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HT1_5 Deutz Maintenance manual Revision B

1. First 1000 Hr zo LL aa Hour Reading First 1500 Hr LL LL ee E 21 Hour Reading First 2000 Hr LL LL LL eg Hour Reading First 2500 Hr LL LL LS E E 21 Hour Reading First 3000 Hr LL LL ee eg Hour Reading First 3500 Hr L LL LL LS 2 21 Hour Reading First 4000 Hr LL LL LL eg Hour Reading First 4500 Hr E E EZ ENE EE Hour Reading Service Record Sheet LOI LOTO First 5000 Hr L LL LL EZA Hour Reading First 5500 Hr Lee LL LS eg Hour Reading First 6000 Hr LL LL LS LS OZ 2 Hour Reading First 6500 Hr E ZZL Hour Reading First 7000 Hr Lee er ee eg Hour Reading First 7500 Hr Leer ee eg Hour Reading First 8000 Hr LL LL ee eg Hour Reading First 8500 Hr Lee er ee 2 21 Hour Reading First 9000 Hr LL LL ee ee Hour Reading First 9500 Hr LL LL ee eg Hour Reading First 10000 Hr LL LL ee eg Hour Reading Note It may be essential to change the engine Oil and Filter Air Filter s and Fuel Filter s more frequently Check machine service schedule and applications requirements 1 un Service Schedules CALENDAR EQUILIVANTS 10Hour
2. Hi Lift Arm Pins 4 No Points Tipping Ram Pins 2 No Pins Hi Lift Rams 4 No Points Steering Ram 2 No Points Skip Pivot Pins 1 Pin 2 No Points ane 7 Parallel Link Arm Pins 2 No Points Centre Point Articulation Casting 2 No Points 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 Settings METRIC Grade 8 8 Bolts Hexagon A F mm 8 10 13 17 19 24 30 36 46 55 12 9 Bolts Note All bolts are of high tensile strength and must not be replaced by bolts of a lesser tensile specification Deutz 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 Installation Pre Re tightening tightening 1st Step 2nd Step 3rd Step 4th Cylinder head cover Rocker arm setting Intake elbow Air intake pipe Exhaust manifold Oil drain screw sheet Metal oil tray Injection valve fastening Lube oil filter cartridge Starter 20 Flui
3. Make sure the correct lubricating oil is being used Refer to Fluids amp Lubricants section Fuel in the lubricating oil engine operating Review the operation for excessive idling resulting in the engine too cold running below normal temperature Fuel lift pump leaking Repair or replace the fuel lift pump One or more injector worn or Check and externally clean the injector If the problem still malfunctioning persists the injector must be checked by a FIE specialist or replace with new Worn or malfunction fuel injection pump Check for operation of the FIP FIP Injection pump not delivering fuel The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent Internal bearing or component damage Have oil sample analysed Repair engine as required Fault Finding CHART C3 Lubricating Oil pressure low Cause Incorrect lubricating oil specification of viscosity Remedy Make sure the correct lubricating oil is being used Refer to Fluids amp Lubricants section Look for reduced viscosity from dilution with fuel Fuel dilution in lubricating oil can originate from fuel injection pump driveshaft seal or fuel transfer pump Review reduce the lubricating oil change intervals Pressure switch or gauge fault Verify the pressure switch is functioning c
4. PARKING BRAKE PILOT CONTROL PRESSURE FROM CHARGE PUMP WHEEL MOTOR CASE DRAINS 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 switch sends a signal to de energise the solenoid valve This removes the pilot pressure and the brake springs in the wheel motors push out the brake pads This is time dependant and for a smoother operation a restrictor is used in the hydraulic tank return line ensuring softer engagement of the brakes 35 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 driving the wheels of the dumper and a small gear pump mounted to the end to power the main steering tipping and hi lift functions of the dumper The axial piston pump draws oil through a suction flow return flow filter unit This filter unit ensures the pump always ensures a positive pressure of 0 5 bar to the pump This pre charge improves start up and cold start characteristics of the dumper and the r
5. ORGINAL INSTRUCTIONS HT1 5 Site Dumper MAINTENANCE INSTRUCTION MANUAL NC ENGINEERING HAMILTONSBAWN LTD 2 Killyrudden Road Hamiltonsbawn Co Armagh BT61 9SF Tel 028 38871970 Fax 028 38870362 email sales nc engineering com www nc engineering com REVISION B 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 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 2006 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 Contents Declaration of Conformity Noise Level Declaration Vibration Declaration Technical Specifications Maintenance
6. DEC 1920 040 Sound levels DEC 1920 041 Skip controls DEC 1920 042 eX Do not operate dumper without reading manual DEC 1920 044 Keep clear of tipping area 1 5T HT Maintenance Manual 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 maintained Maintenance must be carried 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 e Operating with low quality fuel See Fluids amp Lubricants section for more information e Operating in a very dusty environment e Operating continuously at high engine load e Operating in an environment with lots of chaff e Operating in an extremely hot or cold environment e Operating continuously on slopes e Operating continuously at high altitude e Operating in an environment with high humidity First 50 Hr ZE OL Le LIST N EST Hour Reading First 100 Hr LL LL LS LS ee Hour Reading First 500 Hr y LL ee eg Hour Reading
7. Replace the bearing support Tighten to torque Set the counter pressure valve Replace the cylinder block and valving assembly 71 Fault Finding CHART E3 Wheel motor does not revolve The motor does not revolve No flow to ee Check the pump drive the motor and pump inlet i ais a ES Check the safety valve Se condition regulator pressure Gars YES j Excessive internals Replace the cylinder block leaks and valving assembly YES The brake reminds Check the brake pilot circuit engaged 72 Fault Finding CHART E4 Wheel motor does not revolve at its normal speed under load The motor does not revolve at its normal speed under load Pump flow is ee sad Check the pump drive speed Working pressure TES Check the safety valve is too low setting pressure regulator YES Bad working of the orking of the Check the replenishing circuit replenishing circuit J YES Excessive internals Replace the cylinder block leaks and valving assembly 73 Fault Finding CHART E5 Wheel motor revolves irregularly The motor revolves irregularly Pump flow is irregular Check the pump flow J Excessive internals YES leaks Replace the cylinder block and valving assembly CHART E6 Wheel motor leaks The motor leaks l The housing YES Check the drai
8. Replace valve seals Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent Piston rings not sealing Evident with persistent blue smoke at all speeds loads Check the engine compression 59 Fault Finding CHART A15 Engine will not shut off Cause Electrical fuel shut off solenoid ESOS valve not functioning properly Remedy Check for correct operation of the ESOS Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent 60 Fault Finding CHART B1 Fuel consumption excessive Cause Additional load on engine Remedy Check repair accessories and vehicle components Operator technique Review operation for correct gear shifts deceleration and idling Fuel Leaks Check for external leaks and engine lubricating oil dilution For fuel dilution check for internal leaks at the fuel transfer pump and injection pump Inspect and correct as required leaks in the high p
9. water Temperature gauge sensor faulty Verify that the gauge and temperature sensor are correct Thermostat faulty incorrect or missing Check replace thermostat Air or combustion gasses in the cooling system Make sure the fill rate is not exceeded and the correct vented thermostat is installed If aeration is continued check for a compression leak through the head gasket Coolant pump faulty Check routing and operation of vent line Vent line from engine and or radiator blocked or incorrectly routed sudden overheating Check routing and operation of vent line Cooling passages in radiator cylinder head head gasket or block blocked Flush the system and fill with clean coolant Fuel inject pump timing incorrect If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment 68 Fault Finding CHART D3 Coolant under temperature Cause Air flow across radiator excessive Remedy 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 faulty Verify that the gauge and temperature sensor are correct Thermostat faulty open not sealing Check replace thermostat Coolant not flowing by tempera
10. A13 Engine exhaust smoke excessive Black smoke Cause Engine being lugged down Remedy Use appropriate gear for the task 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 Exhaust leak at the manifold Check correct leaks in the manifold gasket Look for a cracked manifold One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent Injection pump timing incorrect Retarded if smokes under load and engine quieter than normal e Advanced is smokes under load and engine noisier than usual If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment Engine compression low in one or more cylinders Check the engine compression 58
11. Decals Descriptions Safety Decals Descriptions Introduction Service Record Servicing Schedules Torque Settings Fluids amp Lubricants Safety Information Maintenance Battery Air Cleaner Coolant System Engine Oil Check Change Hydraulic Oil Check Towing Procedure Brake System Hydraulic System Storage Electrics Fault Finding Dumper will not start or difficult to start No exhaust smoke Dumper will not start or difficult to start Exhaust smoke Engine will not crank or cranks slowly Engine starts then stops Page No 10 12 14 15 16 19 21 26 27 28 29 30 31 33 34 35 36 42 44 45 46 47 48 Contents Page No Fault Finding continued Engine poor running 49 Engine poor running at idle 50 Engine excess noise 51 Engine compression knocks 52 Engine reduced power output 53 Engine will not reach maximum rpm 55 Engine rpm surges 56 Engine excessive vibration 57 Engine exhaust smoke excessive Black smoke 58 Engine exhaust smoke excessive White Blue smoke 59 Engine will not shut off 60 Fuel consumption excessive 6l Fuel Oil leaking from exhaust manifold 62 Lubricating oil consumption excessive 63 Lubricating oil contaminated 64 Lubricating oil pressure low 65 Lubricating oil pressure high 66 Coolant loss 67 Coolant over temperature 68 Coolant under temperature 69 Coolant contaminated 69 Poor hydrostatic drive performance 70 Noisy wheel motor 71 Wheel motor does not revolve 72
12. Do not use petrol diesel fuel or paraffin to clean your skin e Clean away all dirt from around the dipstick and tube e Ensure the engine oil is warm NOT HOT and dumper is positioned on firm level ground e Pull the dipstick A from the engine wipe the oil off the dipstick using clean paper roll e Put the dipstick back into its tube and push it firmly down Remove the dipstick and check oil level If the oil is below the recommended level DO NOT use the dumper until sufficient oil has been added to bring it up to the required level ADDING OIL e Unscrew the engine oil filler cap B and add clean fresh oil of the correct grade see technical specification Ensure the oil is from an clean source and the container is clean e Check the oil level frequently when adding oil too much oil can damage the engine Allow time for the oil to drain to the sump before checking the level e When the oil level is up to the full mark on the dipstick refit the engine oil filler cap and ensure the dipstick has been firmly pushed back into the dipstick pipe 31 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 Ensure the oil is warm but not hot as contaminants held in suspension will b
13. Having identified a cause the suggested remedy is given The charts are designed to identify causes through a process of elimination starting with the simplest and most easily rectified faults There are many reasons why the dumper may malfunction Due to the level of effort involved in tracing a fault it is recommended this guide is followed Do not make assumptions Start with the simplest things i e no low fuel fuses etc Systematically work through each of the possible causes Confirm your diagnosis before dismantling and assembling Follow the recommended repair procedures in the manual Some of the tasks in this guide must only be carried out by suitably qualified and competent personnel For example fuel injection pump removal and replacement If you are unsure DO NOT attempt the task 44 Fault Finding CHART Al Dumper will not start or difficult to start no exhaust smoke Cause Electrical isolator not turned on Remedy Turn isolator on Not in Neutral Check the FNR lever is in the NEUTRAL position 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 30A amp 100A Check fuses in fuse box behind the steering column plate Display powering up but not starting engine Check the start inhibit relay behind the steering column plate Electrical fuel shut off s
14. Lwa A Weighted sound power level Lp A Weighted sound pressure level 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 m s 0 4 Hand Arm am m s2 01 9 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 Technical Specifications FOURWHEEL DRIVE DUMPER CAPACITY Max safe bad 1500 kg Heaped 825L Stuck 658L Water 494L ENGINE Deutz D2008L08 3 Cylinder Water Cooled Naturally Aspirated Displacement 17L Max power 24 7KW 33bhp 2500 rpm Max torque 104Nm 1600 rpm Emissions Euro 2 compliant TRANSMISSION Hydrostatic automotive Twin Lock permanent 4 wheel drive Accaleration by foot pedal amp braking from hydrostatic retardation DRIVE CHARACTERISTICS Forward Reverse 0 12 kmh 0 7 5 mph Steering ange 36 5 Turning Circle 6 55m Grade ability 50 Tyres 10 0 75 15 3 traction Profile Steering Priority load sensing hydrostatic centre pivot Workin
15. Wheel motor does not revolve at its normal speed under load 13 Wheel motor revolves irregularly 74 Wheel motor leaks 74 Engineering Hamiltonsbawn Ltd Manufacturers of Agricultural and Industrial Equipment 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 Machine description Site Dumper Make NC Type HT1 5 Manufactured by NC Engineering Hamiltonsbawn Ltd Address 2 Killyrudden Road Hamiltonsbawn Richhill Co Armagh BT61 9SF This machinery has been designed and manufactured in accordance with the following European Standards 2006 42 CE Machinery Directive Measured Sound Power Level 101 dB LWA Guaranteed Sound Power Level 101 dB LWA Net Installed Power 24 7kW A technical construction file for this machine is retained at the above address Declaration Wi 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 Noise Level Declaration The noise levels are measured according to IS06395 1998 The noise level of this machine is Lwa 101dB A Le 85dB A
16. corroded Remedy 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 and charging the battery No electrical connection to the starter solenoid Check voltage to solenoid Crankshaft rotation restricted Manually turn the engine and check for any severe rotational resistance Solenoid or starter motor fault Replace starter motor Starter motor operating but not cranking Remove the starter motor and check for broken teeth on the ring gear or broken starter motor spring 47 Fault Finding CHART A4 Engine starts then stops Cause No fuel supply in tank Remedy 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 loading Disengage the hydraulic controls Idle speed too low for accessories Adjust the idle speed Refer to the machines service manual for correct adjustment procedures and idling speed 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 Fuel is aerated Check the fuel system for loose connections and possible air
17. freeze products are on the following page If another anti freeze is used refer to the manufacturers instructions and ensure a corrosion inhibitor is included Must be ethylene glycol based DONOT use Organic Acid Technology OAT antifreeze Do not use solutions of more than 45 or less than 35 antifreeze or damage to the cooling system will occur 45 antifreeze 55 water solution maintains protection down to 1 35 C The fresh water must meet the following specifications pH value 20 deg C 6 5 8 5 Chloride ion content Max 100mg l Sulphate ion content Max 100mg I Total Hardness 3 20 dGH corresponds to earth alkali content Ca 0 54 3 56 mmol l Mg Carbonate Hardness Min 3 d Corresponds to content of CaCO Max 53 4 mg l Never use sea water river or lake water brackish water or industrial waste water for conditioning the coolant Specifications of the water quality are made by the local water board The water must be conditioned if it deviates from the above specification Contact NC for further assistance The strength of the anti freeze solution should be checked at least once a year preferably at the beginning of a cold period It is an advantage to leave the anti freeze in all year round as it gives continued protection against corrosion Always renew anti freeze every two years A 45 anti freeze mixture is required even if frost protection is not required as this raises the coolants
18. ingress points Rectify and bleed the fuel system Fuel lift pump not operating correctly fuel supply inadequate Check that the lift pump is operating and delivering fuel to the injection pump Fuel is waxing due to extremely cold weather Verify by inspecting the fuel filter Clean the filter and use acclimatised fuel Fuel is contaminated or incorrect grade of diesel used Refer to Fluids amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Fuel filter s blocked fuel supply restricted Check replace the fuel filter s Check fuel lines for restriction Fuel drain return line blocked or not connected properly Verify that the fuel return line is not obstructed and connected to the top of the fuel tank 48 Fault Finding CHART A5 Engine poor running Cause Condition occurs only at idle Remedy Refer to Chart A6 for possible poor running at idle faults Engine is cold Cold starting aid is not working Check for the correct operation of the cold start advance If the engine will not reach operating temperature refer to Chart D3 Fuel injection lines leaking Inspect and correct as required leaks in the high pressure lines fittings injector sealing washers or delivery valves WARNING Fine jets of fluid can penetrate the skip Keep face and hands well clear of pressurised flui
19. injection pump Fuel filter s blocked fuel supply restricted Check replace the fuel filter s Check fuel lines for restriction Fuel is contaminated or incorrect grade of diesel used Refer to Fluids amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Inlet and exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances Engine compression low in one or more cylinders Check the engine compression Injection pump timing incorrect If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent 50 Fault Finding CHART A7 Engine excessive noise Cause Drive belt squeal insufficient tension or abnormally high
20. injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent 53 Fault Finding CHART A9 Engine reduced power output continued Cause Exhaust leak at the manifold Remedy 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 amp exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances Injection pump timing incorrect If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment Engine compression low in one or more cylinders Check the engine compression 54 Fault Finding CHART A10 Engine will not reach maximum rpm Cause Tachometer faulty if fitted Remedy Verify the engine speed with a hand held tachometer Measure on the fan drive
21. loading Remedy 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 materials on the pulleys Check the tension of the accessory drive belts Cold start advance not working properly Check for the correct operation of the cold start advance If the engine will not reach operating temperature refer to Chart D3 Air intake or exhaust leaks Refer to Charts A13 amp A14 Fuel is contaminated or incorrect grade of diesel used Refer to Fluids amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Inlet and exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances Inlet and exhaust valve springs broken Check and fit new valve springs Worn crank connecting rod bearings knocking under load Check replace rod and main bearings Excessive camshaft bearing wear Check bearings engine overhaul required Worn or damaged pistons and or piston rings Check piston assemblies engine overhaul required One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Gear train noise Visually inspect
22. loading Disengage the hydraulic controls Throttle adjustment incorrectly set or binding Check the engine maximum rpm is as specified in the Technical Specifications section Check the throttle linkages and cable for binding etc Fuel is contaminated or incorrect grade of diesel used Refer to Fluids amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Fuel injection lines leaking Inspect and correct as required leaks in the high pressure lines fittings injector sealing washers or delivery valves WARNING Fine jets of fluid can penetrate the skip Keep face and hands well clear of pressurised fluid and wear protective glasses If fluid penetrates your skin seek medical help immediately Fuel filter s blocked fuel supply restricted Check replace the fuel filter s Check fuel lines for restriction Fuel is aerated Check the fuel system for loose connections and possible air ingress points Rectify and bleed the fuel system Fuel lift pump not operating correctly fuel supply inadequate Check that the lift pump is operating and delivering fuel to the injection pump 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 One or more
23. loosen hydraulic fittings when the engine is running Hydraulic oil leaks at high pressure can easily penetrate the skin If the skin is penetrated with hydraulic oil seek expert medical attention immediately When removing hoses from the machine always cap them with a clean cap and also the port on the component must be capped to prevent dirt getting into the system It is not the dirt you can see will cause the damage it is the particles invisible to the human eye ALWAYS CAP hoses amp components ALL COVERS AND PANELS MUST BE FITTED BEFORE DUMPER IS USED 27 Maintenance 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 BATTERY e Always wear safety glasses when working on the battery e Always disconnect the Negative battery lead C before disconnecting the Positive battery lead D e Always connect the Positive battery lead D first when reconnecting the battery e Never allow a metal object to touch both battery terminals at the same time or allow them to touch the positive terminal D and the vehicle chassis simultaneously e When charging the battery hydrogen gas is produced Ensure the area is well ventilated to prevent risk of explosion from a build up of hydrogen Do not smoke M weld cut grind etc in the vicinity of a battery being charged e Ifthe skin is ex
24. oil cooler leak External engine coolant leak Visually inspect the engine and components for seal gasket or hose connection leaks Make sure all hose clips are in good condition and torqued to the recommended figure Overheating or compression gasses leaking resulting in loss through the radiator overflow Refer to Chart D2 Lubricating oil cooler leak Check replace the oil cooler Look for coolant in the oil Cylinder head gasket leak Check replace the head gasket Cylinder head cracked or porous Check replace the head Cylinder block coolant passages leaking Check replace the cylinder block 67 Fault Finding CHART D2 Coolant over temperature Cause Incorrect coolant level Remedy 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 Clean the mesh grill on the bonnet Check repair the fan shroud anti recirculation sealing Check fan blades replace if necessary Coolant pump or fan drive belts loose Check correct the belt tension Radiator hose collapsed restricted or Check replace hose leaking Oil level over full Check oil level Cooling system pressure cap incorrect or Check replace cap faulty Over concentration of antifreeze Remove some of the coolant from the system and replace with
25. Fault Finding CHART A14 Engine exhaust smoke excessive White Blue smoke Cause Fuel is contaminated or incorrect grade of diesel used Remedy Refer to Fluids amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Oil level incorrect Check oil level Diesel or hydraulic oil in sump Check oil consistency If oil contamination is suspected check hydraulic oil pump for leaks past the seal into the engine Drain flush and fill with clean oil Coolant temperature too low over cooling Light blue or white high speed light load Refer to Chart D3 Injection pump timing incorrect Retarded if smokes under load and engine quieter than normal Advanced is smokes under load and engine noisier than usual If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment One or more injector worn or malfunctioning White blue smoke at operating temperature Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Coolant leaking into combustion chamber Refer to Chart D1 Leaking valve stem seals Evident after long idle period then acceleration
26. ace any part of the body in any area of the machine where there is a hydraulic leak while the system is pressurised a HE REPAIR AREA The repair area should be level clean dry well ventilated and have adequate lighting Keep the floor clean wipe up spilt oil and grease Always use the correct tool for the job keep tool in good condition NEVER IMPROVISE TOOLS Jacks hoists lifting chains and ropes should be checked before use Do they have sufficient lifting capacity and are they properly certified Do not attempt to lift heavy objects on your own WHEN REPAIRING Safety prop raised tipped skips Always wear eye protection Always wear ear protectors when in a noise environment Release any pressure from the hydraulic system before carrying out repairs If the machine is lifted or suspended always support the machine on suitable blocks Always remove the start switch key to prevent accidental starting Never work with the engine running unless absolutely necessary Never start the engine unless in a well ventilated area Carbon Monoxide fumes can KILL Always exercise extreme caution when welding grinding or burning against risk of fire Keep suitable fire extinguishers near by Never smoke or leave the engine running when refuelling Always use genuine spares from NC Engineering Always check and test the machine thoroughly before putting it back to work Observing these points will help to ensure the repair of the dum
27. and measure gear backlash Replace gears as required 51 Fault Finding CHART A8 Engine compression knocks Cause Fuel is aerated Remedy 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 amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Injection pump timing incorrect If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment Inlet and exhaust valve springs broken Check and fit new valve springs One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Coolant operating temperature incorrect Refer to Charts D2 amp D3 52 Fault Finding CHART A9 Engine reduced power output Cause No fuel supply in the tank Remedy 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 and other changes in vehicle
28. ation by foot pedal Simple and safe operation drive direction on the steering column Heavy duty centre console for leg protection Simple Instrument panel Including fuel gauge hourmeter warning lights for parking brake oll temperature oll pressure engine temperature Folding ROPS as standard Easy access to engine compartment for serice and mantenance Recovery bracket as standard 33 1 HP engine 24 7 Kw Excellent power to weight ratio Theft deterrent Cesar Data Tag System as standard Ample ground clearance Excellent tuming circle Reversing sarm standard Separate fuel and hydraulic filer compartments Skip tps over 90 Adjustable suspension seat OPTIONAL EQUIPMENT Road Ught Kit Flashing Beacon Spare Wheel Biodegradable Hydraulic Oll FOPS Roof Skip manufactured from ST52 or Hardox Cab NC Engineering Hamittonsbawn Ltd 2 Killyrudden Road Hamittonsbawn Richnill Co Armagh Northern Ireland BT61 SSF Tek 44 0 28 3887 1970 Fax 44 0 28 3887 0362 Emal salesOnc engineering com Web www nc engineering com 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 from the NC Spares department son Engine oil level E
29. boiling point Serious damage can be caused to the engine if corrosion inhibitors are not used 22 Fluids amp Lubricants Deutz Cooling System protective agent Aral Antifreeze extra Avia Antifreeze APN BASF Glysantin G48 Protect Plus ESSO ESSO Antifreeze Extra Fuchs Europe Fricifin Mobil Mobil Antifreeze Extra OMV OMV Coolant plus Shell Glyco Shell Castrol Castrol Antifreeze NF Total Glacelf MDX Valvoline G48 Antifreeze BP BP Anti frost code No X2270A 23 Fluids amp 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 Pre filters and water separators must be checked daily and cleaned if necessary ACCEPTABLE FUELS No warranty liability whatsoever will be accepted for failure of injection equipment where the failure is attributed to the quality and grade of fuel used Only the following types of fuel are considered acceptable by NC e EN590 Diesel fuel types Auto C0 C1 C2 C3 C4 e ASTM D 975 88 grade no 1 D amp 2 D e NATO code F 54 e JIS K2204 grade 1 amp 2 EFFECT OF FUEL CONTAMINANTS DIRT A severely damaging contaminant Finely machined and mated surfaces such as delivery valves and distributor rotor are susceptible to the abrasive nature of dirt particles Increased wear will almost cer
30. bris e Ifremoving hoses always cap them and the port they are removed from NEVER e Fit new hoses if both ends do not have a plastic cap fitted to seal them e Fit new valves pumps motors filters etc if all the ports have not been plugged e Use dirty containers for oil storage e Use dirty containers or funnels for filling the hydraulic system e Store hydraulic components on the floor or in areas where welding or grinding is done or in a dirty environment HYDRAULIC FILTERS The system components are maintenance free other than the following e Return flow Suction flow filter e Suction strainer When renewing these filters the area around the filter should be thoroughly cleaned before removing the old filters to prevent the ingress of dirt into the hydraulic system Hydrostatic drive systems need to be run on an exceptionally clean oil Remember it is the small particles of dirt invisible to the naked eye that does the harm When removing these parts it is recommended the system is drained and refilled with filtered clean new hydraulic oil as specified in the Fluids amp Lubricants section 38 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 C of the visual indicator Do not over fill the hydraulic tank as it needs room to vent air Replace filler cap imme
31. cap A on the radiator to release any built up pressure escape Remove the cap when all the pressure is released e Undo the hose clip on the bottom radiator hose and pull it off the radiator e Allow the coolant to drain into a suitable container e Flush the system by pouring clean water into the radiator filler neck e Refit the bottom hose and tighten the clip Dispose of used coolant in an environmentally safe way REFILLING THE COOLING SYSTEM e Ensure the engine is cold e Remove the radiator cap and add coolant mix to just below the top of the filler neck on the radiator allowing time for the coolant to settle as necessary Replace the filler cap see Fluids amp Lubricants section regarding coolant mix e Start the engine and allow it to run for approximately 2 minutes e With the engine stopped and the cool remove the filler cap and top up as necessary to just below the bottom of the filler neck Repeat the above process and toping up again until the level remains steady This will ensure all the air has been expelled from the system 30 Maintenance CHECKING ENGINE OIL LEVEL Oil is toxic If you swallow any oil do not induce vomiting seek medical advice immediately Used engine oil contains harmful contaminants which can cause skin cancer Do not handle used engine oil more than necessary Always use barrier cream or wear gloves to prevent skin contact Wash skin contaminated with oil in warm soapy water
32. d and wear protective glasses If fluid penetrates your skin seek medical help immediately Fuel is aerated Check the fuel system for loose connections and possible air ingress points Rectify and bleed the fuel system Fuel lift pump not operating correctly fuel supply inadequate Check that the lift pump is operating and delivering fuel to the injection pump Fuel filter s blocked fuel supply restricted Check replace the fuel filter s Check fuel lines for restriction Fuel is contaminated or incorrect grade of diesel used Refer to Fluids amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Inlet and exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances Engine compression low in one or more cylinders Check the engine compression Injection pump timing incorrect If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Ch
33. diately after filling CHANGING THE HYDRAULIC OIL Before draining the hydraulic tank ensure the hydraulic oil is warm NOT HOT e Lower the skip and the hi lift sections to their normal fully down positions e Stop the engine and allow to cool e Release any pressure from the hydraulic lines by moving the levers back and forward several times e Remove the bung on the underside of the tank and drain the oil into a suitable container approx 30L of volume It is extremely important to follow the correct oil fill procedure to prevent internal damage to the hydrostatic drive pump e Fill the hydraulic oil tank with HVZ 46 oil to approx level at C Remove hose B and manually fill with clean filtered hydraulic oil e Crank the engine over but do not let it start this will allow the drive pump to get lubricated Refill hose B as above e Repeat this procedure about 5 times e Start the engine and idle for a period of five minutes This allows the oil to fill the hoses oil cooler and filter e Stop the engine and wait approximately one minute recheck the oil level and fill to level as indicated by C 39 Maintenance CHANGING THE FILTER ELEMENT At the required service interval the element in the RKM suction flow return flow filter will need changing e Unscrew the cap B on the top of the RKM filter there will P be oil in this filter it may spill over on to the tank and will take a few minutes to drain down
34. ds amp 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 should be used in a normal work cycle immediately Glazing of the piston cylinder bores resulting in excessive oil consumption could occur if the engine is gently run in Under no circumstance should the engine be allowed to idle for extended periods e g warming up without load A minimum API CH4 grade of must be used Superior grades of oil may be more appropriate for heavy duty applications such as sustained high loads operating at elevated temperatures Oil Viscosity Minimum Temperature C Maximum Temperature C SAE 0W30 SAE 0W20 SAE 5W20 SAE 5W40 SAE 10W30 SAE 15W40 NC recommend Fuchs Lubricants the dumper comes pre filled with SAE 15W40 oil If you are in any doubt as to the correct grade of oil to use contact NC ENGINE OIL CAPACITY Choose the grade of oil to suit the temperature range as detailed in the table above The engine oil capacity including filter and clean sump is approx 5 8L Never overfill above the top dipstick mark 21 Fluids amp Lubricants COOLANT MIXTURES Anti freeze can be harmful Obey the manufacturers instructions when handling neat or diluted antifreeze An approved list of anti
35. e When the oil has drained down a bit remove part C this will leave the element exposed e Remove the element D it may be a bit tight to remove from its seating in the housing e Replace with a new element and refit the components B amp C e Start the dumper and allow to idle for 5 minutes to ensure oil gets into the filter element REPLACING FILTER ELEMENTS Always use replacement filters supplied by NC other filters may be of lesser quality and lead to increased wear in the hydraulic components resulting in oil leaks 40 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 refill with clean fresh oil to the correct specification Also drain the coolant from the system and replace with fresh coolant of the correct mix amp specification Check hydraulic oil level and top up as required Fill the fuel tank to prevent condensation forming inside the tank and contaminating the fuel Store the machine on flat level ground which is not liable to flooding standing water or airborne contamination Smear any exposed metal parts with grease amp rams Remove the battery and store in a safe well ventilated area DO NOT store the battery on a concrete floor It is best to place a rubbe
36. e drained with the oil This will also allow the oil to drain quicker and more thoroughly e Place a suitable receptacle under the engine drain plug 15 to 20L capacity Oil will gush from the hole when the drain plug is removed Hot oil and engine components can burn you Keep to one side when you remove the plug e Remove the drain plug A and its FOOring Let the oil drain out then clean and refit the drain plug with a new M ring Torque tighten the drain plug to 32Nm 241bf ft e Loosen anti clockwise and remove the filter Let the oil drain out The engine oil filter B MUST be changed when the engine oil is renewed Unscrew the filter canister using a chain wrench if necessary e Clean the seal face of the filter head e Smear the seal on the new filter canister with clean engine oil screw the filter on until it just contacts the filter head Tighten the filter at another 1 2 of a turn e Check the seal of the filter for tightness NOTE use only genuine filters from NC Using non genuine parts may result in loss of engine oil pressure and subsequent engine damage e Through the filler point fill the engine with the recommended oil to the MAX mark on the dipstick Wipe up any spilt oil and replace the filler cap ensuring it is secure e Operate the engine until the Low Oil Pressured warning LED goes out Check for oil leakage When the oil has cooled check oil level again and if necessary top up with clean engine
37. ecified intervals between oil changes have not been reached the oil should be changed at least once a year 4 If operating under arduous conditions do an oil flush amp change the engine oil amp filter every 250 hours gt The oil service interval will be affected if there is a high sulphur content in the fuel Refer to fuels amp lubricants section If operating in dusty adverse conditions do these jobs more frequently 7 These jobs must be done by a qualified engineer Service Schedules WHEEL MOTORS Operation 50 0100 1000 2000 Service Points amp Fluid Levels Hr Hr Hr Hr Hubs Check for Leaks Tightness of Axle Mounting bolts Torque to 244Nm 1801bf ft Tightness of Motor Mounting bolts Torque to 135Nm 100Ibf ft Tightness of Wheel Rim Nuts Torque to 170Nm 1251bf ft Hydrostatic Drive amp Hydraulics vertion reed coal rity Pre start Cold Checks Hydraulic oil level Return to tank filter element Suction strainer wash with paraffin if necessary Hydraulic Oil Functional Test Forward amp Reverse Direction Change operation Neutral Start Operation BRAKES Parking Brake Operation Check Note L First Interval Hr Service only AIR INDUCTION SYSTEM Operanen Check air filter restriction indicator Check woo Note T LJ Every 10 hours Service Schedules DUMPER CHASSIS Operation 10 50 100 500 1000 Grease Points Hr Hr Hr Hr Hr
38. eck for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent Camshaft or tappets damaged Inspect camshaft and tappets 49 Fault Finding CHART A6 Engine poor running at idle Cause Engine is cold Cold starting aid is not working Remedy Check for the correct operation of the cold start advance If the engine will not reach operating temperature refer to Chart D3 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 and replace adjust as necessary Fuel injection lines leaking Inspect and correct as required leaks in the high pressure lines fittings injector sealing washers or delivery valves WARNING Fine jets of fluid can penetrate the skip Keep face and hands well clear of pressurised fluid and wear protective glasses If fluid penetrates your skin seek medical help immediately Fuel is aerated Check the fuel system for loose connections and possible air ingress points Rectify and bleed the fuel system Fuel lift pump not operating correctly fuel supply inadequate Check that the lift pump is operating and delivering fuel to the
39. elivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent 56 Fault Finding CHART A12 Engine excessive vibration Cause Engine not running smoothly missing Remedy 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 accessories faulty Check replace the vibrating component Refer to correct installation procedure and torque figures Fan hub faulty Inspect replace the fan hub Refer to correct installation procedure and torque figures Engine mounts loose or broken Check replace the engine mounts Refer to correct installation procedure and torque figures Inlet amp exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances Engine compression low in one or more cylinders Check the engine compression Alternator bearing worn or damaged Check replace the alternator Flywheel housing misaligned Check replace the flywheel alignment Injection pump timing incorrect If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment 57 Fault Finding CHART
40. emoving the FIP Check with local Deutz agent 55 Fault Finding CHART A11 Engine rpm surges Cause Fuel level low Remedy 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 specified in the Technical Specifications section Check the throttle linkages and cable for binding etc Fuel injection lines leaking Inspect and correct as required leaks in the high pressure lines fittings injector sealing washers or delivery valves WARNING Fine jets of fluid can penetrate the skip Keep face and hands well clear of pressurised fluid and wear protective glasses If fluid penetrates your skin seek medical help immediately Fuel tank cap vent breather blocked Inspect amp rectify as required Replace cap if necessary Fuel is aerated Check the fuel system for loose connections and possible air ingress points Rectify and bleed the fuel system One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel d
41. g brakes Hydrostatic retardation Park brake Automatic in rear wheel motors NOISE LEVELS LWA 101dBiA LPA 85dB A TANK CAPACITIES Fuel 29L Hydraulic 29L SKIP Hydraulically operated skip tipping to 91 Heavy duty fully welded skip with Smm thick steel reinforced upper side walls for greater strength Operated by a multi axis joystick for increased performance ELECTRICAL Heavy duty 335 Battery 12V 54h Wiring harness in protective skeving Reversing alarm HYDRAULICS 35cc Automotive control hydrostatic pump 300 bar 14cc Gear pump 170 bar Hydraulic test points fitted as standard Easy access return oil filter on top of tank SEATING amp CONTROLS Adjustable suspension seat accsesible from both sides Clear access across dumper via galvanised steps Super bright warning lights on fully featured display instrument Sted constructed centre console for extra leg protection Column mounted directional control lever Anti slip floor SERVICE ACCESS Easy access for service maintenance Lockable hinged engine cover Battery mounted inside the engine bay We reserve the right to change the above specifications without prior notice FEATURES Unrivalled operator accessibility snd comfort Excellent rough terrain performance from permanent 4 wheel drive Heavy duty construction skip manufactured trom emm steel plate and reinforced around top Column operated forward and reverse drections with acceler
42. isk of cavitation can significantly reduced The gear pump draws oil through a suction strainer element and feeds the steering and main hydraulic functions of the dumper The gear pump incorporates a load sensing valve for the steering and also has two outlets one for the steering and one for the main system Steering of the dumper is by means of a double acting hydraulic cylinder mounted at each end on the two half s of the chassis with the centre point articulation this cylinder when open and closed will provide the steering lock to lock operation The supply of oil is governed by a steering valve unit See schematic layout on flowing page 36 A S L a T ao a Vv ao lt 1 Li gz 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 e Thoroughly clean the machine before any maintenance e Use fresh clean hydraulic oil from a sealed container e Ensure old gasket particles and excess sealing compound etc do not enter the system if they do drain them out e Ensure new parts and fittings are kept in sealed bags etc and they are stored away from any contamination e Remove any flaking paint from around the area being maintained e Use paper roll not rags to wipe parts e Inspect the inside of new tanks for de
43. ke sure the correct lubricating oil is being used Refer to Fluids amp Lubricants section Look for reduced viscosity from dilution with fuel Fuel dilution in lubricating oil can originate from fuel injection pump driveshaft seal or fuel transfer pump Review reduce the lubricating oil change intervals Excessive leaking out of the breather tube system blocked Check the breather tube areas for sign of lubricating oil loss If necessary replace the breather gauze Lubricating oil cooler leak Check for lubricating oil in coolant Turbocharger leaking lubricating oil into the air intake or exhaust Inspect the air crossover tube for evidence of lubricating oil transfer Valve guide seals are leaking Replace valve guide stem seals as required Piston rings not sealing Lubricating oil being consumed by the engine Blue smoke from the exhaust Check engine compression Worn cylinder bores Lubricating oil being consumed by the engine Blue smoke from the exhaust Check engine compression Glazed cylinder bores De glaze bores as required 63 Fault Finding CHART C2 Lubricating Oil contaminated Cause Remedy Coolant in the lubricating oil internal engine Refer to Chart D1 component leaks Lubricating oil sludge excessive Change oil amp filter Review reduce the lubricating oil change intervals If operating in arduous conditions change oil more frequently
44. n circuit pressure IS and filter condition too high YES The seals are deteriorated Replace the seals EG YES Check tightening of mounting screws bleed screws and hydraulic fittings The assembly is incorrect 74
45. ncorrectly Set the valve clearances to the recommended clearances 61 Fault Finding CHART B2 Fuel Oil leaking from exhaust manifold Cause Remedy Operating for extended periods under light or Review operation for correct gear shifts deceleration and idling no load Intake air or exhaust leaks Refer to Charts A13 amp A14 Turbocharger lubricating oil drain line obstructed Check clean line Exhaust leak at the manifold or turbocharger Check correct leaks in the manifold or turbocharger gaskets Look for a cracked manifold Valve guide seals are leaking Replace valve guide stem seals as required One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Injection pump timing incorrect If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment 62 Fault Finding CHART C1l Lubricating Oil consumption excessive Cause Oil leaks Remedy 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 of viscosity Ma
46. ngine coolant level Fuel and water sedimentor Axle service points Hydraulic oil level Air filter restriction indicator Engine oil filter Hydraulic return to tank filter Grease point Skip pivot pins Grease point Hi lift arm pins Grease point Parallel link are pins Grease point Tipping ram pins Grease point Hi lift rams Grease point Centre point articulation casting Maintenance Decal Descriptions Syn Grease point Steering ram Axle oil Fuel filter Engine mounted Hydraulic oil Air filter element Engine coolant Engine checks 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 need to be replaced they can be obtained from NC spares department Hydraulic oil i j Ignition key positions Seat belt must be worn D No repairs to ROPS Pinch points 3 Caution moving parts Do not open when hot Fit skip prop before accessing area Wheel nut torque Tyre pressure Safety Decals and Descriptions DEC 1920 038 Eien 19 fe Safe gradients Lower skip before moving Visibility Transport No passengers Towing Read manual DEC 1920 039 Sot Maintenance decal
47. o either the towing hitch optional or the tying down eyes at the front or rear axle The dumper may only be towed when the following steps have been carried out Failure to observe these tasks will invalidate any remaining warranty and seriously damage the hydrostatic drive pump and wheel motors Open the high pressure circuit on pump Parking brakes released on both wheel motors Max Towing speed 2 Kmph Max towing distance 1 Km OPENING THE HIGH PRESSURE CIRCUIT Unscrew bypass valve A by 2 turns RELEASING PARKING BRAKES Ensure the dumper is on a level surface and that the wheels are chocked to prevent it rolling away Remove amp 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 wheel motor Tighten the nut C until the motor shaft turns freely while holding the screw After releasing always insert a new rubber plug 34 Maintenance BRAKE SYSTEM The main brake system on this dumper is provided by hydrostatic retardation by releasing the accelerator pedal The parking brake is automatically applied when accelerator pedal is released this will act as a secondary emergency brake THE BRAKES ARE ALWAYS ON UNLESS THE ACCELERATOR PEDAL IS PRESSED DOWN WHEN THE DUMPER IS STARTED TO TANK HIGH PRESSURE LINES
48. oil DO NOT OVERFILL 32 Maintenance Oil is toxic If you swallow any oil do not induce vomiting seek medical advice immediately Used engine oil contains harmful contaminants which can cause skin cancer Do not handle used engine oil more than necessary Always use barrier cream or wear gloves to prevent skin contact Wash skin contaminated with oil in warm soapy water Do not use petrol diesel fuel or paraffin to clean your skin HYDROSTATIC DRIVE OIL To ensure proper lubrication and operating temperatures of the drive pump amp 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 Blue Colour Hydraulic oil to DIN51524 3 DO NOT use zinc free hydraulic oil HYDRAULIC OIL LEVEL CHECKING Ensure the engine is stopped Ensure the oil cooler and hydraulic hoses are full by running the dumper a few minutes prior to checking the oil level In this condition the oil level should always be above the suction strainer in the tank ideally just below the top C of the visual indicator Do not over fill the hydraulic tank as it needs room to vent air The oil level should be checked daily and topped up if necessary Overfilling may cause oil leaks 33 Maintenance TOWING PROCEDURE The dumper may only be towed using suitable towing equipment such as a towing bar or cable These must be fixed t
49. olenoid ESOS valve not functioning properly Check for correct operation of the ESOS Fuel filter blocked with water or other contamination Drain fuel water separator or replace fuel filter Fuel lift pump not operating correctly fuel supply inadequate Check that the lift pump is operating and delivering fuel to the injection pump Fuel is aerated Check the fuel system for loose connections and possible air ingress points Rectify and bleed the fuel system Check the fuel inlet restriction Maximum inlet restriction to the fuel transfer pump must not exceed 0 1 Bar 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 Fuel drain return line blocked or not connected properly Verify that the fuel return line is not obstructed and connected to the top of the fuel tank Fuel filter s blocked fuel supply restricted Check replace the fuel filter s Check fuel lines for restriction Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent Injection pump timing incorrec
50. orrectly Lubricating oil filter blocked Change lubricating oil filter Review reduce the lubricating oil change intervals If operating in arduous conditions change oil more frequently Lubricating oil filter drain down valve not fitted Change lubricating oil filter Suction tube loose or broken seal leaking Check replace seal Oil pump pressure relief valve stuck open Replace oil pump assembly Lubricating oil pump worn Replace oil pump assembly 65 Fault Finding CHART C4 Lubricating Oil pressure high Cause Incorrect lubricating oil specification of viscosity Remedy Make sure the correct lubricating oil is being used Refer to Fluids amp Lubricants section Look for reduced viscosity from dilution with fuel Fuel dilution in lubricating oil can originate from fuel injection pump driveshaft seal or fuel transfer pump Review reduce the lubricating oil change intervals Pressure switch or gauge fault Verify the pressure switch is functioning correctly Engine running too cold Refer to Chart D3 Oil pump pressure relief valve stuck closed Replace oil pump assembly 66 Fault Finding CHART D1 Coolant loss Cause Incorrect coolant level Remedy 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
51. per is as safe as possible Only trained persons should carry out repairs 26 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 levels on dumper ensure the machine is switched off positioned on firm stable ground with the handbrake applied The area should be well ventilated and free from all sources of possible contamination i e quarry dust grinding sparks or similar Never check fluid levels near naked flames or hot surfaces CLEANING When cleaning it is preferable to use a biodegradable cleaner Do not use solvents or similar products which can damage rubber and plastics Take care to clean the oil and fuel tank filler necks Areas around drain plugs should also be cleaned Never direct a pressurised water jet on electrical equipment CHANGING OILS Ensure the machine is on solid level ground Only carry out lubrication tasks in a clean area free of contamination of the air Draining of oils is best carried out when they are warm NOT HOT Clean up spilt oil immediately Use only fresh oils of the recommended type and grade Contaminated water Fluids Oils Filters must be disposed of in an environmentally safe way WORKING ON THE HYDRAULIC SYSTEM Never attempt to tighten or
52. posed to battery electrolyte the affected skin must immediately be washed with running water e If eyes are exposed to battery electrolyte wash the eyes with running water and obtain immediate professional medical attention e To remove the battery disconnect the leads and undo the nuts amp bolts E holding the clamping bar Always use the lifting handles when moving a battery 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 gt activated When major maintenance work is being carried out always disconnect the battery removing the negative battery lead first When the battery isolator lever is in the ON F position the machine electrical circuit is fully activated The battery isolator lever may be removed when in the OFF position G and may be used for anti theft protection Maintenance AIR CLEANER SERVICING The air cleaner needs serviced when red fills the window A on the visual indicator B reads 25 kpa This should be one of the daily machine checks Maximum protection for the engine against dust is possible only if the air cleaner is serviced correctly The only way to determine if an air cleaner requires cleaning or replacing is to check When the air cleaner has been services press the button C to reset the indicator Never run the engine with the filtration elemen
53. pulley and this will be the engine rpm Engine overloaded Verify high idle speed without load Investigate operation to ensure correct gear is being used Throttle adjustment incorrectly set or binding Check the engine maximum rpm is as specified in the Technical Specifications section Check the throttle linkages and cable for binding etc Fuel is aerated Check the fuel system for loose connections and possible air ingress points Rectify and bleed the fuel system Fuel lift pump not operating correctly fuel supply inadequate Check that the lift pump is operating and delivering fuel to the injection pump Fuel is contaminated or incorrect grade of diesel used Refer to Fluids amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Fuel filter s blocked fuel supply restricted Check replace the fuel filter s Check fuel lines for restriction One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before r
54. r mat between the battery and the floor Securely chock the wheels or the dumper may be lifted clear of the ground and placed on suitable axle stands to prevent damage to the tyres In either case leave the parking brake off 41 Maintenance ELECTRICS Battery 335 Type 700CCA 90Ampere Hour Capacity Alternator 50A Belt driven The alternator is very sensitive to temperature High temperatures will affect the performance of the alternator and may eventually cause damage to it Never remove the exhaust lagging as this is a temperature resistant material If the exhaust is to be removed always ensure it is refitted with lagging of the following minimum specification Must be able to withstand temperatures of 800 C RELAY amp FUSE BOX LAYOUT Fuses 1 Fuel Pump 2 FNR Switch 3 Horn 4 Drive 5 Accelerator pedal switch 6 Beacon 7 Instrument Display Relays 1 Start inhibit relay 2 Reverse drive 3 Forward drive 42 43 Fault Findin 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 each one dedicated to a particular fault category The charts are designed to identify possible causes by performing checks and where applicable specific tests on the dumper
55. ressure lines fittings injector sealing washers or delivery valves WARNING Fine jets of fluid can penetrate the skip Keep face and hands well clear of pressurised fluid and wear protective glasses If fluid penetrates your skin seek medical help immediately Fuel is contaminated or incorrect grade of diesel used Refer to Fluids amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Intake air or exhaust leaks Refer to Charts A13 amp A14 Engine compression low in one or more cylinders Check the engine compression Injection pump timing incorrect If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent Inlet amp exhaust valve clearances set i
56. s Daily 50 Hours Weekly 100 Hours Fortnightly 500 Hours Six Months 1000 Hours Yearly 2000 Hours 2 Years Service checks should be carried out at which ever interval occurs first Do not use a machine which is due for a service Make sure any defects found during the regular maintenance are rectified immediately i e If the dumper has completed less than 2000 hours at the 2 year period carry out the 2000 hour service EN GINE Service Points amp Fluid Levels Operation ae a 250 500 10001 2000 2000 Hr Hr Hr Hr Hr Hr Oil level Check Coolant Quality Level Check Coolant or Oil Leaks Check Fuel Pre Filter amp Water Sedimentor Check for contamination amp Drain V Belts Check if necessary 6 re tighten or renew Oil amp Filter Change o All Hoses amp Electrical Cables Condition Check Radiator Clean Fuel Filter Change Air Cleaner Outer Element Change Fuel Diaphragm Pump Check Air Cleaner Inner Element Change Fuel Diaphragm Pump Change Fuel Pre Filter Element Change Cooling System Drain amp Fill V Belts Change Injectors Change High Pressure Fuel Lines Inspect Note L First Interval Hr Service only during engine running in period The oil level should be checked twice a day for the first 250 hours then once a day is sufficient Check amp change if noticeable performance related problems due to fuel restrictions gt If the sp
57. t If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new 45 Fault Finding CHART A2 Dumper will not start or difficult to start exhaust smoke Cause Cold starting aid not working if fitted Remedy Check for the correct operation of the cold start advance Intake air insufficient 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 Fuel is aerated Check the fuel system for loose connections and possible air ingress points Rectify and bleed the fuel system Fuel lift pump not operating correctly fuel supply inadequate Check that the lift pump is operating and delivering fuel to the injection pump Fuel is contaminated or incorrect grade of diesel used Refer to Fluids amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Fuel filter s blocked fuel supply restricted Check replace the fuel filter s Check fuel lines for res
58. tainly lead to greater leakage uneven running and poor fuel delivery WATER Water can enter the fuel through poor storage or careless handling and will condense in fuel tanks The smallest amounts of water can result in effects that are just as disastrous to the fuel injection pump as dirt causing rapid wear corrosion and in severe cases even seizure It is vitally important that water is prevented from reaching the fuel injection equipment The filter water trap must be inspected daily and drained if necessary Ist Fuel filter Water trap 2nd Fuel Filter If water trap is full of water the 2nd fuel filter must also be drained WAX Wax is precipitated from diesel fuel when the ambient temperature falls below that of the fuels cloud point causing a restriction in fuel flow resulting in rough engine running Special winter fuels Super Diesel may be available for engine operation at temperatures below 0 C These fuels have a lower viscosity and limit wax formation 24 Fluids amp Lubrication HYDRAULIC OIL HVZ 46 High Viscosity Blue Colour DIN51524 3 Viscosity index 150 DONOT USE ZINC FREE HYDRAULIC OILS GENERAL GREASE POINTS Multi purpose grease 25 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 pl
59. triction Fuel drain return line blocked or not connected properly Verify that the fuel return line is not obstructed and connected to the top of the fuel tank Check the fuel inlet restriction Maximum inlet restriction to the fuel transfer pump must not exceed 0 1 Bar Injection pump timing incorrect If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment Inlet and exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Engine compression low in one or more cylinders Cranking speed too slow Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Check the engine compression Refer to Chart A3 for possible low cranking speed faults Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes have been eliminated before removing the FIP Check with local Deutz agent 46 Fault Finding CHART A3 Engine will not crank or cranks slowly Cause Starting electrical connections loose or
60. ts removed from the air cleaner e Squeeze the solids ejector to remove material from the pre cleaner drop tube e To service the air cleaner first clean its surrounding area and then release the 2 retention latches D holding on the end cover E e Remove the primary filter F by pulling it out from the x main filter body this will expose the inner safety filter G Either renew or clean these elements Clean by using compressed air to carefully blow dust out of the filter e Reassemble by reversing the above procedures e Replace the service cover The AINLETO arrow should line up with the air cleaner inlet DO NOT force cover onto air cleaner The cover should go on with no extra force If cover is not flush to the body the filter is not properly seated in the housing 7 29 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 draining the system e When the engine is cold check the coolant level by unscrewing the radiator cap A and add coolant until the coolant is just below the top of the filler neck e Replace the expansion tank filler cap A DRAINING THE COOLING SYSTEM e Ensure the engine is cold carefully undo the pressure
61. ture sensor A total coolant loss may result in the gauge showing a low temperature initially Check coolant level Check clean coolant passages CHART D4 Coolant contaminated Cause Coolant rusty operating without the correct mixture of antifreeze and water Remedy Drain and flush the cooling system Fill with the correct mixture of antifreeze and water Review the coolant interval change Lubricating oil leaks from lubricating oil cooler head gasket head and cylinder block Refer to Chart D1 69 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 amp adjust if necessary Test pressure on G port on pump Test pressure on ports M1 amp M2 on pump Contact NC regarding refurbishment or replacement Dumper will not move drive Check FNR lever is engaged Check Fuses amp Relays Check continuity of wires to solenoid on pump Test pressure on G port on pump Check the flow from G port on pump 70 Fault Finding CHART E2 Noisy wheel motor Noisy motor J Motor is noisy m without load NO Motor is noisy YES under load YES Regular rumbling worn bearing support J Vibrations mountings YES and or hydraulic piping become loose Clattering boost YES pressure too low EG Cavitation excessive YES internal leaks

HT1_5 Deutz Maintenance manual Revision B

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