NC SW6, Maintenance Instructions Manual

Page 1: ...E 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 REVISI...

Page 2: ...ore it is very important that your new equipment operations and instructions are explained to you by a Dealer Representative following delivery of your equipment This will explain the operating contro...

Page 3: ...rations used in this manual are correct at the time of issue NC reserves the right to make changes in this manual at any time without prior notice Copyright 2010 NC Engineering Hamiltonsbawn Ltd All r...

Page 4: ...17 6T PST Maintenance Manual 19 Service Record 20 Service Schedules 21 Torque Settings 24 Fluids and Lubricants 25 Safety Information 28 Maintenance 29 Battery 30 Air Cleaner 31 Coolant System 32 Engi...

Page 5: ...n designed and manufactured in accordance with the following European Standards 2006 42 CE Machinery Directive Measured Sound Power Level 102 dB LWA Guaranteed Sound Power Level 103 dB LWA Net Install...

Page 6: ...ise Level Declaration The noise levels are measured according to ISO6395 1998 The noise level of this machine is LWA 103dB A LPA 85dB A LWA A Weighted sound power level LPA A Weighted sound pressure l...

Page 7: ...Arm aha m s 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 t...

Page 8: ...ximum Automatic safety lock to hold skip in a central position when travelling Heavy duty fully welded skip with 8mm thick steel base reinforced around top for greater strength Operated by a multi axi...

Page 9: ...tio 18 6 1 Engine compression see Note 2 Direction of rotation viewed from front crank shaft pulley end Clockwise Valves 4 per cylinder Valve tip clearances measured cold inlet 0 19 to 0 27mm 0 007 to...

Page 10: ...urately achieved failure to tighten accurately to the specified angle could result in the bolt preload being incorrect this will lead to eventual failures It is good practice to replace all bolts that...

Page 11: ...sioner retaining bolts 22 26 16 19 Item Torque Setting Angle Nm lbf ft Oil sump retaining bolts A 22 26 16 19 Oil sump plug B 40 60 30 44 Item Torque Setting Angle Nm lbf ft Rocker cover retaining bol...

Page 12: ...ector retaining 22 26 16 19 bolts Item Torque Setting Angle Nm lbf ft Water temperature sender switch 22 26 16 19 Item Torque Setting Angle Nm lbf ft Cold start advance switch 22 24 16 19 Item Torque...

Page 13: ...etaining bolts 22 26 16 19 Item Torque Setting Angle Nm lbf ft High pressure fuel pipes 25 29 19 22 Item Torque Setting Angle Nm lbf ft Power take off PTO pump bolts SAE A M10 bolts 43 51 32 38 SAE B...

Page 14: ...Nm lbf ft Starter motor retaining bolts 43 51 32 38 Item Torque Setting Angle Nm lbf ft Alternator retaining bolts 47 34 7 Item Torque Setting Angle Nm lbf ft Oil cooler drain plug 20 25 15 18 Item T...

Page 15: ...ed it can be obtained from the NC Spares department Ref No Symbols Description 1 Engine Oil Level 2 Engine Coolant Level 3 Fuel and Water Sedimentor 4 Transmission Oil Level 5 Axle Service Points 6 Ax...

Page 16: ...e Point Drive Shafts 17 Transfer Box Oil Level 18 Transmission Oil Filter 19 Oil Pressure Filter 20 Axle Oil 21 Engine Oil Filter 22 Fuel Filter 23 Check Drive Shaft Bolts 24 Air Filter Element 25 Tra...

Page 17: ...be obtained from NC spares department Part No Symbol Descriptions DEC 1920 001 Tyre pressure and wheel nut torque DEC 1920 002 Hydraulic Oil DEC 1920 003 Fuel DEC 1920 004 Stay clear of tipping area D...

Page 18: ...DEC 1920 014 Recommended brake fluid DEC 1920 015 Recommended brake fluid Circular DEC 1920 016 No repairs to ROPS DEC 1920 017 Stay clear of pinch points DEC 1920 018 Read manual Apply handbrake bef...

Page 19: ...ance 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...

Page 20: ...500 Hr Date Hour Reading First 5000 Hr Date Hour Reading First 6000 Hr Date Hour Reading First 6500 Hr Date Hour Reading First 7000 Hr Date Hour Reading First 7500 Hr Date Hour Reading First 8000 Hr D...

Page 21: ...lant or Oil Leaks Check Fuel Pre Filter Water Sedimentor Check for contamination Drain Oil Filter Change All Hoses Condition Check Radiator Clean Fan Belt Condition Check Fuel Filter Change Air Cleane...

Page 22: ...el Check Transmission Oil Change Transmission Filter Change Transmission Strainer Clean Drive Shafts Security Functional Test Forward Reverse Gear Change operation Check Transmission Main Line Pressur...

Page 23: ...Steering Ram 2 No Points Note First 50 Hr Service only HYDRAULICS SYSTEM Service Points Fluid Levels Operation 10 Hr 100 Hr 500 Hr Return to tank filter element Change Pressure filter element Change S...

Page 24: ...3 4 117 87 9 16 14 3 13 16 170 125 5 8 15 9 15 16 238 175 3 4 19 1 1 8 407 300 7 8 22 2 1 5 16 650 480 1 25 4 1 1 2 970 715 1 1 4 31 7 1 7 8 1940 1430 1 1 2 38 1 2 1 4 3390 2500 METRIC Grade 8 8 Bolts...

Page 25: ...If a diesel particulate filter is fitted a low ash type oil must be used to prevent the filter clogging COOLANT MIXTURES Anti freeze can be harmful Obey the manufacturers instructions when handling ne...

Page 26: ...ceptible to the abrasive nature of dirt particles Increased wear will almost certainly lead to greater leakage uneven running and poor fuel delivery WATER Water can enter the fuel through poor storage...

Page 27: ...YP SAE90 BP Energear Hypo 90 AXLE OIL NC recommend Mobil 424 International Specification API GL4 M2C 41B 134D JD20C 23 Litres Alternative Suppliers 1 Shell Spirax S4 TXM BP Tractran 10 NC recommend Mo...

Page 28: ...uchs Renolit EP2 grease Alternative Suppliers 1 GENERAL GREASE POINTS Multi purpose grease 1 Do not mix different type of oils grease as they may react with each other If topping up use the same type...

Page 29: ...lift heavy objects on your own WHEN REPAIRING Safety prop tipped skips Always wear eye protection Always wear ear protectors when in a noise environment Release any pressure from the hydraulic system...

Page 30: ...d 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...

Page 31: ...cinity of a battery being charged If the skin is exposed to battery electrolyte the affected skin must immediately be washed with running water If eyes are exposed to battery electrolyte wash the eyes...

Page 32: ...leaning or replacing is to check Never run the engine with the filtration elements removed from the air cleaner Squeeze the solids ejector C to remove material from the pre cleaner drop tube To servic...

Page 33: ...coolant to drain into a suitable container Flush the system by pouring clean water into the expansion tank filler neck Refit the bottom hose and tighten the clip Dispose of used coolant in an environm...

Page 34: ...ller 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 Check the oil level frequently when adding oil too...

Page 35: ...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 Operate the engine until the...

Page 36: ...ears 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 ext...

Page 37: ...f hot oil as it can cause serious burns 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 Unscrew and disca...

Page 38: ...d 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...

Page 39: ...park brake is engaged and that one pair of wheels is blocked on each side Ensure the skip is in the lowered position and locked in the forward position Ensure the brake fluid reservoir is full and th...

Page 40: ...gap should be greater than 1mm 0 04 in If gap is less than 1mm renew the pads RENEW THE BRAKE PADS Disengage the parking brake A lever horizontal Slacken the nuts D and unhook the clevis E Loosen and...

Page 41: ...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...

Page 42: ...urate oil level checking At the drive head casing remove fill level plug A Oil should be level with the bottom of the fill level hole If necessary top up with the recommended axle oil Clean and refit...

Page 43: ...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 t...

Page 44: ...cap fitted to seal them Fit new valves pumps motors filters etc if all the ports have not been plugged Use dirty containers for oil storage Use dirty containers or funnels for filling the hydraulic s...

Page 45: ...C other filters may be of lesser quality and lead to increased wear in the hydraulic components resulting in oil leaks SUCTION STRAINER FILTER Empty the tank according to the above procedure The sucti...

Page 46: ...ck hydraulic oil level and top up as required Fill the fuel tank to prevent condensation forming inside the tank and contaminating the fuel Store the machine on flat level ground which is not liable t...

Page 47: ...ve 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 with...

Page 48: ...48...

Page 49: ...49...

Page 50: ...harts 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 leve...

Page 51: ...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...

Page 52: ...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 Injection pump timing incorrect If the pump...

Page 53: ...ure that the alternator is functioning correctly and charging the battery No electrical connection to the starter solenoid Check voltage to solenoid Crankshaft rotation restricted Manually turn the en...

Page 54: ...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...

Page 55: ...e of diesel used Refer to Fluids Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Inlet and exhaust valve cle...

Page 56: ...ly restricted Check replace the fuel filter s Check fuel lines for restriction Fuel is contaminated or incorrect grade of diesel used Refer to Fluids Lubricants section for recommended diesel fuels If...

Page 57: ...diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Inlet and exhaust valve clearances set incorrectly Set the valve clearances to the recommended...

Page 58: ...rom a temporary tank Injection pump timing incorrect If the pump has recently been removed and replaced the timing could be incorrect if the correct removal procedures were not followed The timing can...

Page 59: ...ep face and hands well clear of pressurised fluid and wear protective glasses If fluid penetrates your skin seek medical help immediately Fuel filter s blocked fuel supply restricted Check replace the...

Page 60: ...or Remove extra injector sealing washer Inlet exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances Injection pump timing incorrect If the pump has recently b...

Page 61: ...d or incorrect grade of diesel used Refer to Fluids Lubricants section for recommended diesel fuels If the fuel is suspect verify by operating the engine with clean fuel from a temporary tank Fuel fil...

Page 62: ...netrates your skin seek medical help immediately Fuel tank cap vent breather blocked Inspect rectify as required Replace cap if necessary Fuel is aerated Check the fuel system for loose connections an...

Page 63: ...gine mounts Refer to correct installation procedure and torque figures Inlet exhaust valve clearances set incorrectly Set the valve clearances to the recommended clearances Engine compression low in o...

Page 64: ...clean the injector If the problem still persists the injector must be checked by a FIE specialist or replace with new Worn or malfunction fuel injection pump FIP Injection pump not delivering fuel Ch...

Page 65: ...ct if the correct removal procedures were not followed The timing can only be checked by a FIE specialist using the correct equipment One or more injector worn or malfunctioning White blue smoke at op...

Page 66: ...ion pump FIP Injection pump not delivering fuel Check for operation of the FIP The FIP must be taken to a local FIE specialist to have the fuel delivery timing checked Ensure that all obvious causes h...

Page 67: ...ank Intake air or exhaust leaks Refer to Charts A13 A14 Engine compression low in one or more cylinders Check the engine compression Injection pump timing incorrect If the pump has recently been remov...

Page 68: ...leaks in the manifold or turbocharger gaskets Look for a cracked manifold Valve guide seals are leaking Replace valve guide stem seals as required One or more injector worn or malfunctioning Check an...

Page 69: ...the lubricating oil change intervals Excessive leaking out of the breather tube system blocked Check the breather tube areas for sign of lubricating oil loss If necessary replace the breather gauze Lu...

Page 70: ...ft pump leaking Repair or replace the fuel lift pump One or more injector worn or malfunctioning Check and externally clean the injector If the problem still persists the injector must be checked by a...

Page 71: ...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 Revie...

Page 72: ...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 chan...

Page 73: ...ine and components for seal gasket or hose connection leaks Make sure all hose clips are in good condition and torqued to the recommended figure Overheating or compression gasses leaking resulting in...

Page 74: ...ith 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 cooli...

Page 75: ...ct 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...

Page 76: ...box Check selector lever is engaging the gears on the gearbox turret Check handbrake sensor switch Check transmission oil level Check Action 1 Is there noise when selecting direction YES Check 3 NO Ch...

Page 77: ...ure setting 15 Is pump being driven by converter YES Check pump pressure NO Renew damaged parts 23 Is the noise present when in neutral or when in gear NEUTRAL Check 24 IN GEAR Check 27 16 Are clutch...

Page 78: ...n YES Renew worn parts NO Check 31 31 Are dog teeth gear worn YES Renew NO Check 32 32 Are selector rod detent springs broken YES Renew NO Check 33 33 Are the selector rods worn or broken YES Renew NO...

Page 79: ...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 sy...