NC HT1.0 User manual

HT1.0 Site Dumper
HT1.0 Site DumperHT1.0 Site Dumper
HT1.0 Site Dumper
MAINTENANCE
MAINTENANCE MAINTENANCE
MAINTENANCE
INSTRUCTION
INSTRUCTION INSTRUCTION
INSTRUCTION
MANUAL
MANUALMANUAL
MANUAL
NC ENGINEERING (HAMILTONSBAWN) LTD
2 Killyrudden Road, Hamiltonsbawn, Co Armagh, BT61 9S
Tel: [phone] ax: 028 38870362
email: [email protected]om www.nc-engineering.com
REVISION B
ORGINAL INSTRUCTIONS

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 maximum productivity from your new dumper.

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 of
issue. NC reserves the right to make changes in this manual at any time without prior notice.
Copyright © 2010 NC Engineering (Hamiltonsbawn) Ltd
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system or transmitted in any form or by any other means, electronic, mechanical,
photocopying or otherwise without prior permission of
NC Engineering (Hamiltonsbawn) Ltd

4
Contents
Page No.
De laration of Conformity 6
Noise Level De laration 7
Vibration De laration 8
Te hni al Spe ifi ations 9
Maintenan e De als Des riptions 10
Safety De als Des riptions 12
Introdu tion 14
Te hni al Spe ifi ation 15
Servi e Re ord 23
Servi e S hedules 24
Torque Settings 27
Fluids & Lubri ants 30
Safety Information 35
Maintenan e 36
Battery 37
Air Cleaner 39
Coolant System 40
Engine Oil Check / Change 41
Hydraulic Oil Check 43
Towing Procedure 44
Brake System 45
Hydraulic System 46
Storage 51
Electrics 52

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 excessive noise 61
Engine compression knocks 62
Engine reduced power output 63
Engine will not reach maximum rpm 65
Engine rpm surges 66
Engine excessive vibration 67
Engine exhaust smoke excessive (Black smoke) 68
Engine exhaust smoke excessive (White / Blue smoke) 69
Engine will not shut off 70
uel consumption excessive 71
uel / Oil leaking from exhaust manifold 72
Lubricating oil consumption excessive 73
Lubricating oil contaminated 74
Lubricating oil pressure low 75
Lubricating oil high pressure 76
Coolant loss 77
Coolant over temperature 78
Coolant under temperature 79
Coolant contaminated 79
Poor hydrostatic drive performance 80
Noisy wheel motor 81
Wheel motor does not revolve 82
Wheel motor does not revolve at its normal speed under load 83
Wheel motor revolves irregularly 84
Wheel motor leaks 84

6
Engineering (Hamiltonsbawn) Ltd.
Manufacturers of Agricultural and Industrial Equipment
2 Killyrudden Road, Hamiltonsbawn, Tel: 028
38871970
Richhill, o. Armagh.
Fax: [phone]
Northern Ireland. E.mail: info@nc engineering.com
8T619SF www.nc-engineering.com
EC – DECLARATION OF CONFORMITY
Machine description : Site Dumper
Make NC
Type HT1.0
Manufactured by NC Engineering (Hamiltonsbawn) Ltd
Address: 2 Killyrudden Road, Hamiltonsbawn Richhill,
Co. Armagh. BT61 9S
This machinery has been designed and manufactured in accordance with the following European
Standards: -
2006/42/CE: Ma hinery Dire tive
Measured Sound Power Level: 98 dB LWA
Guaranteed Sound Power Level: 99 dB LWA
Net Installed Power: 18kW
A technical construction file for this machine is retained at the above address.
Declaration
Signed: ______________________________________
Name: David Wilson CEng; MSc; MIAgrE
Being the responsible person appointed by the manufacturer (or nominated representative of the manufacturer established in
the EC) and employed by:
NC Engineering (Hamiltonsbawn) Ltd
This declaration of Conformity complies with Regulation 22 of The Supply of Machinery (Safety) Regulations 1992

7
Noise Level De laration
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.

8
Vibration De laration.
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 purposes only. It is the responsibility of the employer to access
vibration exposure based on the actual site conditions and operating practices at the point of use.
Employers should not rely solely on published vibration figures when undertaking risk assessments.
Depending on the site conditions cycle times may need to be adjusted in order to reduce operator
exposure levels.

9
Te hni al Spe ifi ations

10
Maintenan e De al Des riptions
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 from
the NC Spares department.
Ref No. Symbols Description.
1 Engine oil level.
2 Engine coolant level.
3 uel and water sedimentor.
4 Axle service points.
5 Hydraulic oil level.
6 Air filter restriction indicator.
7 Axle oil.
8 Check evacuator and drain.
9 Engine oil filter.
10 Hydraulic return to tank filter.
11 Grease point - Skip pivot pins.
12 Grease point - Hi lift arm pins.
13 Grease point - Parallel link arm pins.
14 Grease point - Tipping ram pins.

11
Maintenan e De al Des riptions
Ref No. Symbols Description.
15 Grease point - Hi lift rams.
16 Grease point - Centre point articulation casting.
17 Grease point - Steering ram.
18 uel filter.
19 Hydraulic oil.
20 Engine checks.
21 Engine coolant.

12
Safety De als and Des riptions
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 need to be replaced
they can be obtained from NC spares department.
Part No. Symbol. Descriptions.
DEC~1920-002 Hydraulic oil.
DEC~1920-003 uel.
DEC~1920-010 Ignition key positions.
DEC~1920-012 Seat belt must be worn.
DEC~1920-016 No repairs to ROPS.
DEC~1920-017 Pinch points.
DEC~1920-019 Caution moving parts / Do not open when hot.
DEC~1920-027 it skip prop before accessing area.
DEC~1920-031 Battery.
DEC~1920-032 Wheel nut torque / Tyre pressure.

13
Safety De als and Des riptions
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 / Read manual.
DEC~1920-037 Maintenance decal.
DEC~1920-043 Keep clear of tipping area.

14
Introdu tion
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 ould be killed or seriously injured if the ma hine is not
orre tly prepared and maintained.
Maintenan e must be arried out by suitably qualified personnel only
To ensure the best performance of the machine ensure the service tasks are carried out at the
correct intervals (see service schedules)
If the machine is working in adverse conditions, then the service intervals should be reduced.
Examples of adverse conditions are:
• Operating with low quality fuel (See Fluids & Lubri ants section for more information)
• Operating in a very dusty environment
• Operating continuously at high engine load
• Operating in an environment with lots of chaff
• Operating in an extremely hot or cold environment
• Operating continuously on slopes
• Operating continuously at high altitude
• Operating in an environment with high humidity

15
Te hni al Spe ifi ations.
Item Fa tory Spe ifi ation 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 Surface latness - 0.05mm
0.0020in.
Valve Recessing Intake and Exhaust -0.05 to 0.25mm
-0.0020 to 0.0098in
0.40mm
0.0157in.
Valve Stem to Valve Guide
Valve Stem
Valve Guide
Clearance
O.D.
I.D.
0.035 to 0.065mm
0.0014 to 0.0025in.
6.960 to 6.975mm
0.2741 to 0.2746in.
7.010 to 7.025mm
0.2760 to 0.2765in.
0.10mm
0.0039in.
-
-
Valve ace Angle (Intake)
Angle (Exhaust)
1.047 rad
60°
0.785 rad
45°
-
-
Valve Seat Angle (Intake)
Angle (Exhaust)
Width
1.047 rad
60°
0.785 rad
45°
2.12mm
0.0835in.
-
-
Valve Spring ree Length
Tilt
Setting Load
37.0 to 37.5mm
1.457 to 1.476in.
-
117.4N / 31.0mm
11.97kgf / 31.0mm
26.4lbs / 1.22in.
36.5mm
1.437in.
1.0mm
0.039in.
100.0N / 31.0mm
10.2kgf / 31.0mm
22.5lbs / 1.22in.
Engine Body

16
Te hni al Spe ifi ations.
Item Fa tory Spe ifi ation 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 Alignment - 0.25mm
0.0098in.
Tappet to Tappet Guide
Tappet
Tappet Guide
Clearance
O.D.
I.D.
0.020 to 0.062mm
0.0008 to 0.0024in.
19.959 to 19.980mm
0.7858 to 0.7866in.
20.000 to 20.021mm
0.7874 to 0.7882in.
0.07mm
0.0028in.
-
-
Timing Gear
Crank Gear to Idle Gear 1
Idle Gear 1 to Cam Gear
Idle Gear 1 to Injector Pump Gear
Idle Gear 1 to Idle Gear 2
Idle Gear 2 to Governor Gear
Backlash
Backlash
Backlash
Backlash
Backlash
0.032 to 0.115mm
0.0013 to 0.0045in.
0.036 to 0.114mm
0.0014 to 0.0045in.
0.034 to 0.116mm
0.0013 to 0.0046in.
0.033 to 0.117mm
0.0013 to 0.0046in.
0.030 to 0.117mm
0.0012 to 0.0046in.
0.15mm
0.0059in.
0.15mm
0.0059in.
0.15mm
0.0059in.
0.15mm
0.0059in.
0.15mm
0.0059in.
Governor Gear
Governor Gear to Injection Pump
Gear
Backlash 0.030 to 0.117mm
0.0012 to 0.0046in.
0.15mm
0.0059in.
Engine Body (Continued)

17
Te hni al Spe ifi ations.
Engine Body (Continued)
Item Fa tory Spe ifi ation 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 1.0244in.
25.967 to 25.980mm
1.0223 to 1.0228in.
0.020 to 0.054mm
0.0008 to 0.0021in.
26.000 to 26.021mm
1.0236 to 1.0244in.
25.967 to 25.980mm
1.0223 to 1.0228in
0.10mm
0.0039in.
-
-
0.10mm
0.0039in.
-
-
Idle Gear
Idle Gear 1
Idle Gear 2
Side Clearance
Side Clearance
0.20 to 0.51mm
0.0079 to 0.0201in.
0.20 to 0.51mm
0.0079 to 0.0201in.
0.80mm
0.0315in.
0.80mm
0.0315in.
Camshaft Side Clearance
Alignment
0.07 to 0.22mm
0.0028 to 0.0087in.
-
0.30mm
0.0118in.
0.01mm
0.0004in.
Cam Height Intake
Exhaust
28.80mm
1.1339in.
29.0mm
1.1417in.
28.75mm
1.1319in.
28.95mm
1.1398in.
Camshaft Journal to Cylinder Block Bore
Camshaft Journal
Cylinder Block Bore
Oil Clearance
O.D.
I.D.
0.050 to 0.091mm
0.00197 to 0.00358in.
35.934 to 35.950mm
1.4147 to 1.4153in.
36.000 to 36.025mm
1.4173 to 1.4183in.
0.15mm
0.0059in.
-
-
Piston Pin Bore I.D. 22.000 to 22.013mm
0.8661 to 0.8667in.
22.03mm
0.8673in.
Piston Pin to Small End Bushing Clearance 0.014 to 0.038mm
0.00055 to 0.00150in.
22.002 to 22.011mm
0.8662 to 0.8666in.
22.025 to 22.040mm
0.8671 to 0.677in.
0.15mm
0.0059in.
-
-

18
Te hni al Spe ifi ations.
Engine Body (Continued)
Item Fa tory Spe ifi ations 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 Alignment - 0.05mm
0.0020in.
Crankshaft Alignment - 0.02mm
0.0008in.
Crankshaft to Crankshaft Bearing 1 Oil Clearance
O.D.
I.D.
0.034 to 0.114mm
0.0013 to 0.0045in.
47.934 to 47.950mm
1.8872 to 1.8878in.
47.984 to 48.048mm
1.8891 to 1.8916in.
0.20mm
0.0079in.
-
-
Piston Ring Gap
[D1005-E2B]
Top Ring 0.30 to 0.45mm
0.0118 to 0.0177in.
1.25mm
0.0492in.
Second Ring 0.30 to 0.45mm
0.0118 to 0.0177in.
1.25mm
0.0492in.
Oil Ring 0.25 to 0.40mm
0.0098 to 0.0157in.
1.25mm
0.0492in.

19
Te hni al Spe ifi ations.
Engine Body (Continued)
Item Fa tory Spe ifi ation 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 1.8909in.
0.20mm
0.0079in.
-
-
Crankshaft to Crankshaft Bearing 3
Crankshaft Journal
Crankshaft Bearing 3
Oil Clearance
O.D.
I.D.
0.029 to 0.091mm
0.0011 to 0.0036in.
51.921 to 51.940mm
2.0441 to 2.0449in.
51.974 to 52.019mm
2.0462 to 2.0480in.
0.20mm
0.0079in.
-
-
Crankpin to Crankpin Bearing
Crankpin
Crankpin Bearing
Oil Clearance
O.D.
I.D.
0.034 to 0.098mm
0.0013 to 0.0039in.
39.959 to 39.975mm
1.5732 to 1.5738in.
40.004 to 40.050mm
1.5750 to 1.5768in.
0.20mm
0.0079in.
-
-
Crankshaft Side Clearance 0.15 to 0.31mm
0.0059 to 0.0122in.
0.50mm
0.0197in
Cylinder Liner I.D. D1105-E2B 78.000 to 78.019mm
3.0709 to 3.0716in.
78.15mm
3.0768in.
Cylinder (Oversized) D1105-E2B 78.500 to 78.519mm
3.0906 to 3.0913in.
78.65mm
3.0965in.

20
Te hni al Spe ifi ations.
Lubri ating System
Item Fa tory Spe ifi ations 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
0.0024 to 0.0071in.
-
Outer Rotor to Pump Body Clearance 0.100 to 0.180mm
0.0039 to 0.0071in.
-
Inner Rotor to Cover Clearance 0.025 to 0.075mm
0.0010 to 0.0030in.
-
Cooling System
Item Fa tory Spe ifi ations Allowable Limit
an Belt Tension 7.0 to 9.0mm / 98N
0.28 to 0.35in. / 98N
(10kgf, 22lbs)
-
Thermostat Valve Opening
Temperature
(At Beginning)
Valve Opening
Temperature
(Opened
Completely)
69.5 to 72.5°C
157.1 to 162.5°
85°C
185°
-
-
Radiator Cap Pressure alling
Time
10 seconds or more
88 → 59kPa
0.9 → 0.6kgf/cm²
13 → 9psi
-
Radiator Water Leakage
Test Pressure
No Leak at Specified
Pressure
137kPa
1.4kgf/cm²
-