Home

ST10 maintenance manual Revision C

1. Check the electronic fault codes Do all the necessary fault finding checks before removal of the high pressure fuel pump Refer to NC for assistance for removal amp replacement procedures 73 Fault Finding CHART A12 Engine excessive vibration Cause Remedy Engine not running smoothly missing Refer to Chart A5 Oil level over full Check oil level 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 Set the valve clearances to the recommended clearances incorrectly Engine compression low in one or more Check the engine compression cylinders Alternator bearing worn or damaged Check replace the alternator Flywheel housing misaligned Check replace the flywheel alignment ECU or electrical sensor fault Check the electronic fault codes Check the electrical connections at the ECU and sensors Drive line components worn or unbalanced Check and inspect drive line components such as prop shafts Refer to Page 23 of this manual 74 Fault Finding CHART A13 Engine exhaust smoke excessive Black smoke Cause Remedy E
2. Check the electronic fault codes Check the electrical connections at the injectors Engine compression low in one or more cylinders Cranking speed too slow Worn or malfunction high pressure fuel pump Check the engine compression Refer to Chart A3 for possible low cranking speed faults Check the electronic fault codes Do all the necessary fault finding checks before removal of the high pressure fuel pump Refer to NC for assistance for removal amp replacement procedures 63 Fault Finding CHART A3 Engine will not crank or cranks slowly Cause Remedy Starting electrical connections loose or Clean and tighten connections corroded 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 Check voltage to solenoid 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 64 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 fo
3. Set the valve clearances to the recommended clearances Engine compression low in one or more cylinders Check the engine compression One or more injector worn or malfunctioning Check the electronic fault codes Check the electrical connections at the injectors ECU or electrical sensor fault Worn or malfunctioning high pressure fuel pump Check the electronic fault codes Check the electrical connections at the ECU and sensors Check the electronic fault codes Do all the necessary fault finding checks before removal of the high pressure fuel pump Refer to NC for assistance for removal amp replacement procedures 67 Fault Finding CHART A7 Engine excessive noise Cause Drive belt squeal insufficient tension or abnormally high 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 Coolant temperature sensor fault Check the electrical connection at the coolant sensor Check the correct electrical wires for open or short circuits Check the electronic fault codes Test the coolant sensor If engine will not reach operating temperature refer to Chart D Air intake or exhaust leaks Refer to Charts A13 amp A14 ECU or electrical sensor fault Check the ele
4. ORGINAL INSTRUCTIONS ST10 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 D Dear Customer Even if you have operated this type of equipment before it 1s 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 O 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 Contents Declaration of Conformity Noise Level Declaration Vibration Declaration Technical Information Maintenance Deca
5. E718 Engine position sensor fault camshaft sensor abnormal pulse width or frequency E719 Engine speed crankshaft position sensor fault no signal E720 Engine speed crankshaft position sensor data erratic target disc gap signal missing E725 Wiring harness resistance too high or too low cylinder 4 E726 Wiring harness resistance too high or too low cylinder 2 E727 Wiring harness resistance too high or too low cylinder 1 E728 Wiring harness resistance too high or too low cylinder 3 E729 Engine injector bank 1 cylinders 2 and 4 ECU fault E730 Engine injector bank 2 cylinders 1 and 3 ECU fault E737 Engine knock sensor fault E738 Hand throttle position sensor fault data erratic E745 Minimum injector drive pulse drift cylinder 4 injector not responding correctly Make a note of the occurring fault code s and contact NC for further assistance 89 Fault Finding DUMPER GEARBOX Before commencing any checks make sure that the correct type of transmission fluid has been used and that it is at the correct level CHART F1 Lack of Power Cause Remedy 1 Poor Engine condition Check amp if necessary repair engine 2 Low oil level Top up system 3 Worn pump Check flow and if necessary repair or renew pump 4 Torque converter damage Check and if necessary repair or renew torque converter 5 Low main line pressure See fault Low main line pressure 6 Clutches slipping See fault Low clutch pressure 7 Int
6. no load Intake air or exhaust leaks Refer to Charts A13 amp A14 Turbocharger lubricating oil drain line Check clean line obstructed 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 ECU or electrical sensor fault Check the electronic fault codes Check the electrical connections at the ECU and sensors One or more injector worn or Check the electronic fault codes Check the electrical connections malfunctioning at the injectors 79 Fault Finding CHART CI Lubricating Oil consumption excessive Cause Remedy Oil leaks Inspect the engine for visible signs of leaks Pay particular attention to the seals gaskets oil cooler and external connections Oil level over full Check oil level Incorrect lubricating oil specification of viscosity 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 Crank case ventilation CCV system blocked Check the breather tube area for signs of lubricating oil loss Check and if necessary replace the CCV filter Lubricati
7. system defective Check the throttle assembly Check electronic fault codes Fuel is contaminated or incorrect grade of diesel used STOP THE ENGINE Replace the fuel filters Operate the engine with a temporary supply of the correct grade of clean fuel 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 WARNING Dirty fuel will cause damage to the high pressure fuel pump amp injectors Turbocharger boost control pipe leaking or damaged or waste gate diaphragm ruptured Check boost control pressure Inspect and tighten fittings repair pipes replace waste gate assembly Fuel injection lines leaking Replace defective high pressure fuel lines WARNING DO NOT repair defective fuel lines If there is a fuel leak remove and discard the necessary components and install new ones WARNING Fine jets of fluid at high pressure can penetrate the skin Keep face and hands well clear of pressurised fluid and wear protective glasses If fluid penetrates your skin get 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 inadequa
8. 3 compliant TRANSMISSION Torque converter c w 4 speed forward and reverse power shutte transmission Permanent 4 wheel drive DRIVE CHARACTERISTICS Forward Reversa tst 0 49 km 0 3 1 mph 2nd 0 7 0 km 0 4 9 mph ar 0 16 9 kmm 0 10 6 mph sn 0 32 kn 0 20 mph Steering ange 30 Turning circle 1288m Grade abllit y 50 Tyres 500 60 R22 5 traction Profils Steering Priority load sensing hydrostatic centre pivot Working brakes Multi plate oll Immersed discs mounted on both axes Park brake Hand operated locking on dry disc acting on gearbox NOISE LEVELS UNA TO4dIB A LPA 8506A TANK CAPACITIES Fug TAL Hydraulc 70L SKIP Manufactured from higher tensile steels Hydraulcally operated skip tipping to over 20 Heavy duty fully welded skip with amp mm thick steel base reinforced upper side wals for greater strength Operated by a multi axis Joystick for Increased performance ELECTRICAL Heavy duty 60045 Battery 12V 185Ah 1000CCA Wiring hamees n protective sasing Reversing alarm HYDRAULICS Hydraulic test points fitted as standard Easy access return oil fitter on top of tank Easy access pressure filter SEATING amp CONTROLS Adustable suspension saat accessible from both sides Clear access across dumper vla galvanised steps Extra wide brake padal Super bright warning lights on fully featured display instrument Steel constructed centre console for extra leg protection
9. Aejdsig jeueg useg 7D 59 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 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 If possible talk to the operator for a description of the fault Also check if any recent maintenance or repair has been carried out on the dumper 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 N
10. Cause Remedy Pressurisation of gearbox casing Water in oil combined with heat from Replace renew dipstick dipstick blows out oil leaking from torque converter causes steam Carry out flushing procedure dipstick tube Refill with recommended grade of oil Gearbox overfilled with oil Drain the oil level to the correct level See page 23 Clutch failure Friction lining Water ingress Renew friction plates separation Carry out flushing procedure Refill with recommended grade of oil Overheating transmission oil See fault finding table E11 Badly worn noisy bearings Water ingress Fit new bearings Carry out flushing procedure Insufficient lubrication Refill with recommended grade of oil 98 Fault Findin Transmission Oil Contaminated with water continued If the transmission cooler becomes contaminated due to the ingress of water stop the engine immediately Drain oil from the transmission sump and external cooler circuit into a suitable container Caution The oil could be hot avoid contact with the skin to prevent scalds INSPECTION Inspect the transmission generally for visible means of water entry into the system Disconnect the transmission cooler circuit and clean thoroughly The transmission cooler is a possible source of water contamination and should be tested for a possible failure as follows COOLER TEST PROCEDURE 1 Remove the cooler from its mounting Drain the remaining oil water fr
11. Converter internal leakage Check and if necessary renew converter 3 Converter relief valve faulty Check and if necessary repair relief valve 4 Restriction in converter feed See fault Overheating point 10 CHART F6 Low Pump Flow Cause Remedy 1 Low oil level Top up system 2 Blocked suction strainer Clean suction strainer 3 Worn Pump Repair or renew pump CHART F7 High Converter Out Pressure Cause Remedy 1 Oil cooler lines blocked Clean cooler free blockage 2 Converter in pressure incorrect Check converter in pressure correct 3 Converter relief valve faulty Check and if necessary repair relief valve 91 Fault Finding DUMPER GEARBOX CHART F8 Low Lubricant Pressure Cause Remedy 1 Low mainline pressure See fault Low mainline pressure 2 Oil cooler lines blocked Clean cooler free blockage 3 Ruptured lubrication line Repair line 4 Converter internal leakage Check amp if necessary renew converter 5 Converter relief valve faulty Check amp if necessary repair or renew relief valve 6 Leak at pump to case joint indicated by Check and if necessary repair or replace ow cooler flow 7 Restriction in converter feed See fault Overheating point 10 CHART F9 Low Clutch Pressure and or Clutch Slipping Cause Remedy 1 Low mainline pressure See fault Low mainline pressure 2 Worn Pump Check flow and if necessary repair or renew pump 3 Blocked restrictor orific
12. Is pump being driven by converter YES Check pump pressure NO Renew damaged parts 16 Are clutch sealing rings damaged YES Tap pressure gauge into clutch feed lines to monitor pressure NO Check clutch plates for damage 17 Isthere drive in one direction only YES Check 19 NO Check 18 18 Is the start switch in the run position and supplying current to the YES Check 19 neutral start relay NO Rectify 19 Isthe fault only when the transmission is hot YES Dismantle solenoid and check components NO Check micro switches relays and wiring loom 20 Is the noise a growl hum or grinding YES Check gears for damage wear NO Check 21 21 Is the noise a hiss thump or bumping YES Check bearings for damage wear NO Check 22 22 Isthe noise a squeal YES Check free running gears for seizure NO Check 23 23 Isthe noise present when in neutral or when in gear NEUTRAL Check 24 IN GEAR Check 27 95 Fault Finding CHART GI Dumper gearbox continued Check Action 24 Isthe counter shaft or it bearings worn or damaged Renew damaged parts Check 25 25 Isthere excessive backlash in the gears Adjust by checking shaft end float Check 26 26 Is the main shaft pilot bearing worn Renew Check gear teeth for scuffing 27 Isthe main shaft rear bearing worn Renew Check 28 28 Are the sliding gear teeth worn or damaged Renew gears Check 29 29 Are the selector fork
13. Operator level gaar selection kver with integrated clutch button Column mounted directional control lever Heater vert at foot level Anti sip floor Horn operable from joystick SERVICE ACCESS Easy access for service maintenance Lockable hinged engine cover Battary mounted In lockable step compartment Lockable tool box compartment on step Separate lockable fuel amp hydraulic filler flaps Wa reserve the right to change the above specifications without prior notice FEATURES Urrivalled operator accessibility and comfort Excellent rough terrain performance from permanent 44v heel drive Heavy duty construction skip manufactured from amm steel plate and reinforced around top Column operated forward and reverse directions with acceleration 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 tempersture Folding ROPS as standard Easy access to engine compartment for service and maintenance Recovery brackets as standard 130 HP engine 97 Kw Excellent power to weight ratio Theft deterrent Cesar Data Tag System as standard Ample ground clearance Superior turning circie Reversing alarm standard Handbrake safety device will not move until released Lockable toolbox and battery co
14. Seal amp Injector Seals Change Fan Belt Change Injectors Change Injector s Leak Off Rail o Change High Pressure Fuel Lines Change Check amp change if noticeable performance related problems due to fuel restrictions f operating under arduous conditions do an oil flush amp change the engine oil amp filter every 250 hours The oil service interval will be affected if there is a high sulphur content in the fuel Refer to fuels amp lubricants section When engine is operated with 20 bio diesel change the engine oil amp filter every 250 hours Refer to fuels amp lubricants section re operating with bio diesel If operating in dusty adverse conditions do these jobs more frequently Will require changing if operating in arduous applications Only fitted until serial No 032067 These jobs must be done by a qualified engineer 23 Service Schedules AXLE Operation 10 50 100 1000 2000 Service Points amp Fluid Levels Hr Br Hr HE Mr Hubs Check for Leaks Axle Oil Level incl Hubs when applicable Check Axle Oil Change Tightness of Mounting bolts Torque to 970Nm 7151bf ft Tightness of Wheel Rim Nuts Torque to 680Nm 500Ibf ft GEARBOX Operation 10 50 100 500 1000 H H H H H Pre start Cold Checks r S Transmission oil level Check Transmission Oil Change Transmission Filter Change Transmissi
15. Transmission Oil Contaminated with water Carefully inspect the gearbox for signs of water contamination Contaminated oil will contain water droplets or be visibly emulsified Water droplets may be visible on the dipstick or inside the filler tube For oil analysis purposes the maximum permissible water content of the oil is 0 10 If the transmission has be contaminated with water faults or damage to the gearbox may be apparent as a result Before remedying thoroughly investigate and rectify the cause of the water contamination CHART H1 Transmission Oil Contaminated with water Cause Remedy 1 Water ingress during filling topping up Carry out flushing procedure Refill with the recommended grade of oil 2 Missing Incorrect dipstick or damaged Renew missing incorrect damaged components filler tube Carry out flushing procedure Refill with the recommended grade of oil 3 Machine operated in deep water Carry out flushing procedure Refill with the recommended grade of oil 4 Gearbox casings damaged Inspect amp renew damaged components Carry out flushing procedure Refill with the recommended grade of oil 5 Gearbox oil circuit pipes hoses dam Inspect amp renew damaged components aged Carry out flushing procedure Refill with the recommended grade of oil Gearbox faults caused typically by water contamination and other factors related to the transmission oil Fault Possible
16. automatically when the lift pump is operated Make sure that as much air as possible is REMOVED from the system before starting the engine The system can be bled by simply turning the started switch to ON not start position the pump can be heard operating Note the pump will turn off after a pre determined period of time IMPORTANT Do not attempt to bleed the high pressure fuel system by loosening the high pressure pipe connections even when the engine is not running To bleed the fuel system follow the correct procedure Call NC if in doubt WARNING DO NOT open the high pressure fuel system with the engine running Engine operation causes high fuel pressure High pressure fuel spray can cause serious injury or death 36 Fluids amp Lubrication GEARBOX OIL NC recommend Fuchs Titan TO4HD10 Up to 30 C Ambient Alternative Suppliers Shell Spirax CX10 Mobil Trans HD10 BP Autran 4 10 NC recommend 704HD30 For Temperatures above 30 C Ambient Alternative Suppliers Shell Spirax CX30 Mobil Trans HD30 BP Autran 4 30 TRANSFER BOX NC recommend Mobile HP222 Grease Alternative Suppliers Shell Gadus S3 V220C 2 Fuchs Renolit LX EP 2 BP Energrease LC2 NC recommend Mobilube HD90 International Specification API GL5 1Litre Alternative Suppliers Shell Spirax MB90 Titan Gear HYP SAE90 BP Energear Hypo 90 AXLE OIL NC recommend Mobil 424 International Specification API GL4 M2C 41B 134D JD20C 23 Litres A
17. 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 83 Fault Finding CHART D1 Coolant loss Cause Remedy Incorrect coolant level Check the level Coolant leaking from engine radiator Visually inspect the radiator hoses and connections to locate the leak If oil is present in the coolant check for an engine oil cooler leak External engine coolant 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 Refer to Chart D2 resulting in loss through the radiator overflow 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 84 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 l
18. ep ten Hour Reading Hour Reading First 4000 Hr First 9500 Hr BE EE 2 Date satis dent f Hour Reading Hour Reading First 4500 Hr First 10000 Hr Date manner Date osse nets 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 TT TT N N Service Schedules CALENDAR EQUILIVANTS 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 ENGINE Service Points amp Fluid Levels OPeration 10 50 500 1000 2000 6000 Hr Hr Hr Hr Hr Hr Oil level Check Coolant Quality Level Check Coolant or Oil Leaks Check Fuel Filter amp Water Sedimentor Check for contamination amp Drain Fuel Filter on dumper adjacent to radiator Change Oil amp Filter Change All Hoses Condition Check Radiator Clean Fan Belt Condition Check Fuel Filter engine mounted Change Air Cleaner Outer Element Change Crankcase Ventilation Filter Change Air Cleaner Inner Element Change Valve Clearances Check amp Adjust Oil Filler amp Dipstick O Rings Change Cooling System Drain amp Fill Rocker Cover
19. important that water is prevented from reaching the fuel injection equipment The filter water trap must be inspected daily and drained if necessary The pre filter is fitted with an electronic water in fuel sensor linked to the instrument display FILTERS The pre filter element locks in position using a Key Track system which ensures only genuine high quality filter replacements are used The existing Dieselmax Tier 2 30 micron filter element will not fit If there appears to be a problem when fitting filters always check the part numbers FUEL SYSTEM PARTS amp CLEANINESS It is critical the engine is thoroughly cleaned prior to removing any part of the fuel injection system The fuel filtration system has been designed to remove contaminants from the fuel supply however contamination during service maintenance work is a significant risk to fuel injection equipment failure Any work carried out which involves disturbing the fuel delivery system will require the machine to be cleaned thoroughly before any work in commenced Consult NC for areas to be cleaned High pressure pipes MUST be replaced with new ones if loosened or removed When initially installed the fuel pipes create a seal re using old pipes will not guarantee a good seal and increase the risk of contamination Pre filter Water trap Main Fuel Filter If water trap is full of water the main fuel filter must also be drained WAX Wax is precipitated from diesel fu
20. industry A high percentage biodiesel mixture 220 can lead to fuel gelling and filter blocking in low temperature operation it may also effect the power and performance of the engine To minimise the risk of engine damage when using a B20 mix there are additional service requirements The engine oil must be a grade CH4 as minimum specification Do not leave unused B20 biodiesel in the fuel tank for extended periods top up each day Make sure that 1 in 5 fuel tank fills use standard diesel to EN590 specification this will help to prevent gumming Make sure regular oil sampling is completed look for excessive unburnt fuel content water or wear particles Change the engine oil and filter more frequently as a minimum half the recommended intervals or as indicated by oil sampling 32 Fluids amp Lubricants Change the fuel filters more frequently as a minimum half the recommended intervals or if there are engine performance related issues Make sure the fuel 1s stored correctly care must be taken to make sure no water enters the machine fuel tank or the storage tank Water will encourage micro bacterial growth Make sure that the fuel pre filter is drained DAILY not every week as currently advised Only JCB Engines built after jan 2007 are applicable i e engines with 07 on the end of their serial number and factory filled with CH4 oil this is not approved with other manufacturers Use h
21. 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 Fuel cleanliness is extremely important 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 D975 91 Class 2 US DF1 US DF2 US DFA e JIS K2204 1992 Grades 1 2 3 and Special Grade 3 e BS2869 Class A2 Biodiesel use amp Service Requirements B20 Biodiesel RME content blended with mineral derived diesel 20 maximum ASTM D6751 DIN 51606 ISO 14214 may be used Do not leave unused B20 Biodiesel in the tank for extended periods top up each day Make sure that 1 in 5 fuel tank fills is of standard EN590 specification diesel to help reduce gumming Make sure regular oil sampling is carried out to look for unburnt fuel water or wear particles Use sample bottles Part Number LUB 1895 500 available from NC Change the engine oil amp filter more frequently as a minimum at half the recommended intervals on page 7 or sooner if there are engine performance related issues Change the fuel filters more frequently as a minimum at half the recommended intervals on page 7 or soo
22. 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 40 Maintenance AIR CLEANER SERVICING The air cleaner needs serviced when the red line on the visual indicator line A reads 75 kpa the box on the indicator labelled service when red B will also be filled This should be one of the daily machine checks Maximum protection for the engine against dust 1s 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 Never run the engine with the filtration elements removed from the air cleaner e Squeeze the solids ejector C to remove material from the pre cleaner drop tube e To service the air cleaner first clean its surrounding area and then release the 4 retention latches D lift off the top lid E e Remove the primary filter F by pulling it out from the 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 41 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
23. may adversely affect the performance of the parking brake 50 Maintenance AXLES The axles have totally enclosed amp sealed multi plate brakes and compensate automatically for brake wear As the brakes wear ensure the fluid reservoir is kept topped up to the MAX level Over a period of time wear may necessitate replacement of the friction discs and or the slave cylinder seals These parts should be replaced as required and the system bled in accordance with the brake bleeding instructions A badly maintained axle is a danger to the operator and the people working around him Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the axle in a safe and efficient working condition CHECK OIL LEVEL e Ensure the machine is parked on level ground to ensure accurate oil level checking e Atthe drive head casing remove fill level plug A Oil should be level with the bottom of the fill level hole e f necessary top up with the recommended axle oil Clean and refit fill level plug A CHANGING AXLE OIL e Set the machine level with the tyres just clear of the ground Manually rotate both wheels of the axle to bring the OIL LEVEL mark on the hubs to the vertical position with the fill level plug D at the bottom e Remove the fill level plug D from the hubs and the drain plug B from the drive head casing Allow time for the oil to drain out e Clean and refit drain
24. obstructed and connected to the top of the fuel tank 65 Fault Finding CHART A5 Engine poor running Cause Remedy Condition occurs only at idle Refer to Chart A6 for possible poor running at idle faults Engine is cold Coolant temperature sensor fault Check the electrical connection at the coolant sensor Check the correct electrical wires for open or short circuits Check the electronic fault codes Test the coolant sensor If engine will not reach operating temperature refer to Chart D Fuel injection lines leaking Replace defective high pressure fuel lines WARNING DO NOT repair defective fuel lines If there is a fuel leak remove and discard the necessary components and install new ones WARNING Fine jets of fluid at high pressure can penetrate the skin Keep face and hands well clear of pressurised fluid and wear protective glasses If fluid penetrates your skin get 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 operates and delivers fuel to the high pressure fuel pump Check the correct electrical wires for open or short circuits Fuel filter s blocked fuel supply restricted Check replace the fuel filter s Check fuel lines for restriction Fuel is contaminated or incorrect
25. 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 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 BRAKE FLUID Under NO circumstances must conventional brake fluid be used or added to the brake system This will cause damage to the rubber sealing components and may cause the brakes to fail ALL COVERS AND PANELS MUST BE FITTED BEFORE DUMPER IS USED 39 Maintenance BATTERY LOCATION The battery is located in the left hand footstep assembly It is accessed by turning the key lock A on the side and then hinging the step B towards the
26. plug B e Set both hub OIL LEVEL marks to the horizontal C e Fill the axle with the specified quantity of oil through the drive head casing fill level plug A see the Fluids amp Lubricants section If the machine has been set level oil should just dribble out of both hubs fill level points e Clean and refit both hub fill level plugs C and fill level plug A 51 Maintenance HYDRAULIC SYSTEM The hydraulic system provides power to the steering skip tip and scraper blade optional extra functions The hydraulics consists of an engine driven pump drawing oil from a tank In the tank there is a suction strainer filter and breather cap fitted the tank is made from a transparent material and the level of oil can be seen through the side of it a max and min decal shows the operator the correct level The pump incorporates a load sensing valve for the steering and also has two outlets one for the steering and one for the main system A return to tank filter is fitted and is of the replaceable cartridge type Steering of the dumper is by means of a double acting hydraulic cylinder mounted at each end on the two halfs 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 Steering Cylinder Scraper Blade Cylinder optional 52 Maintenance HYDRAULICS During any hydrauli
27. temperatures takes place Chemically Modified Vegetable Oils FAME VOME These fuels have been derived from a wide range of vegetable oils and animal fats resulting in better stability viscosity and cetane number tan those produced from unmodified vegetable oils but it is recognised with the finished fuel characteristics These oils are less stable than mineral oil derived fuels when stored and they will readily degrade producing fatty acids methanol and water none of which are desirable in the FIE These effects are known to be accelerated when the fuel is sorted in the presence of air and water together An extract common statement from the FIE manufactures specifies that The fuel injection equipment manufacturers can accept no liability whatsoever for failure attributable to operating their products with fuels for which the products were not designed and no warranties or representations are made as to the possible effects of running these products with such fuels 31 Fluids amp Lubricants The three most common Fame types are RME Rapeseed methyl ester preferred crop in Europe SME Soyabean methyl ester preferred crop in USA Less common FAME s can be derived from animal fats eg Modified beef extracts and reclaimed cooking oils B20 Biodiesel Biodiesel refers to pure fuel before it is blended with diesel fuel When biodiesel is blended with diesel fuel it 1s referred to as B5 B20 etc where the number indi
28. 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 21 Service Record Sheet First 50 Hr First 5000 Hr D te 2n soos Date s a nt dst e Hour Reading Hour Reading First 100 Hr First 5500 Hr Datei hate Date esset Rm Hour Reading Hour Reading First 500 Hr First 6000 Hr Date Date sisi Hour Reading Hour Reading First 1000 Hr First 6500 Hr Date tos Date indue Hour Reading Hour Reading First 1500 Hr First 7000 Hr Date ves Date tech sis cases Des First 2500 Hr First 8000 Hr Date sis MEDE DRIE EE BEA EE Hour Reading Hour Reading First 3000 Hr First 8500 Hr Date EE Date Hour Reading Hour Reading First 3500 Hr First 9000 Hr Date teen ES Date
29. wheel 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 weld cut grind etc in the vicinity of a battery being charged e Ifthe skin is exposed 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 would be dangerous if the engine was to be started or the electrical system 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
30. ART 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 at the fuel tank fuel lines filters and lift pump Replace defective high pressure fuel lines WARNING DO NOT repair defective fuel lines If there is a fuel leak remove and discard the necessary components and install new ones WARNING Fine jets of fluid at high pressure can penetrate the skin Keep face and hands well clear of pressurised fluid and wear protective glasses If fluid penetrates your skin get medical help immediately Intake air or exhaust leaks Refer to Charts A13 amp A14 Engine compression low in one or more cylinders Check the engine compression ECU or electrical sensor fault Check the electronic fault codes Check the electrical connections at the ECU and sensors One or more injector worn or malfunctioning Check the electronic fault codes Check the electrical connections at the injectors Inlet amp exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances 78 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
31. Angle Tightening Procedure The following example explains the recommended torque angle procedure A torque es ER angle gauge should be used for accuracy but as a visual check the bolts can be match marked as described below 1 Tighten the bolt to the specified torque specified torque values will be detailed in the relevant sections B 2 Mark a line across the centre of the bolt and a second line on the part to be clamped the two lines should be aligned as shown at A 7 3 Mark a third line at the specified torque angle in this instance the additional torque ES 1 angle is 90 This line must be marked the specified angle in a clockwise direction L to further tighten the bolt as shown in B 490 4 In some instances angle torque tightening can be specified in two stages for instance in this example the first angle quoted is 90 shown at B and then a second angle of C 180 angle is from the LAST tightened position as shown at C 5 Tighten the bolt so that the line on the bolt aligns with the angle s marked on the 180 Beh aa item to be clamped remember to ensure complete accuracy an angle gauge should be use Technical Specifications Engine Torque Figures Item Nm Lb ft Angle Oil cooler drain plug 35 40 26 29 Item Nm Lb ft Angle Oil sump retaining bolts A 22 26 16 19 Oil sump plug B 40 60 30 44 Technical Specifications Engine Torque Figures Item Nm Lb ft Angle Fuel filter reta
32. OT attempt the task ELECTRONIC FAULT CODES The engine fuel injection system is electronically controlled The electronic control unit records some system faults as code The codes can be accessed by connection of the correct computer diagnostic software to the machine CAN system Access the fault codes to help identify engine faults Fault code data is given in this manual Refer to Section Electronic Fault Codes Fault code data is also included with the ServiceMaster DieselMax diagnostics software 60 Fault Finding ENGINE WARRANTY INFORMATION 1 All fuel system parts replaced during the warranty period must be returned to NC Engineering 2 Warranty claims not supported with the returned part will be declined 3 To prevent removed part contamination an allowance time of 1 hour is given for cleaning the engine jet wash dry prior to removing any of the fuel system components The removed components should be capped amp bagged Caps kits are available from NC Engineering 4 Any parts that are not cleaned and not capped and bagged or have evidence of external contamination will result in the subsequent warranty claim being rejected 5 Ifa fault is diagnosed using Service Master i e a sensor then a screen dump of the error code should be taken use Ctrl Print Screen key combination the screen dump should be attached to an email with the dumper serial number also included 6 Anallowance of 1 hour has been allowed for
33. ade of oil to use contact NC If a diesel particulate filter is fitted a low ash type oil must be used to prevent the filter clogging 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 11 5 L MIN and 14L MAX mark on the dipstick COOLANT MIXTURES Anti freeze can be harmful Obey the manufacturers instructions when handling neat or diluted antifreeze NC recommends JCB High Performance anti freeze If another anti freeze is used refer to the manufacturers instructions and ensure a corrosion inhibitor is included Must conform to standard ASTM D6210 and must be ethylene glycol based DONOT use Organic Acid Technology OAT antifreeze Do not use solutions of more than 60 or less than 50 or damage to the cooling system will occur 50 solution maintains circulation down to 33 C and protects against damage to 40 C 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 50 anti freeze mixture is required even if frost protection is not required as this raises the coolants boiling point 27 Fluids amp Lubricants FUEL SPECIFICATION The quality and grade of fuel can seriously affect the
34. al level E133 High pressure fuel pump mechanical system not responding E134 Injector metering rail pressure sensor fault voltage above normal or shorted high E135 Injector metering rail pressure sensor fault voltage below normal or shorted low 88 Fault Finding CHART EI Fault codes continued Fault Code Description E138 Fuel pump calibration trim circuit fault calibration fault E142 Fuel metering solenoid fault E159 Cylinder power imbalance data erratic E700 High pressure fuel pump delivery pressure low data below normal level E701 High pressure fuel solenoid valve number 1 fault data erratic E702 High pressure fuel pump mechanical system not responding E703 High pressure fuel pump delivery pressure low data above normal level E704 Engine knock sensor fault abnormal pulse width or frequency E705 Minimum injector drive pulse drift cylinder 2 injector not responding correctly E706 Minimum injector drive pulse drift cylinder 1 injector not responding correctly E707 Minimum injector drive pulse drift cylinder 3 injector not responding correctly E708 Engine control module main relay fault relay not responding correctly E709 Engine coolant temperature validity no fault temperature sensor data is plausible E715 Boost pressure validity no fault air pressure sensor data is plausible E716 Throttle pedal position sensor fault data erratic
35. amp Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank WARNING Dirty fuel will cause damage to the high pressure fuel pump amp injectors 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 ECU or electrical sensor fault Check the electronic fault codes Check the electrical connections at the ECU and sensors One or more injector worn or malfunctioning White blue smoke at operating temperature Check the electronic fault codes Check the electrical connections at the injectors Coolant leaking into combustion chamber Refer to Chart D1 Leaking valve stem seals Evident after long idle period then acceleration Replace valve seals Piston rings not sealing Evident with persistent blue smoke at all speeds loads Check the engine compression 76 Fault Findin CHART A15 Engine will not shut off Cause Remedy Stop Switch or stop switch electrical system Check the operation of the stop switch Check the correct electrical wires failure for open or short circuits T Fault Finding CH
36. be worn US cNLY DEC 1920 014 tea vaar rg Recommended brake fluid RAEE FL PACHE BML Hw DEC 1920 015 ae Ram Recommended brake fluid Circular mers CL rc ML EIE DEC 1920 016 No repairs to ROPS Safety Decals and Descriptions Part No Symbol Descriptions DEC 1920 017 AIA Stay clear of pinch points DEC 1920 018 DEC 1920 019 DEC 1920 020 DEC 1920 023 DEC 1920 024 UE Read manual Apply handbrake before leaving dumper Release handbrake before moving dumper Caution moving parts Do not open when hot Forward and Reverse Tyre pressure and wheel nut torque Rear Tyre pressure and wheel nut torque Front DEC 1920 025 DEC 1920 026 DEC 1920 027 DEC 1920 028 DEC 1920 029 Sound levels Safe gradients No tipping on a gradient Lower skip before moving Fit skip prop before access Don t operate controls without reading the operators manual Skip controls DEC 1920 030 Maintenance decal DEC 1920 031 20 ST10 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
37. bled instrument display unit If an electronic fault occurs this information with be visible on the instrument If an ECU sends an error message the attention light at the bottom of the display will be illuminated the hour meter will rear StoP and the error codes will be cycled up to a maximum of 10 codes at 1 second intervals Error codes will cycle here Error code active Attention Error All codes can be accessed via a suitable laptop computer running the applicable diagnostics software The computer must be connected to the dumper via the CANbus socket located under the floor panel using the correct Data Link Adapter DLA The ECU incorporates a data logging feature so should faults occur they will be logged into the ECU memory CHART E1 Fault codes Fault Code Description E001 Engine ECU warning E002 Engine speed crankshaft position sensor data erratic target disc tooth signal missing E004 Fuel timing pressure sensor ECU circuit fault voltage below normal or shorted low E008 Inlet manifold air pressure sensor TMAP fault voltage above normal or shorted high E009 Inlet manifold air pressure sensor TMAP fault voltage below normal or shorted low E010 Throttle pedal position sensor fault voltage above normal or shorted high E011 Throttle pedal position sensor fault voltage below normal or shorted low E012 Hand throttle position sensor fault voltage above normal or shor
38. 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 I806395 1998 The noise level of this machine is Lwa 104dB A Lpa 85dB A Lwa A Weighted sound power level Lpa 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 ay m s 0 25 Hand Arm apa m s lt 2 4 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 load 10000 kg Heaped SO70L Struck 4140 Water 24006 ENGINE JCBAAAT 4 cylinder Turbo with After Cooling Displacement 44L Max power 97KW 1306hp 2 2200 rpm Max torque 525Nm 1300 rpm Emissions Euro
39. c 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 debris 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 Tank Suction Strainer e Tank Return Line Filter e Steering Line Pressure Filter 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 Whe
40. cates the percentage of biodiesel in the fuel for example B5 contains 5 biodiesel Biodiesel has different characteristics than mineral based fuels in that it is able to mix with water and therefore will have a high water retention capacity this could lead to seals swelling fuel system corrosion and seal damage Biodiesels will cloud at higher temperatures than mineral based fuels To explain Cloud Point the lowest temperature at which fluid can flow and performs its functions is referred to as Pout Point Just prior to reaching its Pour Point the diesel fluid becomes cloudy due to crystallization of waxy constituents this is know as Cloud Point Using diesel at temperature below its cloud point can result in filter clogging To prevent this happening preheating will be required Using B20 biodiesel can result in unburnt fuels accumulating in the engine oil ultimately this can affect the engine oil efficiency and lead to engine damage with standard diesel any unburnt fuel evaporates off the lubricating oil Biodiesels must be stored to exclude water absorption and oxidation The natural properties of biodiesel make it a good medium for micro bacterial growth these microbes can cause fuel system corrosion and early fuel filter blocking It will be necessary to consult and seek advice from your fuel supplier the effectiveness of conventional antibacterial additives when used in biodiesel is still being investigated in the fuel
41. ccessed from the underside of the dumper Wear can occur either by stretching of the handbrake cable or wear on the disc pads themselves causing a reduction in efficiency Brake pads generate dust which if inhaled may endanger health Wash off the calliper assembly before commencing work Clean hands thoroughly after work ADJUSTING THE PARKING BRAKE TAKE UP THE CABLE SLACK e Disengage the parking brake A lever horizontal and turn the handle grip clockwise half a turn e Test the parking brake e Ifthe brake fails the test repeat the procedure CHECK THE PADS e Use feeler gauges to check the gap between the brake disc B and the face of the brake calliper housing C e The gap should be greater than 1mm 0 04 in If gap is less than 1mm renew the pads RENEW THE BRAKE PADS e Disengage the parking brake A lever horizontal e Slacken the nuts D and unhook the clevis E e Loosen and remove bolts F and remove the calliper assembly e Remove the old brake pads from the calliper assembly and fit the new pads Align the flat across the top of the pads with the calliper housing e Refit the calliper assembly to the gearbox torque bolts F to 244Nm 180Ibf ft e Refit clevis E e Adjust the cables effective length so that the park brake is fully engaged with the lever A vertical e Adjust at D and or at the clevis E amp tighten nuts e If more adjustment is required this can be done at the park bra
42. crew the filter canister using a chain wrench if necessary Clean the seal face of the filter head Smear the seal on the new filter canister with clean engine oil screw the filter on until it just contacts the filter head Turn the filter at least another 3 4 of a turn NOTE use only genuine filters from NC The engine oil filter is designed with a drain down valve 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 Pressure 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 oil DO NOT OVERFILL 44 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 GEARBOX LUBRICATION To ensure proper lubrication and operating temperatures it is important that the appropriate lubricants are used and the correct oil level maintained This level sh
43. ctify and bleed the fuel system Check the fuel inlet restriction Maximum inlet restriction to the fuel transfer pump must not exceed 100mm Hg 4 Hg 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 One or more injector worn or malfunctioning Check the electronic fault codes Check the electrical connections at the injectors ECU or electrical sensor fault Check the electronic fault codes Check the electrical connections at the ECU and sensors Worn or malfunctioning high pressure fuel pump Check the electronic fault codes Do all the necessary fault finding checks before removal of the high pressure fuel pump Refer to NC for assistance for removal amp replacement procedures 62 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 Air intake system blocked or restricted Visually check the air intake and exhaust intake for blockage or obstruction remove as required Check the air filter elements for signs of b
44. ctors 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 dumper is as safe as possible Only trained persons should carry out repairs 38 Maintenance BEFORE YOU START e Clean the machine before starting any maintenance e Allow the machine to cool e Ensure strict cleanliness is observed at all times e 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 1 e quarry dust grinding sparks or similar Never check fluid levels near naked flames
45. ctronic fault codes Check the electrical connections at the ECU and sensors Fuel is contaminated or incorrect grade of diesel used STOP THE ENGINE Replace the fuel filters Operate the engine with a temporary supply of the correct grade of clean fuel 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 WARNING Dirty fuel will cause damage to the high pressure fuel pump amp injectors Inlet and exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances Make sure the are not bent or the rocker levers are not severely worn Turbocharger noise Check turbocharger impeller and turbine wheel for housing contact 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 the electronic fault codes Check the electrical connections at the injectors Gear train noise Visually inspect and measure gear backlash Replace gears as required 68 Fault Finding CHART A8 Engine compression knocks Cau
46. diagnosis of the fuel system using Service Master 7 ECU s should not be replaced without prior authorisation from NC Before replacing a ECU the following points should be noted ECU connectors removed amp inspected amp re flash ECU with Service Master Only after this and with approved authorisation should the ECU be changed 8 Any service issues diagnosed as an external engine concern e g fuel hoses filter lift pump alternator etc can be rectified in the field as normal 61 Fault Finding CHART A1 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 e Check battery Check main line fuses 30A amp 100A e 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 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 1s operating and delivering fuel to the injection pump Fuel is aerated Check the fuel system for loose connections and possible air ingress points Re
47. e brake design But bleeding of the system may be necessary on occasions if pipe work is damaged causing system leakage A LED is provided on the display to indicated if the brake fluid becomes low The brakes on this dumper provide means of effective braking with minimum maintenance However it is vital during maintenance on the dumper that the general condition of the system i e pipe work pedal operation fluid level and general tightness is checked and deficiencies corrected immediately FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH BRAKE SYSTEM BLEEDING e Position the machine on firm level ground and ensure the park brake is engaged and that one pair of wheels is blocked on each side e Ensure the skip is in the lowered position and locked in the forward position e Ensure the brake fluid reservoir is full and that during bleeding its level does not fall below the ADD level B mark e Attach a tube to the brake bleed screw C ensuring that the free end of the tube is immersed in fluid contained in a suitable container e Open the brake bleed screw and apply full brake pedal strokes of the brake pedal until all air is expelled e Close the brake pedal screw with the pedal fully depressed e Repeat the procedure using the opposite bleed screw e Top up the reservoir to the MAX level A mark 48 Maintenance TRANSMISSION PARKING BRAKE The parking brake is mounted on the transmission gearbox and can be a
48. e fault Low main line pressure point 4 9 Clutch pistons sticking on return stroke Check repair clutch piston s and seal s 10 Cored galleries on front housing pump mounting face wrong depth indicated by excessively low pressure and flow on converter out cooling line 11 Leakage across pump mounting face and front case Replace front housing or rectify existing housing Check for damaged surface on both components and loose pump mounting bolts 93 Fault Finding CHART GI Dumper gearbox Cause Remedy Dumper will not drive forward reverse Check handbrake released Check FNR lever engaged Check fuses Check drive inhibit relay Check forward amp reverse relays Check operation of solenoid valve on top of the gearbox Check selector lever is engaging the gears on the gearbox turret Check handbrake sensor switch Check transmission oil level A Ifthe transmission is noisy start at check 1 B Ifthe transmission is overheating start at check 4 C Ifthe transmission will not pull start at check 12 D Ifthere is no drive in one or both directions start at check 17 E If the transmission is jumping out of gear start at check 29 F If the transmission is sticking in gear start at check 39 G Ifthe rations are crash changing start at check 41 Check Action 1 Isthere noise when selecting direction YES Check 3 NO Check2 2 Is there noise when running with direction selector in neutral and YES Chec
49. e in F R solenoid Remove F R solenoid and clear restriction in solenoid valve block valve block both F R clutches will indicate low pressure 4 Clutch seals worn Confirm with a clutch leak test if required renew clutch seals 5 Clutch piston rings worn Confirm with a clutch leak test renew piston rings 6 Mechanical failure Strip amp rebuild clutch renew parts as required CHART F10 Low Cooler Flow Cause Remedy 1 Converter relief valve faulty Check amp if necessary repair or renew relief valve 2 Leak at pump to case joint Check and if necessary repair or replace 3 Worn pump Check flow and if necessary repair or renew pump 4 Internal leakage Check internal cored galleries and castings for porosity Check condition of seals 5 Restriction in converter feed See fault Overheating point 10 92 Fault Finding DUMPER GEARBOX CHART F11 Overheating Cause 1 Low oil level Remedy Top up system High oil level Drain to correct level Trapped or kinked hoses in cooler system Renew or repair hoses Repair or renew the converter relief valve Oil cooler blocked Clean cooler Operating in wrong gear range Select correct gears to suit working conditions 2 3 4 Low converter out pressure and flow rate 5 6 7 Water system overheating Rectify water system problems e g radiator cooler lines low water level etc 8 Oil aerated foaming Se
50. eak 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 leaking Check replace hose Oil level over full Check oil level Cooling system pressure cap incorrect or faulty Check replace cap Over concentration of antifreeze Remove some of the coolant from the system and replace with 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 ECU or electrical sensor fault One or more injector worn or ma
51. eater kits in low ambient temperature territories The biodiesel must meet the following standards ASTM D6751 DIN 51606 ISO 14214 Note If necessary use a test kit to confirm the fuel specification Testing kits are available not from JCB currently use the internet as a source for the kits Note If performance related issues are to be reported to JCB Service and the engine has been run on biodiesel then the fuel system must be filled with standard diesel at least 2 x tank fills to EN590 specification and relevant stall speeds recorded prior to making the report Warranty JCB have shown a commitment to support the environment by approving the use of biodiesel blended fuels Failure to follow the additional recommended service requirements may lead to a warranty claim being declined Failures resulting from the incorrect use of biodiesels or other fuel additives are not defects of the JCB Dieselmax engine workmanship and therefore will not be supported by JCB Warranty If the recommended actions are not taken there may be the following consequences low temperature filter clogging injectors lacquering sticking deterioration of seals and rubber hoses corrosion of metal parts in the fuel system engine performance problems These risks will be increased if the fuel has been poorly stored that is deteriorated through oxidation and or water absorption Sulphur Content High sulphur content can cause engine wear High s
52. el 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 may be available for engine operation at temperatures below 0 C These fuels have a lower viscosity and limit wax formation 35 EFFECT OF FUEL CONTAMINANTS INJECTOR CALIBRATION Although the injector operating components are by necessity very small even the most advanced manufacturing techniques do not ensure consistent injection cycle characteristics between injectors Small variations in the metering orifice sizes will alter the time duration for the start amp stop of the injection For this reason it is necessary to individually test amp record the operating characteristics of each inject assembly at the factory The results of the test are printed on the side of the injector as a code known as C2I codes The codes for each injector fitted to the engine are programmed into the ECU The operating software in the engine ECU uses the data to adjust the control of the injector solenoid coil accordingly The injector is therefore effectively calibrated to the ECU It follows that if injectors are removed they must always be refitted in their original positions If new injectors are fitted the engine ECU must be reprogrammed with the new injector codes BLEEDING THE FUEL SYSTEM The engine features an electrically operated fuel lift pump The system is designed to bleed
53. engine is cool before checking the coolant level or draining the system e When the engine is cold if the coolant level is below the minimum level C remove the filler cap A and add coolant until the coolant is just below the maximum level line B e Replace the expansion tank filler cap A DRAINING THE COOLING SYSTEM e Ensure the engine is cold carefully undo the expansion tank filler cap A 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 expansion tank 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 expansion tank cap and add coolant mix to the maximum level mark B on the tank 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 ensuring the coolant doesn t drop below the minimum level C mark e With the engine stopped and the cool remove the filler cap and top up as necessary to just below the maximum level mark Repeat the above process and toping up again until the level remains steady This will
54. ensure all the air has been expelled from the system Always ensure the coolant level is just below the maximum level line as this will give the best cooling performance 42 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 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 e Check the oil level is between the two marks on the dipstick e If necessary add recommended oil through the filler point B 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 leve
55. erify the condition of the mounts and replace adjust as necessary Fuel injection lines leaking Replace defective high pressure fuel lines WARNING DO NOT repair defective fuel lines If there is a fuel leak remove and discard the necessary components and install new ones WARNING Fine jets of fluid at high pressure can penetrate the skin Keep face and hands well clear of pressurised fluid and wear protective glasses If fluid penetrates your skin get 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 operates and delivers fuel to the high pressure fuel pump Check the correct electrical wires for open or short circuits 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 STOP THE ENGINE Replace the fuel filters Operate the engine with a temporary supply of the correct grade of clean fuel 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 WARNING Dirty fuel will cause damage to the high pressure fuel pump amp injectors Inlet and exhaust valve clearances set incorrectly
56. ernal leakage Check internal cored galleries and castings for porosity Check condition of seals 8 High stall speeds See fault High stall speeds 9 Low stall speeds See fault Low stall speeds 10 Overheating See fault Overheating CHART F2 Low Mainline Pressure in neutral Cause Remedy 1 Worn pump Check flow and if necessary repair or renew pump 2 Blocked suction strainer Clean suction strainer 3 Pressure maintaining valve sticking Free off or renew valve leaking 4 Oil aerated foaming Internal leaking in cored galleries inspect repair transmission Dirty suction strainer clean strainer High oil level drain to correct level Incorrect grade of oil drain then refill with correct oil CHART F3 High Stall Speeds in Forward amp Reverse Cause Remedy 1 Damaged converter blades Check and if necessary renew converter 2 Clutches slipping See fault Low clutch pressure 3 Internal leakage Check internal cored galleries and castings for porosity Check condition of seals 90 Fault Finding DUMPER GEARBOX CHART F4 Low Stall Speeds in Forward amp Reverse Cause Remedy 1 Poor engine condition Check and if necessary repair engine 2 Torque converter reaction member clutch Check and if necessary renew torque converter slipping CHART F5 Low Converter Out Pressure Cause Remedy 1 Low mainline pressure See fault Low mainline pressure 2
57. evel ground and block the wheels securely to prevent any movement Select Neutral and release the parking brake e Disconnect and remove the drive shafts completely from the dumper e Connect the towing vehicle via the rigid tow bar before removing the wheel blocks e When towing is complete block the wheels securely BEFORE removing the tow bar and reconnecting the drive shafts RECONNECTING DRIVE SHAFTS The propshafts must have both ends on exactly the same plane as shown in X The yokes must not be at right angles as in Y or at an intermediate angle as shown in Z When reconnecting always apply Loctite 242 to the threads of all flange bolts The retraining straps C should always be replaced with new ones as they will stretch over time Torque item A to 75 85 Nm and B to 118 Nm 47 Maintenance BRAKE SYSTEM The brake system is filled with high grade hydraulic oil DO NOT USE CONVENTIONAL BRAKE FLUID This will cause serious damage to the dumper and degrades the brake performance to dangerous levels NC recommend Fuchs Renoil HVZ15 USE ONLY mineral based brake fluids RECOMMENDED BRAKE FLUID FUCHS RENOIL HVZ15 The brake system is filled via a fluid reservoir which is remotely mounted from the brake master cylinder The reservoir is located under the bonnet on the rear anti recirculation baffle Normally adjustment of the brakes is not reguired due to the automatic compensation which is built into the axl
58. grade of diesel used STOP THE ENGINE Replace the fuel filters Operate the engine with a temporary supply of the correct grade of clean fuel 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 WARNING Dirty fuel will cause damage to the high pressure fuel pump amp injectors 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 ECU or electrical sensor fault Check the electronic fault codes Check the electrical connections at the ECU and sensors Worn or malfunctioning high pressure fuel pump Check the electronic fault codes Do all the necessary fault finding checks before removal of the high pressure fuel pump Refer to NC for assistance for removal amp replacement procedures Camshaft or tappets damaged Inspect camshaft amp tappets 66 Fault Finding CHART A 6 Engine poor running at idle Cause Coolant temperature sensor fault Remedy Check the electrical connection at the coolant sensor Check the correct electrical wires for open or short circuits Check the electronic fault codes Test the coolant sensor If engine will not reach operating temperature refer to Chart D Engine mounts over tightened damaged or loose V
59. hometer Measure on the fan drive 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 position sensor TPS system defective Check the throttle assembly Check electronic fault codes 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 operates and delivers fuel to the high pressure fuel pump Check the correct electrical wires for open or short circuits Fuel is contaminated or incorrect grade of diesel used STOP THE ENGINE Replace the fuel filters Operate the engine with a temporary supply of the correct grade of clean fuel 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 WARNING Dirty fuel will cause damage to the high pressure fuel pump amp injectors Fuel filter s blocked fuel supply restricted Check replace the fuel filter s Check fuel lines for restriction Turbocharger waste gate actuator diaphragm ruptured Repair or replace turbocharger One or more injector worn or malfunctioning Check the electronic fault codes Check the electrical connections at the injectors Wor
60. ine and surrounding area has been thoroughly cleaned prior to completing any maintenance tasks Do complete all work in accordance with the Service Manual procedures Do disconnect both the battery positive and battery negative cables prior to completing any welding on the machine Do use the recommended grade of fuel EN590 The fuel injection pump injector or other parts of the fuel system can be damaged if you use a fuel or fuel additives not recommended by JCB Do make sure all the necessary new parts are available before starting any maintenance work Do not crack the injector high pressure fuel lines to bleed the fuel system The system operates at pressure in excess of 1200 bar 174001bs in Do not steam clean the electronic control unit ECU or the ECU connectors Do not touch the ECU connector pins this will eliminate the possibility of damage caused by electrostatic discharge Do not leave any fuel connections open for any extended period of time Do not open any new parts packaging until the part is ready to be fitted Unnecessary exposure will increase the risk of contamination Do not reuse high pressure fuel pipes Reusing the pipes will lead to potential fuel leaks Do not attempt to remove and replace the rail pressure sensor or high pressure valve It is not possible to refit these components without the risk of fuel leaks If the valve or sensor is diagnosed as faulty then a new c
61. ing at the injectors Have an oil sample analysed Repair engine as required 81 Fault Finding CHART C3 Lubricating Oil pressure low Cause Oil level incorrect Remedy Check oil level Incorrect lubricating oil specification of viscosity 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 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 82 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
62. ining strap 22 26 16 19 bolt Item Nm Lb ft Angle Fan belt tensioner retaining 22 26 16 19 bolts Technical Specifications Engine Torque Figures Item Nm Lb ft Angle Thermostat housing 22 26 16 19 retaining bolts Item Nm Lb ft Angle Water inlet connector 22 26 16 19 retaining bolts Technical Specifications Engine Torque Figures Item Water temperature sender switch Item Exhaust manifold retaining bolts first stage final stage angle torque Item Inlet manifold retaining bolts Angle Fig 8 Lb ft Angle Lb ft Angle 16 19 Technical Specifications Engine Torque Figures Item Power take off PTO pump bolts SAE A MIO bolts SAE B M12 bolts Item Nm Lb ft Angle Lifting bracket retaining 43 51 32 38 bolts Technical Specifications Engine Torque Figures Item Angle Alternator retaining bolts Item Nm Lb ft Angle Starter motor retaining 43 51 32 38 bolts 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 Ref No Symbols Description Engine Oil Level Engine Coolant Level BOE Fuel and Water Sedimentor LS as i 1 aL Tran
63. ion equipment For example contaminants in the fuel pump will develop internal wear to cause internal leakage and hence lower discharges Use of poor quality fuels and poor maintenance could also lead to contaminants entering the fuel injectors There is a possibility of catastrophic equipment failure if debris should prevent the injectors from fully closing The main contaminants can be classified as follows These contaminants can appear during manufacture assembly and operation Solid Particles sand fibres metallic particles welding scale sealing materials and wear particles etc Liquid usually water and incompatible oils and gases Gases air sulphur dioxide etc which can create corrosive compounds if dissolved in the fluid It is critical that the machine is thoroughly cleaned prior to completing any maintenance work The main filter is rated at 2 micron 0 002mm 0 0007874in Listed are a few typical comparisons of micron size Red Blood Cell 8 Microns 0 008mm 0 000315 in Human Hair 70 microns 0 07mm 0 00275 in Grain of Salt 100 microns 0 1mm 0 00394 in The smallest particle visible to the naked eye is 40microns 0 00157 in approximately 29 Fluids amp Lubricants Common Rail Safety Checklist The following safety checklist is intended to help remind you of safety procedures and practices relating to a common rail engine SAFETY IS YOUR RESPONSIBILITY Do make sure the eng
64. k 9 ratio selector in 1st NO Check 19 3 Is there air in the hydraulic system YES continue running to expel air NO Check4 4 Is the fluid level correct YES Check 5 NO Check level only when machine is cold amp top up as required 5 Are the oil passages restricted YES Clear the restriction NO Check6 6 Is the suction strainer restricted YES Remove amp clean strainer NO Check7 7 Is pump pressure as specified YES Check 9 NO Check clutch pressure maintenance valve is free to operate 8 When flow testing pump is output low YES Renew pump NO Check converter sprag clutch for wear or slip 94 Fault Finding CHART GI Dumper gearbox continued Check Action 9 Does the noise continue when the direction selector is in forward YES Check 10 or reverse NO Check 11 10 IS the transmission misaligned YES Renew mountings and check position NO Check converter out pressure and flow 11 Are the pump brushes worn YES Renew NO Check converter for wear amp cooler for restriction to flow 12 Is the transmission not pulling in one direction only YES Check 16 NO Check 13 13 Isthe transmission not pulling in both forward amp reverse YES Stall test machine amp Check 14 NO Check 16 14 Is converter pressure as specified YES Check 15 NO Inspect converter relief valve for damage Check cooler bypass valve pressure setting 15
65. ke mounting position e In the event of insufficient adjustment remove screw G the anti rotation clip and adjust the lever H on the spline Rotate the lever by one spline and refit the assembly Torque the screw to 12 5Nm 15 5Nm 9 2 11 5Ibf ft e Test the parking brake Maintenance ADJUSTING THE PARKING BRAKE continued On this machine the parking brake when fully engaged disconnects the transmission drive The machine is prevented from driving with the park brake engaged To complete the test move the park brake lever fractionally forward until the warning light is extinguished hold the lever in this position for the duration of the test DO NOT move the lever too far forward otherwise the park brake will not be fully operational With the parking brake engaged select third gear Make sure the brake pedals are engaged push down hard on the brake pedal and select forward drive If the dumper starts to move forward during the test immediately apply the foot brake and reduce the engine speed Slowly release the brake pedals if the dumper has not moved use the accelerator to gradually increase the engine speed ABOUT HALF WAY UP REV RANGE The dumper should not move DO NOT test for longer than 20 seconds If the dumper moved inspect the calliper pads and reset as described in the text DO NOT use a machine with a faulty parking brake Non approved modifications to axle ratios machine weight or wheel and tyre sizes
66. l 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 43 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 Ensure the oil is warm but not hot as contaminants held in suspension will be drained with the oil This will also allow the oil to drain quicker and more thoroughly 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 Remove the drain plug A and its O ring Let the oil drain out then clean and refit the drain plug with a new O ring Torque tighten the drain plug to 40 60Nm 30 44lbf ft Loosen and remove the filter housing drain plug B Let the oil drain out then clean and refit the drain plug with a new O ring Torque tighten the drain plug to 35 40Nm 26 30lbf ft The engine oil filter C MUST be changed when the engine oil is renewed Uns
67. lfunctioning Check the electronic fault codes Check the electrical connections at the ECU and sensors Check the electronic fault codes Check the electrical connections at the injectors 85 Fault Finding CHART D3 Coolant under temperature Cause Air flow across radiator excessive Remedy Check repair the louvers 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 temperature 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 Engine oil cooler or cooler housing allowing cross contamination of coolant with engine oil Remove the oil cooler assembly and check relevant sealing ele ments for damage Lubricating oil leaks from lubricating oil cooler head gasket head and cylinder block Refer to Chart D1 86 Fault Finding Electronic Fault codes The dumper is fitted with a CAN ena
68. locking 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 1s operating and delivering fuel to the injection pump Fuel is contaminated or incorrect grade of diesel used STOP THE ENGINE Replace the fuel filters Operate the engine with a temporary supply of the correct grade of clean fuel 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 WARNING Dirty fuel will cause damage to the high pressure fuel pump amp injectors 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 Check the fuel inlet restriction Maximum inlet restriction to the fuel transfer pump must not exceed 100mm Hg 4 Hg One or more injector worn or malfunctioning Check the electronic fault codes Check the electrical connections at the injectors Inlet and exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances One or more injector worn or malfunctioning
69. ls and Descriptions Safety Decals and Descriptions 10T ST Maintenance Manual Service Record Service Schedules Torque Settings Fluids and Lubricants Safety Information Maintenance Battery Air Cleaner Coolant System Engine Oil Check Change Gearbox Oil Check Change Towing Procedure Brake System Park Brake Axle Oil Check Change Hydraulic System Storage Electrics Fault Finding Page No 17 19 21 22 23 26 27 38 39 40 41 42 43 45 47 48 49 51 52 55 56 60 Engineering Hamiltonsbawn L td 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 STIO 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 104 dB LWA Guaranteed Sound Power Level 104 dB LWA Net Installed Power 97kW A technical construction file for this machine is retained at the above address Declaration 7 Signed Name David Wilson CEng MSc MIAgrE Being the responsible person appointed
70. lternative Suppliers Shell Spirax S4 TXM BP Tractran 10 NC recommend Mobile HP222 Grease Alternative Suppliers Shell Gadus S3 V220C 2 Fuchs Renolit LX EP 2 BP Energrease LC2 NC recommend Fuchs Renolin HVZ15 Brake system International Specification ISO VGI5 Alternative Suppliers Shell Tellus S2V Velocite SM15 BP Bartran HV13 HYDRAULIC OIL NC recommend Fuchs Renolin CL32 Alternative Suppliers Shell Tellus S2 M32 Mobil DTE24 BP Auto Hydraulic 32 GENERAL GREASE POINTS Multi purpose grease 37 FOR YOUR SAFETY IF THE DUMPER DEVELOPS A FAULT Park the machine in a safe area if possible If this is not possible take measures to warn others of the machine position Remove the start switch key Contact a qualified person to rectify the fault Do not place any part of the body in any area of the machine where there is a hydraulic leak while the system is pressurised 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 tipped skips Always wear eye protection Always wear ear prote
71. mpartment both fully galvanised Separate fuel and hydraulic Miler compartment Adjustable steering column Adjustable suspension seat Skip tps over 90 Electronic dive by wire throttle system Skip manufactured from higher tensile steels Flashing beacon OPTIONAL EQUIPMENT Road Light Kit Spare Wheel Blodegradable Hydraulic ON FOPS Roof Skip manufactured from Hardox Cab Shove spade and brush holders NC Engineering Hamiltonsbawn Ltd 2 Kilyniden Road Hamittonsbawn Richhill Co Armagh Northern Ireland BT61 8SF Tek 44 0 28 3887 1970 Fax 44 0 28 3887 0082 Emal sales nc engineering com Web www ne engineering com Technical Specifications Engine Variants SE Emission compliance SE Number of cylinders Nominal bore size Stroke Cylinder arrangement Combustion Cycle Firing order Displacement Compression ratio SE Engine Compression Direction of rotation Viewed from front crankshaft pulley end Valves Valve clearances measured at the pushrod end of the rockers measured cold Inlet Exhaust Lubricating oil pressure Combustion system High pressure fuel pump 1 Dry weight No cooling fan drive lo go uS nt 4 per cylinder Piston type high pressure with electronically controlled fuel delivery 2 Compression variance between each cylinder should be no greater than 3 5bar 50 Ib in2 3 Engine at normal operating temperature a
72. n or malfunctioning high pressure fuel pump Check the electronic fault codes Do all the necessary fault finding checks before removal of the high pressure fuel pump Refer to NC for assistance for removal amp replacement procedures 72 Fault Finding CHART AII Engine rpm surges Cause Remedy Fuel level low Check fill fuel tank Throttle position sensor TPS system defective Check the throttle assembly Check electronic fault codes Fuel injection lines leaking Replace defective high pressure fuel lines WARNING DO NOT repair defective fuel lines If there is a fuel leak remove and discard the necessary components and install new ones WARNING Fine jets of fluid at high pressure can penetrate the skin Keep face and hands well clear of pressurised fluid and wear protective glasses If fluid penetrates your skin get 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 ECU or electrical sensor fault Check the electronic fault codes Check the electrical connections at the ECU and sensors One or more injector worn or malfunctioning Check the electronic fault codes Check the electrical connections at the injectors Worn or malfunctioning high pressure fuel pump
73. n removing these parts it is recommended the system is drained and refilled with clean new hydraulic oil as specified in the Fluids amp Lubricants section ADDING HYDRAULIC OIL Remove tank filler cap and add oil Do not fill oil level higher than approx 50mm 2 below the horizontal top Replace filler cap immediately after filling 53 Maintenance DRAINING HYDRAULIC OIL Before draining the hydraulic tank ensure the hydraulic oil is warm NOT HOT and the skip is fully lowered e Place a suitable container under the tank and remove the drain plug A allowing the oil to fully drain e Remove the blanking plate B and ensure inside the tank is free of debris e Replace the blanking plate B Torque bolts C to 7Nm e Replace the drain plug A Torque to 5Nm SUCTION STRAINER FILTER e Empty the tank according to the above procedure e The suction strainer is mounted on the inside of the blanking plate Unscrew and replace element e Replace the blanking plate B as per the above procedure RETURN TO TANK FILTER e Inspect indicator D daily When indicator is red the filter element needs replacing e Unscrew cap E to remove the old filter element F The filter element is replaced inside the re useable chimney G STEERING LINE PRESSURE FILTER e Unscrew the bowl H and pull out the filter element e Replace the filter element and refit the bowl REPLACING FILTER ELEMENTS Always use replaceme
74. nd maximum revs Technical Specifications Torque Angle Explanation Insufficient preload of a bolted joint can cause major problems such as cylinder head wrap leaking gasket joints etc There are several methods of achieving an accurate preload of a bolted joint the main methods used on the JCB 444 engine are 1 Torque Control Tightening 2 Angle Control Tightening 1 Torque Control Tightening Using a torque meter to control the torque is the most popular means of controlling preload and in the majority of instances this method is adequate It should be noted that with this process the majority of the torque is used to overcome friction therefore slight variations in the frictional conditions can lead to large changes in the bolt preload 2 Angle Control Tightening Where a more precise preload is required the torque angle tightening method is used The bolt is tightened to a predetermined torque this may be done in stages and then as a final sequence the bolt I s tightened to a predetermined angle this method of tightening the bolts results in a smaller variation in the final preload It is critical that the predetermined tightening angle is accurately achieved failure to tightening accurately to the specific angle could result in the bolt preload being Incorrect this will lead to eventual failures It is good practice to replace all bolts that have tightening using the torque angle procedure A Torque
75. ner if there are engine performance related issues Make sure the fuel is stored correctly care must be taken to make sure no water enters the machine fuel tank or storage tanks Water will encourage micro bacterial growth Make sure that the fuel pre filter is drained DAILY Use heater kits in low ambient temperature territories Biodiesel must meet the following standards ASTM D6751 DIN 51606 ISO 14214 If performance related issues are to be reported to NC and the engine has been run on biodiesel then the fuel system must be filled with standard EN590 diesel at least 2 tank fills Failure to follow the additional recommended service requirements may lead to a warranty claim being rejected Failures resulting from incorrect use of biodiesel or other fuel additives will not be supported by NC Warranty 28 Fluids amp Lubricants Checklists Common Rail Tier 3 Specific In addition to the general safety notices and general good workshop practices issued in this section and throughout the manual there are specific points to note when completing maintenance on Tier 3 equipment Diesel Fuel Quality Important The potential for engine damage due to the use of incorrect or contaminated fuel is much greater with common rail injection technology than with mechanical injection systems Effects of Contamination Once inside the system fuel circuit contaminants greatly effect the performance and life of the fuel inject
76. ng 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 80 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 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 ECU or electrical sensor fault Check the electronic fault codes Check the electrical connections at the ECU and sensors One or more injector worn or Check the electronic fault codes Check the electrical connections malfunction
77. ngine being lugged down 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 Air leak between turbocharger and the intake Check correct leaks in the air crossover tube hoses or through manifold holes in the manifold cover Intercooler faulty Check for blocked cooler matrix Exhaust leak at the manifold or turbocharger Check correct leaks in the manifold or turbocharger gaskets Look for a cracked manifold Turbocharger waste gate faulty Repair or replace waste gate Turbocharger malfunction Replace turbocharger ECU or electrical sensor fault Check the electronic fault codes Check the electrical connections at the ECU and sensors One or more injector worn or Check the electronic fault codes Check the electrical connections malfunctioning at the injectors Engine compression low in one or more Check the engine compression cylinders 75 Fault Finding CHART AI4 Engine exhaust smoke excessive White Blue smoke Cause Improper starting procedure Remedy Verify the starting procedure Fuel is contaminated or incorrect grade of diesel used STOP THE ENGINE Replace the fuel filters Operate the engine with a temporary supply of the correct grade of clean fuel Refer to Fluids
78. nt filters supplied by NC other filters may be of lesser quality and lead to increased wear in the hydraulic components resulting in oil leaks 54 Maintenance STORAGE If the dumper is to be stored for a long period of time the following procedures should be applied e Thoroughly wash down the exterior of the machine and remove any build up of material e Grease all greasing points e 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 e Check hydraulic oil level and top up as required e Fill the fuel tank to prevent condensation forming inside the tank and contaminating the fuel e Store the machine on flat level ground which is not liable to flooding standing water or airborne contamination e Smear any exposed metal parts with grease amp rams e 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 rubber mat between the battery and the floor e 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 55 Maintenance ELECTRICS Battery Heavy Duty 600 45 Battery 1000CCA 185Ampere Hour Capacity Alternator 95A Belt driven The alterna
79. om the cooler 3 Connect an air supply to the transmission oil inlet connection and plug amp seal the outlet 4 Submerge the cooler in a tank of water and apply air pressure to test for leakage If bubbles are visible the integrity of the cooler has broken down and the cooler should be scrapped NOTE air pressure not to exceed 6 Bar 5 Itthe cooler is not damaged it should be cleaned and dried ready for reassembly into the transmission After refilling the transmission with new oil and the engine and transmission have returned to normal working temperatures the operator should periodically stall the torque converter for up to 5 second intervals to remove trapped water To stall the torque converter see below STALLING THE TORQUE CONVERTER 1 Apply the foot brake firmly If necessary set the machine against a fixed obstruction 2 Select 4th gear forward and open the throttle fully Caution DO NOT stall the converter for more than 10 seconds maximum If contamination is severe oil still visibly emulsified repeat the drain fill procedure before returning the machine to service 99 Fault Finding Transmission Oil Contaminated with water continued FLUSHING PROCEDURE 1 Reconnect the hoses on the cooler Ensure the joints are clean and leak proof 2 Renew the oil filter 3 Refill the transmission circuit with the recommended grade of oil 4 Start the engine and continue running for several minutes to reach normal o
80. ommon rail assembly must be fitted 30 Fluids amp Lubricants Usage and Effects of Fuels Note The information that follows does not indicate types of fuel that are acceptable or unacceptable l Low Sulphur Diesel In its basic form because of the process of reducing sulphur by removal of sulphur containing compounds which contribute to mechanical lubrication an increase in the wear rate of the fuel injection equipment could occur In view of this the major fuel producers add suitable lubricity improvers to enable the FIE to run satisfactorily with no acceleration in wear rate They must ensure that the lubricity improvers do not themselves create residual deposits that could block the fuel system eg Filter injectors etc Ultra Low Sulphur Diesel Also known as city diesel Available throughout the UK and some parts of Europe since March 1999 This fuel has a maximum sulphur content of 0 005 by weight and a further reduction in the natural lubricity and aromatic content than experienced with low sulphur diesel Major oil producers will add lubrication improvers and also maintain the total aromatic content to an acceptable level Unmodified Vegetable Oils Burned in diesel engines neat or used as an extender to mineral derived fuel When these are subjected to heat in the fuel injection system they form sticky deposits that can be found inside the fuel pump and a hard lacquer in the injectors where exposure to even higher
81. on Strainer Clean Drive Shafts Security Functional Test Forward amp Reverse Gear Change operation Transmission Main Line Pressure Clutch Disconnect Neutral Start Operation Clutch Back Pressures BRAKES TRANSFER BOX 50 100 1000 2000 H Hr Hr Hr Hr Service Points amp Fluid Levels Oil Leaks Oil Level Oil Note First 10 Hr Service only Note First 100 Hr Service only Note Indicates jobs which should only be undertaken by a specialist 24 Service Schedules DUMPER CHASSIS Operation 10 50 100 500 1000 Grease Points Hr Hr Hr Hr Hr Skip Pivot Pins 2 No Pins Tipping Ram Pins 1 No Pins Centre Point Articulation 3 No Points Steering Ram 2 No Points Drive Shafts 3 No Points Note First 50 Hr Service only HYDRAULICS SYSTEM Operation 10 100 500 Service Points amp Fluid Levels Hr Hr Hr Inspect return to tank filter indicator Return to tank filter element Pressure filter element Suction strainer wash with paraffin 1f necessary Note First 100 Hr Service only Note Every 10 hours only valid to Serial No 032067 AIR INDUCTION SYSTEM Operation w fy Check air filter restriction indicator Check cem Note Every 10 hours 25 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 s
82. ould be checked daily NC recommend Fuchs Titan T04 HD10 GEARBOX OIL LEVEL CHECKING Ensure the engine is stopped and the transmission oil is cool Ensure the oil cooler is full by running the oil cooler a few seconds prior to checking the oil level In this condition the oil level should be between the maximum and minimum marks on the dipstick Gearbox oil level should be checked daily and topped up if necessary Check the oil level using the dipstick At normal running temperatures the oil on the dipstick will rise above the maximum mark Do not overfill the transmission as this may result in oil breakdown due to excessive heat and aeration from the churning action of the gears Early breakdown of the oil will result in heavy sludge deposits that block oil ports and build up on splines and bearings Overfilling may cause oil leaks TRANSMISSION OIL FILL PROCEDURE It is extremely important to follow the correct oil fill procedure to prevent internal damage to the transmission e With the engine stopped fill the transmission with Fuchs Titan T04 HD10 oil to dipstick maximum mark Fill point A e Start the engine and run slowly for a period not exceeding five minutes This allows the oil to fill the filter pump torque converter oil cooler and hoses e Stop the engine and wait approximately one minute recheck the oil level and fill to dipstick maximum level 45 Maintenance CHANGING GEARBOX OIL e When changing the oil i
83. perating temperature Stall the torque converter for 5 seconds Continue running the engine for 5 minutes Repeat the torque converter stall for 5 seconds Continue this procedure for a period of up to 30 minutes 1f possible during machine operation Drain the oil amp fit a new filter Test the oil for contamination 10 Refill the transmission circuit with the recommended grade of oil OOR 2 NOTE If the oil drained at step 9 is clean and free from water contamination return the dumper to working operations If not repeat the flush and fill procedure GENERAL PROCEDURE Between 50 amp 100 hours operating time after cooler failure drain the transmission cooler circuit and refill with the recommended grade of oil and renew the oil filter Oil should no longer show evidence of water contamination Further sampling should be carried out if in doubt 100
84. r added loading form malfunctioning accessories or driven units brakes dragging and other changes in the vehicle loading Disengage the hydraulic controls 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 ingress points Rectify and bleed the fuel system Fuel lift pump not operating correctly fuel supply inadequate Check that the lift pump 1s 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 STOP THE ENGINE Replace the fuel filters Operate the engine with a temporary supply of the correct grade of clean fuel 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 WARNING Dirty fuel will cause damage to the high pressure fuel pump amp injectors 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
85. s loose Tighten screws Check 30 30 Are the selector fork pads or grooves in gears worn Renew worn parts Check 31 31 Are dog teeth gear worn Renew Check 32 32 Are selector rod detent springs broken Renew Check 33 33 Are the selector rods worn or broken Renew Check 34 34 Are the selector fork pads out of position Reposition or renew check interlock Check 35 35 Is there excessive end float in gears or shafts Adjust Check thrust washers and mating faces 36 Is the synchroniser bronze worn Renew synchro pack Check 37 37 38 39 Are steel chips embedded in the bronze Are the synchroniser components damaged Are the sliding gears tight on the splines YES NO Continue using chips will either embed blow bronze or be rejected Check 38 Renew Check free running gears for seizure or damage Free or renew Check 40 96 Fault Finding CHART GI Dumper gearbox continued Check Action 40 Are chips wedged between splines of shaft or gear YES Remove chips NO Ensure that clutch is disengaged when dump pedal is pressed 41 Are steel chips embedded in the bronze YES Continue using chips will either embed blow bronze or be rejected NO Check 42 42 Are the synchroniser spring pins damaged YES Renew synchro NO Check 43 43 Isthe synchroniser bronze worn YES Renew synchro NO Check block pins 97 Fault Finding
86. se Fuel is aerated Remedy Check the low pressure 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 STOP THE ENGINE Replace the fuel filters Operate the engine with a temporary supply of the correct grade of clean fuel 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 WARNING Dirty fuel will cause damage to the high pressure fuel pump amp injectors ECU or electrical sensor fault Check the electronic fault codes Check the electrical connections at the ECU and sensors Inlet and exhaust valve springs broken Check and fit new valve springs One or more injector worn or malfunctioning Check the electronic fault codes Check the electrical connections at the injectors Coolant operating temperature incorrect Refer to Charts D2 amp D3 69 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 loading Disengage the hydraulic controls Throttle position sensor TPS
87. smission Oil Level o Axle Service Points Axle Oil Level Hydraulic Return to Tank Filter Air Filter Restriction Indicator ew pede ee Tele S SO DCE LIT Grease Point Skip Pivot Pins Grease Point Tipping Ram Pins 9 N 1 Grease Point Centre Point Articulation Grease Point Steering Ram Grease Point Drive Shafts 14 Transfer Box Oil Level Maintenance Decal Descriptions Description Transmission Oil Filter Oil Pressure Filter Axle Oil Engine Oil Filter Fuel Filter Check Drive Shaft Bolts Air Filter Element Transmission Oil 23 Transfer Box Oil 24 Fuel Filter Engine Mounted 25 i Engine Coolant 26 eS ED 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 Part No Symbol Descriptions DEC 1920 002 Hydraulic Oil DEC 1920 003 DEC 1920 004 Stay clear of tipping area DEC 1920 006 am Visibility No passengers Towing Transport Read manual s DEC 1920 010 DEC 1920 011 Gear locations DEC 1920 012 Seat belt must
88. t above normal or grounded circuit E080 Injector solenoid valve fault cylinder 2 current above normal or grounded circuit E082 Injector solenoid valve fault cylinder 4 current above normal or grounded circuit E083 Injector solenoid valve fault cylinder 1 current below normal or open circuit E085 Injector solenoid valve fault cylinder 3 current below normal or open circuit E089 Injector solenoid valve fault cylinder 2 current below normal or open circuit E090 Injector solenoid valve fault cylinder 4 current below normal or open circuit E091 Engine ECU fault data erratic E095 Sensor supply voltage 1 5V fault voltage below normal or shorted low E096 Fuel pump control module fault voltage above normal or shorted high E097 Fuel pump control module fault voltage below normal or shorted low E098 Fuel pump control module CAN fault pump not responding correctly E104 Fuel pump control module idle fault data erratic E111 Inlet manifold heater relay enable fault E114 Sensor supply voltage 1 5V fault voltage above normal or shorted high E119 Water in fuel detected no fault data only E122 Water in fuel indicator fault voltage above normal or shorted high E123 Water in fuel indicator fault voltage below normal or shorted low E126 Inlet manifold air pressure sensor TMAP fault data erratic E127 Power supply fault data erratic E129 Battery voltage fault data below normal level E130 Battery voltage fault data above norm
89. t is essential to renew the oil filter and clean out the suction strainer e Ensure the transmission oil is cool but warm to allow it to flow easily e Drain the oil by removing the strainer B e Oil will gush out keep clear of hot oil as it can cause serious burns e Clean strainer using a suitable solvent when refitting the strainer renew the gasket and apply Loctite 242 to bolts A Torque to 10Nm 7 4lbf ft e Unscrew and discard the filter element C e Smear the seal of the filter with transmission oil Screw the filter on until it contacts the filter head then to be tightened a minimum of 3 4 turn equal to 15Nm or 11Ibf ft torque e Fill the system as per the Transmission Oil Fill Procedure above 46 Maintenance TOWING PROCEDURE If there is no transmission damage the dumper may be towed for a distance of approximately 1 5 kilometres 1 mile Always use a rigid tow bar and ensure the gear lever is in neutral Restrict the towing speed to 25km h 15mph If it is necessary to tow the dumper for distances in excess of 1 5 kilometres 1mile the drive shafts to each axle must be disconnected To prevent oil starvation and possible seizure of the transmission Failure to observe this precaution may result in extensive damage to the transmission Removal or disconnection of the drive shafts will disable the parking brake It is essential that the following procedure is adopted e Position the machine on firm l
90. tated 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 26 Fluids amp Lubricants ENGINE LUBRICATING OIL New engines do not require a running in period 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 CJ 4 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 Lower standards of oil do not have the soot or temperature carrying capacity required for Dieselmax common rail engines and must not be used 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 gr
91. te Check that the lift pump operates and delivers fuel to the high pressure fuel pump Check the correct electrical wires for open or short circuits 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 injector worn or malfunctioning Check the electronic fault codes Check the electrical connections at the injectors Exhaust leak at the manifold or turbocharger Gf applicable Extra injector sealing washer installed under injector Inlet and exhaust valve clearances set incorrectly Check correct leaks in the manifold or turbocharger gaskets Look for a cracked manifold Remove extra injector sealing washer Set the valve clearances to the recommended clearances Fault Finding CHART A9 Engine reduced power output continued Cause Remedy Worn or malfunctioning high pressure fuel Check the electronic fault codes pump Do all the necessary fault finding checks before removal of the high pressure fuel pump Refer to NC for assistance for removal amp replacement procedures Engine compression low in one or more Check the engine compression cylinders 71 Fault Finding CHART AI0 Engine will not reach maximum rpm Cause Tachometer faulty 1f fitted Remedy Verify the engine speed with a hand held tac
92. ted high E013 Hand throttle position sensor fault voltage below normal or shorted low E017 Engine coolant temperature sensor fault voltage above normal or shorted high E018 Engine coolant temperature sensor fault voltage below normal or shorted low E023 Inlet manifold air temperature sensor TMAP fault voltage above normal or shorted high E024 Inlet manifold air temperature sensor TMAP fault voltage below normal or shorted low E027 Sensor supply voltage circuit fault voltage below normal or shorted low 87 Fault Finding CHART EI Fault codes continued Fault Code Description E047 Fuel temperature sensor fault voltage above normal or shorted high E049 Fuel temperature sensor fault voltage below normal or shorted low E051 High pressure fuel solenoid valve number 1 fault voltage below normal or shorted low E052 High pressure fuel solenoid valve number 1 fault voltage above normal or shorted high E055 High pressure fuel solenoid valve number 1 fault valve not responding correctly E068 Engine control module ECU internal temperature sensor fault voltage above normal or shorted high E069 Engine control module ECU internal temperature sensor fault voltage below normal or shorted low E076 Injector solenoid valve fault cylinder 1 current above normal or grounded circuit E078 Injector solenoid valve fault cylinder 3 curren
93. tor 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 56 Maintenance ELECTRICS cont d Main Fuse amp Relay Box Fuses Horn amp Brake Lights Drive Dump Switch FNR Switch Beacon Instruments IGN on to ECU Indicators 9 Hazard 10 Rear Fog 11 ECU Power 12 Fuel Pump Relay 13 Fuel Pump 14 ECU Power Hold Relay 15 LH Main Beam 16 RH Main Beam 17 LH Dip 18 RH Dip 19 LH Side Tail 20 RH Side Tail Oo c OV PRE 57 Customer NC ENGINEERING Part no SD9 Dumper i Drawn R Tuplin E REV AMENDMENTS DATE E E c z o o E o E o x 3 o b o E AUTO MOTIVE MARINE amp INDUSTRIAL HARNESS MANUFACTURE BOSTON PE21 7FP TEL 01205 363008 PARKINSON HARNESS TECHNOLOGY MARSH LANE C2 Dash Panel Display Conns ews su n aas uondu se OU ASH Jeduma 9aS ou ped SNIH33NION3 ON Jewojsng BO e cL undni 4 uwera l Siva SiNSWONSWY s IM Paas DayOqUOD EI ee Dss3 Uses aveu SYNLOIVANNVW SSANYYH TWELSNONI 8 NEW 3ALLOW OLN SoOococ sOZLO 131 daz LZad NOLSOS NW HSHwvIlN 90108231 SSSNUVH NOSNIMEN suuo
94. ulphur fuel is not normally found in North America Europe or Australia If you have to use high sulphur fuel you must change the engine oil more frequently 33 Fluids amp Lubricants Low sulphur fuels must have the appropriate fuel lubricity additives these lubricity improvers must not create residual deposits that block the fuel system e g Injectors filters etc Contact your fuel supplier Percentage of Sulphur in the fuel Oil Change Interval 0 5 to 1 0 0 75 of normal More than 1 0 0 50 of normal A combination of water and sulphur will have a corrosive chemical effect on fuel injection equipment It is essential that water is eradicated from the fuel system when high sulphur fuels are used 34 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 certainly lead to greater leakage uneven running and poor fuel delivery This machine uses a 5 micron pre filter with a 2 micron main filter Only use genuine high quality filters available from NC 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

ST10 maintenance manual Revision C

Contents

Download Pdf Manuals

Related Search

Related Contents