitch means that the screw, bolt or nut dimension stands for metric...

  • Page 30: Fluids & Lubricants

    30 fluids & lubricants engine lubricating oil new engines require a running-in period of 200 hours. During this period the dumper should be driven as normal, there is no special need for lower revs, it is ok to drive it a maximum revs but the oil level should be checked twice a day. The dumper shoul...

  • Page 31: Fluids & Lubricants

    31 fluids & lubricants coolant mixtures anti-freeze can be harmful. Obey the manufacturers instructions when handling neat or diluted antifreeze. Nc recommends “comma xstream hd” anti-freeze. If another anti-freeze is used refer to the manufacturers instructions and ensure a corrosion inhibitor is i...

  • Page 32: Fluids & Lubricants

    32 fluids & lubricants fuel specification the quality and grade of fuel can seriously affect the lubrication and overall service life of the fuel injection pump. It is vitally important that the correct grade of fuel is used. Fuel filter/water separator must be checked daily and cleaned if necessary...

  • Page 33: Fluids & Lubricants

    33 fluids & lubricants low fuel be careful not to let the dumper run out of fuel. A low fuel warning light is on the instrument display will illuminate when the fuel level drops to the minimum recommended level. If the dumper runs out of fuel it will be necessary to bleed the fuel system before the ...

  • Page 34: Fluids & Lubrication

    34 fluids & lubrication hydraulic oil hvz 46 high viscosity. (blue colour) din51524-3 viscosity index 150 (nc use a uv dye in the hydraulic oil for testing for leaks this colours the oil a green/brown) donot use zinc free hydraulic oils general grease points multi purpose grease.

  • Page 35: For Your Safety

    35 for your safety if the dumper develops a fault • park the machine in a safe area if possible. If this is not possible take measures to warn others of the machine position. • remove the start switch key. • contact a qualified person to rectify the fault. • do not place any part of the body in any ...

  • Page 36: Maintenance

    36 maintenance before you start • clean the machine before starting any maintenance. • allow the machine to cool. • ensure strict cleanliness is observed at all times. • do not smoke near any fluids. • beware of scalding from hot oils, check oil temperature before draining. • when checking fluid lev...

  • Page 37: Battery Location

    37 battery location the battery is located in the left-hand side under the engine cover (b). It is accessed by unlocking latch (a) on the panel and then pulling lifting it up upwards. Remove the black battery protector (c) to gain access to the battery battery • always wear safety glasses when worki...

  • Page 38: Battery Isolator

    38 battery isolator the battery isolator must always be used when carrying out service or maintenance work. It would be dangerous if the engine was to be started or the electrical system activated. When the battery isolator lever is in the on (a) position the machine electrical circuit is fully acti...

  • Page 39: Maintenance

    39 maintenance air cleaner servicing the air cleaner needs serviced when the yellow level (a) comes into the red (b) on the window on the visual indicator reads and 50 mbar (c). This should be one of the daily machine checks. Maximum protection for the engine against dust is possible only if the air...

  • Page 40: Maintenance

    40 maintenance checking coolant level always check the coolant level when engine is cold this is a pressurised cooling system to prevent scalding never remove the filler cap when the coolant is hot hot coolant will burn you. Always check the engine is cool before checking the coolant level or draini...

  • Page 41: Maintenance

    41 maintenance checking engine oil level • clean away all dirt from around the dipstick and tube. • ensure the engine oil is warm (not hot) and dumper is positioned on firm, level ground. • pull the dipstick (a) from the engine, wipe the oil off the dipstick using clean paper roll. • put the dipstic...

  • Page 42: Maintenance

    42 maintenance draining engine oil it is illegal to pollute, drains, sewers or the ground. Clean up all spilt fluids and or lubricants. Used fluids and or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. • e...

  • Page 43: Maintenance

    43 maintenance hydrostatic drive oil to ensure proper lubrication and operating temperatures of the drive pump & wheel motors it is important that the appropriate grade of lubricants are used and the correct oil level maintained. This level should be checked daily. Nc recommend hvz 46 high viscosity...

  • Page 44: Maintenance

    44 maintenance towing procedure opening the high pressure circuit • unscrew bypass valve (a) by 2 turns releasing parking brakes • remove & dispose of the rubber plug from the brake protector (b). • place the 25mm steel flat over the drum. • tighten the bolt to the bottom of the threading in the whe...

  • Page 45: Maintenance

    45 maintenance brake system when the accelerator pedal is pressed a switch is activated which sends a signal to energise the solenoid on the brake release valve. This links the pilot pressure from the charge pump of the hydrostatic drive pump to release the brakes. When the pedal is released the swi...

  • Page 46: Maintenance

    46 maintenance hydraulic system the hydraulic system provides power to the driven wheels, steering, hi-tip and skip tip functions. The hydraulic tank is made from steel and forms part of the structure of the dumper. The hydraulics system comprises of a axial piston pump providing the power for drivi...

  • Page 47

    47.

  • Page 48: Maintenance

    48 maintenance hydraulics during any hydraulic maintenance extreme care should be taken to ensure cleanliness of the hydraulic circuit. By observing strict hydraulic cleanliness the machine will benefit from fewer hydraulic failures through contamination. Always • thoroughly clean the machine before...

  • Page 49: Maintenance

    49 maintenance adding hydraulic oil remove tank filler cap (a) and add oil. Add clean, filtered hydraulic oil. The oil level should always be above the suction strainer in the tank, ideally just below the top (b) of the visual indicator. Do not over fill the hydraulic tank as it needs room to vent a...

  • Page 50: Maintenance

    50 maintenance changing the filter element at the required service interval the element in the rkm suction flow /return flow filter (a) will need changing. • unscrew the cap (b) on the top of the rkm filter (a), there will be oil in this filter, it may spill over on to the tank and will take a few m...

  • Page 51: Maintenance

    51 maintenance storage if the dumper is to be stored for a long period of time the following procedures should be applied. • thoroughly wash down the exterior of the machine and remove any build-up of material. • grease all greasing points. • start the engine to warm it up. Drain the engine oil and ...

  • Page 52: Maintenance

    52 maintenance electrics relay & fuse box layout description specification battery 12v type: h075 550cca, 59ampere-hour capacity alternator 40a belt driven the alternator is very sensitive to temperature. High temperatures will affect the performance of the alternator and may eventually cause damage...

  • Page 53

    53.

  • Page 54: Fault Finding

    54 fault finding introduction the dumper must be correctly parked and prepared. Maintenance personnel must be suitably qualified and trained. Failure to observe these this notice could result in serious injury of yourself or others the fault finding procedures are given in the form of flow charts ea...

  • Page 55: Fault Finding

    55 fault finding chart a1—dumper will not start or difficult to start (no exhaust smoke) cause remedy no fuel in tank. Check the level in the fuel tank and replenish as required. Display gauge not powering up. • check battery. • check main line fuses 50a. • check fuses in fuse box behind the steerin...

  • Page 56: Fault Finding

    56 fault finding chart a2—dumper will not start or difficult to start (exhaust smoke) cause remedy cold starting aid not working (if fitted). Check for the correct operation of the glow plugs. Intake air insufficient. Visually check the air intake and exhaust intake for blockage or obstruction, remo...

  • Page 57: Fault Finding

    57 fault finding chart a3—engine will not crank or cranks slowly cause remedy starting electrical connections loose or corroded. Clean and tighten connections. Battery charge low. Check battery voltage, charge the battery or replace as required. Make sure that the alternator is functioning correctly...

  • Page 58: Fault Finding

    58 fault finding chart a4—engine starts then stops cause remedy no fuel supply in tank. Check the level in the fuel tank and replenish as required. Engine starting under load. Check for added loading form malfunctioning accessories or driven units, brakes dragging and other changes in the vehicle lo...

  • Page 59: Fault Finding

    59 fault finding chart a5—engine poor running cause remedy condition occurs only at idle. Refer to chart a6 for possible poor running at idle faults. Fuel injection lines leaking inspect and correct as required leaks in the high pressure lines, fittings injector sealing washers, or delivery valves. ...

  • Page 60: Fault Finding

    60 fault finding chart a6—engine poor running at idle cause remedy idle speed too low for accessories. Adjust the idle speed. Refer to the machines service manual for correct adjustment procedures and idling speed. Engine mounts over-tightened, damaged or loose. Verify the condition of the mounts, a...

  • Page 61: Fault Finding

    61 fault finding chart a7—engine excessive noise cause remedy drive belt squeal, insufficient tension or abnormally high loading. Check the tensioner and inspect the drive belt for deterioration. Make sure the water pump, tensioner pulley, fan and alternator turn freely. Check for paint/oil or other...

  • Page 62: Fault Finding

    62 fault finding chart a8—engine compression knocks cause remedy fuel is aerated. Check the fuel system for loose connections and possible air ingress points. Rectify and bleed the fuel system. Fuel is contaminated or incorrect grade of diesel used. Refer to fluids & lubricants section for recommend...

  • Page 63: Fault Finding

    63 fault finding chart a9—engine reduced power output cause remedy no fuel supply in the tank. Check the level in the fuel tank and replenish as required. Oil level incorrect. Check oil level. Engine overloaded. Check for added loading from malfunctioning accessories or driven units, brakes dragging...

  • Page 64: Fault Finding

    64 fault finding chart a9—engine reduced power output (continued) cause remedy exhaust leak at the manifold. Check/correct leaks in the manifold gasket. Look for a cracked manifold. Extra injector sealing washer installed under injector. Remove extra injector sealing washer. Inlet & exhaust valve cl...

  • Page 65: Fault Finding

    65 fault finding chart a10—engine will not reach maximum rpm cause remedy tachometer faulty (if fitted). Verify the engine speed with a hand held tachometer. Measure on the fan drive pulley and this will be the engine rpm. Engine overloaded. Verify high idle speed without load. Investigate operation...

  • Page 66: Fault Finding

    66 fault finding chart a11—engine rpm surges cause remedy fuel level low. Check/fill fuel tank. If the condition occurs at idle, the idle speed is set too low for the accessories. Check the engine idle rpm setting. Throttle adjustment incorrectly set or binding. Check the engine maximum rpm is as sp...

  • Page 67: Fault Finding

    67 fault finding chart a12—engine excessive vibration cause remedy engine not running smoothly/missing. Refer to chart a5. Oil level over full. Check oil level. If the condition occurs at idle, the idle speed is set too low for the accessories. Check the engine idle rpm setting. Fan damaged or acces...

  • Page 68: Fault Finding

    68 fault finding chart a13—engine exhaust smoke excessive (black smoke) cause remedy air intake or exhaust system is blocked. Visually check the air intake and exhaust intake for blockage or obstruction-remove as required. Check the air filter elements for signs of blocking-replace as required. Exha...

  • Page 69: Fault Finding

    69 fault finding chart a14—engine exhaust smoke excessive (white/blue smoke) cause remedy fuel is contaminated or incorrect grade of diesel used. Refer to fluids & lubricants section for recommended diesel fuels. If the fuel is suspect, verify by operating the engine with clean fuel from a temporary...

  • Page 70: Fault Finding

    70 fault finding chart a15—engine will not shut off cause remedy electrical fuel solenoid valve not functioning properly. Check for correct operation of the fuel solenoid valve. Worn or malfunction fuel injection pump (fip). Injection pump not delivering fuel. Check for operation of the fip. The fip...

  • Page 71: Fault Finding

    71 fault finding chart b1—fuel consumption excessive cause remedy additional load on engine. Check/repair accessories and vehicle components. Operator technique. Review operation for acceleration, deceleration and idling. Fuel leaks. Check for external leaks and engine lubricating oil dilution. For ...

  • Page 72: Fault Finding

    72 fault finding chart b2—fuel/oil leaking from exhaust manifold cause remedy operating for extended periods under light or no load. Review operation for acceleration, deceleration and idling. Intake air or exhaust leaks. Refer to charts a13 & a14. Exhaust leak at the manifold. Check/correct leaks i...

  • Page 73: Fault Finding

    73 fault finding chart c1—lubricating oil consumption excessive cause remedy oil leaks. Inspect the engine for visible signs of leaks. Pay particular attention to the seals, gaskets, oil cooler and external connections. Oil level over full. Check oil level. Incorrect lubricating oil. (specification ...

  • Page 74: Fault Finding

    74 fault finding chart c2—lubricating oil contaminated cause remedy coolant in the lubricating oil, internal engine component leaks. Refer to chart d1. Lubricating oil sludge excessive. Change oil & filter. Review/reduce the lubricating oil change intervals. If operating in arduous conditions change...

  • Page 75: Fault Finding

    75 fault finding chart c3—lubricating oil pressure low cause remedy incorrect lubricating oil. (specification of viscosity). Make sure the correct lubricating oil is being used, refer to fluids & lubricants section. Look for reduced viscosity from dilution with fuel. Fuel dilution in lubricating oil...

  • Page 76: Fault Finding

    76 fault finding chart c4—lubricating oil pressure high cause remedy incorrect lubricating oil. (specification of viscosity). Make sure the correct lubricating oil is being used, refer to fluids & lubricants section. Look for reduced viscosity from dilution with fuel. Fuel dilution in lubricating oi...

  • Page 77: Fault Finding

    77 fault finding chart d1—coolant loss cause remedy incorrect coolant level. Check the level. Coolant leaking from engine radiator. Visually inspect the radiator hoses and connections to locate the leak. If oil is present in the coolant, check for an engine oil cooler leak. External engine coolant l...

  • Page 78: Fault Finding

    78 fault finding chart d2—coolant over temperature cause remedy incorrect coolant level. Check the level. Ensure low level is not a result of a coolant leak. Refer to chart d1. Radiator matrix blocked with dirt or chaff. Clean radiator matrix. Air flow to the radiator restricted clear the louvers on...

  • Page 79: Fault Finding

    79 fault finding chart d3—coolant under temperature chart d4—coolant contaminated cause remedy air flow across radiator excessive. Check/repair the mesh grill on the bonnet. Check/repair the fan shroud, anti recirculation sealing. Check fan blades replace if necessary. Temperature gauge sensor fault...

  • Page 80: Fault Finding

    80 fault finding chart e1—poor hydrostatic drive performance cause remedy poor road speed at full engine revs check hydraulic oil level check move off rpm & adjust if necessary test pressure on g port on pump test pressure on ports m1 & m2 on pump contact nc regarding refurbishment or replacement du...

  • Page 81: Fault Finding

    81 fault finding chart e2—noisy wheel motor.

  • Page 82: Fault Finding

    82 fault finding chart e3—wheel motor does not revolve.

  • Page 83: Fault Finding

    83 fault finding chart e4—wheel motor does not revolve at its normal speed under load.

  • Page 84: Fault Finding

    84 fault finding chart e5—wheel motor revolves irregularly chart e6—wheel motor leaks.