machine manual

759OMA3300

OPERATION & MAINTENANCE MANUAL

BD14W WHEEL DOZER

APPLICABLE EQUIPMENT SERIAL NUMBER 16199 & UP (FOR BS6D105-1 ENGINE, ZF MTL AXLES & TRANSMISSION)

BEML LIMITED INDIA

2

QUICK REFERENCE INFORMATION

QUICK REFERENCE INFORMATION

Machine model & serial no.

Engine model & serial no.

Nearest BEML Office & Telephone no.

BD14W WHEEL DOZER

SL.NO..

BS6D105-1

SL.NO

PERIODIC SERVICE ITEM DATE SERVICE METER

DELIVERY

PERIODIC

PERIODIC

PERIODIC

PERIODIC

CONSUMABLE PARTS NO PARTS NAME QTY

355TM 91295 TRANS. PRESSURE FILTER 01

375 HS 02004 ELEMENT HYDRAULIC & STEERING 02

355 AS 00136 AIR FILTER ELEMENT (KIT) 01

950 SK 00027 FILTER ASSY AUTO DRAIN VALVE (KIT) 01

14G 6010645 FAN BELT 02

14G 7010225 COMPRESSER BELT 02

30 Z 5180495 ENGINE OIL CARTRIDGE 01

11 Z 7180235 FUEL FILTER ELEMENT (FINE) (MICO) 01

30 Z 7180369 FUEL CARTRIDGE 01

30 Z 1280296 AIR CLEANER ELEMENT INNER ASSY 01

30 Z 1280133 AIR CLEANER ELEMENT OUTER ASSY 01

30 Z 1260094 O RING FOR DUST PAN 01

30 Z 1280174 AIR CLEANER BLEEDER VALVE 01

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FOREWORD

FOREWORD

This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.

Please read this manual carefully BEFORE operating the machine.

Please continue studying this manual until proper operation is completely reinforced into personal habit.

This manual describes the basic techniques. Skill is performed as the operator or anyone get the correct knowledge and performance of the machine.

Operation, inspection, and maintenance should be carefully carried out, and the safety must be given the first priority. Safety precautions are indicated with marks and technical precautions are indicated with marks in this manual. The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations.

Some photographs and illustration pictures are different from your machine as technical improvement is continuously reflected on it. Revision to up-to-date manual's content is performed in later editions.

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BREAKING IN YOUR NEW MACHINE

BREAKING IN YOUR NEW MACHINE

Each machine is carefully adjusted and tested before shipment. However, a new machine requires careful operation during the first 100 hours to break in the various parts.

If a machine is subjected to unreasonably hard use at the initial operation stage, the potential of performance will prematurely deteriorate and the service life will be reduced. A new machine must be operated with care, particularly with regard to the following items.

After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior to actual operation.

Avoid operation with heavy loads or at high speeds.

Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning should be avoided.

At the first 250 hours of operation, the machine should be maintained in the following manner in addition to usual 250 hours service:

Changing all Oils, oil filters and fuel filter elements.

Checking and adjustment of engine valve Clearances.

For replacement procedure and details, see maintenance table in the maintenance section.

When replacing oil filter elements (cartridges) check their interiors for dirt and dust. If heavily collected, check for possible cause before starting operation.

Hours of operation are indicated by the service meter.

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CONTENTS

CONTENTS

OPERATION 1 SAFETY HINTS 06 2 GENERAL LOCATIONS & SPECIFICATIONS 11 3 OPERATOR'S COMPARTMENT 11 4 INSTRUMENT PANEL AND CONTROLS 14 5 CHECK BEFORE STARTING 18 6 OPERATING YOUR MACHINE 21 11 TOWING 24 12 TRANSPORTATION 24 13 COLD WEATHER OPERATION 25 14 OPENING & CLOSING OF LOCKING CAP 26 15 HANDLING OF BATTERY 26

MAINTENANCE PERIODIC MAINTENANCE

1 PRECAUTIONS FOR MAINTENANCE 28 2 BLEEDING AIR FROM BRAKE CIRCUIT 30 3 MAINTENANCE TABLE 31 4 EVERY 50 HOURS SERVICE 33 5 EVERY 100 HOURS SERVICE 33 6 INITIAL 250 HOURS SERVICE 33 7 EVERY 250 HOURS SERVICE 34 8 EVERY 500 HOURS SERVICE 35 9 EVERY 1000 HOURS SERVICE 35 10 EVERY 2000 HOURS SERVICE 39 11 EVERY 4000 HOURS SERVICE 41 12 WHEN REQUIRED 42 13 TROUBLE SHOOTING GUIDE 46 14 STORAGE 48 15 SERVICE METER 49 16 EQUIPMENT AND ENGINE SERIAL NUMBER 49 17 FUEL, COOLANT & LUBRICANTS 50 18 POWER TRAIN & PARKING BRAKE CONTROL 51 19 DUAL AIR BRAKE SUSTEM SCHEMATIC 52 20 HYDRAULIC CIRCUIT 53 21 ELECTRICAL WIRING DIAGRAM (16199 & UP) 54 23 TRANSMISSIOM OIL CIRCUIT DIAGRAM 4MG-190 55 24 EQUIPMENT COMPONENTS 57

6

SAFETY HINTS

SAFETY HINTS . . . . . Protect yourself and others. Safety is always first.

OPERATION GENERAL

Wear well-fitting helmet, safety shoes and working clothes. If the nature of the work requires safety, wear protective goggles or mask, thick gloves, earplugs or other protection.

Accidents or injuries are liable to occur when the operator is careless or slack. It is most important to bear safe operation in mind at all times.

Take care of your health. Do not drive when tired or after drinking.

Learn the prohibitions, cautions and rules about work procedures in the work site.

When there is a leader, fix standard signals and always follow these signals when operating.

If there should be an accident or fire or any other such unexpected mishap, deal with it quickly, using the nearest apparatus.

Learn before and the locations of the first aid boxes and fire extinguishers and how to use them. It is also important to know the emergency contact system.

Such safety devices include: Guards Canopies - Protective Devices Seat Belts, etc.

Learn about the safety devices on your own machine and about how to use them. Confirm that they are correctly attached in the prescribed position.

Read the Operation and Maintenance Manual carefully. Learn how to use the control devices, gauges and warning devices. Be sure you understand the meaning of the Caution plates. Remember the check points and checking method for engine oil, fuel, cooling water and hydraulic oil levels.

Exhaust gas is dangerous. When running the engine for long periods in a poorly ventilated area, there is a danger of gas poisoning, so open the windows or doors to ensure a good supply of fresh air.

When operating inside a building, always be sure of the clearances of the ceiling, entrances, aisles, etc. and the load limit of the floor.

Never allow other person than the operator to ride on the machine during operation.

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SAFETY HINTS

BEFORE STARTING OPERATION

Examine the lay of the land and the kind of soil at the work site to determine the dangerous points and the best method of operation.

Proceed with the work only after making safety arrangements about the dangerous points.

Inspect leakages from the fuel, lubricating and hydraulic systems. Check that the shoe bolts are not loose, and that no other parts are damaged or missing. Machines having such failures should not be operated.

When getting on or off the machine, use the handrail and step provided. Do not jump up or down from the machine.

Do not leave parts or tools lying around in the vicinity of or on the floor of the operator's compartment. Keep everything in its proper place.

Wipe off thoroughly any grease, oil or mud on the step, handrail, floor or control levers. Failure to do this may cause you to slip.

Check the level of the fuel, lubricants and cooling water. Extinguish cigarettes before checking or replenishing. Check that the radiator cap and each oil filler caps or plugs are firmly fitted &tightened.

Adjust the operator's seat until it is in the most comfortable position for operating.

Always sit in the seat while operating. Do not operate the machine from any other position.

Adjust the seat so that the brake pedal can be depressed all the way with the operator's back against the backrest.

Before operating the machine, check and fasten the seat belt.

Inspect the seat belt and fittings, replace any damaged or worn parts.

To ensure the safety of workers near the machine, always sound the horn to warn them before starting the engine and moving the machine. Be particularly careful to check that the rear is clear before backing the machine.

Inspect the inside of the engine room and remove any dead leaves or paper. Dead leaves or paper are highly inflammable and can cause fires.

Before starting the engine, confirm that all control levers are in "NEUTRAL" or "HOLD".

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SAFETY HINTS

AFTER STARTING THE ENGINE

Confirm that all gauges and warning devices are functioning correctly, and that the gauge readings are within the prescribed range.

Check the play and travel of each lever and pedal Operate the Dozer Attachment to confirm that it is functioning normally.

Move the machine slowly and listen carefully to the engine or gears to confirm that they are not making any unusual noises.

Operate the gearshift lever to confirm that the travel speeds for forward and reverse are functioning normally. Also carry out a brake test at each travel speed.

Choosing a safe place, turn the machine to the left and right to confirm that the steering devices are functioning normally.

If these tests reveal anything wrong, however slight it may be, contact the man in charge of the machine and operate the machine only after obtaining his permission.

DURING OPERATION

Always concentrate. It is extremely dangerous to allow yourself to be distracted or to think of other things when operating a machine.

In dangerous places, or where there is restricted visibility, it is important to get down from the machine and confirm whether it is safe before continuing work.

The work area should be made as flat as possible. If the work area is flat, operation is made much easier and this reduces operator fatigue.

The machine should always be operated at a speed where it can be correctly controlled. Never do the following:

Speeding Sudden starting, sudden

breaking, sudden turning. Snaking Coasting

Be careful of those around you, and always confirm that there is no person or obstacle in the way before driving or turning the machine.

Always operate slowly in crowded places. On haul roads or in narrow places, give way to loaded vehicles

When driving the machine, keep the attachment 40~50 cm above the ground.

Do not allow unauthorized persons into the work area.

Always be aware of the operating capacity of the machine. Using the machine to do work beyond its capacity will not only damage the machine, but may even cause unexpected accidents.

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SAFETY HINTS

The machine condition can be judged from many factors. Changes in the gauges, sound, vibration, exhaust gas color or response of the control levers can indicate the occurrence of some disorder. If any disorder occurs, park the machine immediately in a safe place and take appropriate action. Be especially careful in the case of a fuel leak, as there is danger of fire.

If the machine breaks down and needs to be towed, first confirm that the brakes are working properly, and then tow, using a wire rope or any other suitable towing equipment.

When parking the machine after discontinuing work, put the gearshift lever into "NEUTRAL", apply the brake lock, lower the Dozer Attachment to the ground, and put all safety levers into the "LOCK" position. Never leave the operator's seat without switching the engine off.

When continuing operations after rain, remember that conditions will have changed from those before the rain started, so proceed with caution.

Be particularly careful when approaching the shoulder of the road or cliffs, as they may have been loosened by the rain.

Check the load limits of bridges before crossing.

After earthquakes, confirm that the ground is still firm; after blasting, confirm that there are no unexploded charges remaining.

When operating on uneven ground or in places where there are obstacles, remember the following points:

When operating on uneven ground, drive at as low a speed as possible and avoid sudden changes in direction.

Wherever possible, avoid traveling over large rocks, fallen trees, tree stumps and other such obstacles. Either use the working equipment to remove them, or travel round them.

When it is impossible to avoid traveling over them, put the gearshift lever into a low speed, reduce speed and mount over the obstacle. Just before the front of the machine tips down, reduce speed even more to make the shock of hitting ground as small as possible.

Never mount over an obstacle at an angle; never disengage one steering clutch to travel over an obstacle.

When operating at the edge of a cliff or on the shoulder of a road, remember the following points:

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SAFETY HINTS

When operating in a place where there is danger of the machine falling over the side, be doubly careful. Do not approach the edge of the cliff or road shoulder by mistake.

At the instant when the soil is dumped over the cliff, or when the machine passes the summit of a slope, the machine speed suddenly increases. This is dangerous, so press the decelerator pedal or use the fuel control lever to reduce the speed, and at the same time return the gearshift lever to "NEUTRAL".

When working on river embankments or other places made of piled soil, there is the danger that the weight or vibration of the machine may cause the machine to sink into the piled soil, so be extremely careful when operating in such places. When operating on slopes, remember the following points:

When driving on a slope, always drive directly up or down it. Never drive horizontally or diagonally across the slope, as this may cause the machine to roll over or slip sideways.

When going down a slope, use the engine as a brake. If this is not enough to control the speed of the machine, use the service brake as well.

Never coast down a slope with the gearshift lever in "NEUTRAL".

As far as possible, avoid turning the machine on a slope. It may cause the machine to roll over or slip sideways.

In forest areas, do not mount fallen trees or logs. Piles of leaves or branches are also very slippery, so proceed with caution.

Before going up or down a slope, select a travel speed most suited to the slope. Do not change gear on the slope.

If the engine stalls on a slope, first use the brake to stop the machine, then return the gearshift lever to "NEUTRAL before starting the engine again.

When operating in water or in muddy areas, remember the following points: At night it is very easy to make mistakes in assuming the distance and height of objects and land.

When operating in fog, mist or smoke, where visibility is bad, be especially careful to confirm first whether operation is safe. When visibility drops below safety level, stop work and wait for the visibility to improve.

When operating in snow, remember the following points: Even slight slopes can cause unexpected side slipping, so in such places, operate with extreme caution.

Never use the service brake to stop suddenly on slopes. Lowering the working equipment is a far more effective way to stopping.

During Operation, use the seat belt.

PARKING

When parking the machine, park it in a safe place out side the working area, or in the specified place.

The following factors should be considered when choosing a parking place: it should be on flat, firm ground where there is no danger of rock falls, land- slides or floods.

If the machine has to be parked on a slope, it should be parked facing directly up or down the slope and chocks should be placed under the tires.

When parking the machine, return the gearshift lever to "NEUTRAL", apply the parking brake, and lower the Dozer attachment to the ground. Switch off the engine (After keeping the Engine idle for 5 minutes) and remove the key.

11

GENERAL LOCATIONS AND SPECIFICATIONS

GENERAL LOCATIONS AND SPECIFICATIONS

GENERAL LOCATIONS:

1. Blade attachment 2. Head Lamp 3. Front Wheel 4. Rear Wheel 5. Lift Cylinder 6. Canopy 7. Operators Seat 8. Exhaust Pipe

OPERATING WEIGHT 15000 kg PERFORMANCE Travel speed Forward: Max. 31.4 km/h Reverse: Max. 22.34 km/h Wheel Dozer (attachment) Attachment weight : 1880 kg

ENGINE Model: BEML BS6D105-1 diesel engine Rated rpm : 2000 rpm Flywheel horse power : 126 HP Note: Specifications are subject to change without notice

OPERATOR'S COMPARTMENT

1. Steering Wheel 2. Air Horn 3. Clutch cut off Pedal 4. Service Brake Pedal 5. Accelerator pedal 6. Blade Lift Control Lever 7. Turn Signal lever 8. Gear Shift Lever 9. Throttle Lock

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1. STEERING WHEEL

Turn the steering wheel to steer the vehicle to the desired direction.

2. AIR HORN The Air Horn switch is mounted on the floor board to the left of the Operator. Press this by left foot to sound the Air Horn.

3. CLUTCH CUT-OFF PEDAL When the accelerator is being used for operating the work equipment, always use the left brake pedal to slow or stop the machine. Use this pedal for short while stopping at traffic signals. Do not use the brake pedal repeatedly unless necessary. Do not use the Clutch cut-off pedal as foot rests. Use them only when applying brakes.

4. SERVICE BRAKE PEDAL Pressing forward on the service brake pedal applies air pressure to air brake on all four wheels. There must be at least 3 kg/cm2 pressure in the brake system before the machine is moved. On hills, use the Service brake pedal.

5. ACCELARATOR PEDAL This pedal controls the engine speed and output. The engine speed can be freely controlled between low idling and high idling. Press the pedal to increase the speed of the machine. Release pressure on the pedal to decrease the speed.

6. BLADE LIFT CONTROL LEVER a) RAISE: When the lever is pulled

backwards the Dozer Blade is raised. This position has detent that is released by hand.

b) HOLD: This is the neutral position and Dozer Blade does not move.

c) LOWER: When the lever is pushed forward Dozer Blade is lowered. As this position has no detent the lever returns to HOLD position automatically

d) FLOAT: When the lever is pushed all the way forward, the Dozer Blade is moved by an external force. This position has detent.

7. TURN SIGNAL LEVER / DIMMER SWITCH This lever operates the turn signal lamps.

LEFT TURN : Push lever Forward

RIGHT TURN : Pull lever Backward

When the lever is operated, the turn signal pilot lamp will also light up.

When the steering wheel is turned to the neutral position, the turn signal lever to be return to OFF manually.

Operate the switch for head light dimmer operation.

8. DIRECTION / SPEED CONTROL LEVER Direction Lever: This lever is used to change the direction of travel of the machine (forward or reverse). The engine cannot be started if the directional lever is not at N (Neutral). When operating the directional lever, hold the steering wheel and operate the directional lever with your fingers.

Speed Control Lever: This lever controls the travel speed of machine. This machine has 4-Forward & 3-Reverse speed. Rotate the speed control lever in a suitable direction to obtain the desired range. 1st and 2nd speeds are used for working. 3rd and 4th speeds are used for traveling.

9. THROTTLE LOCK LEVER Locks the engine throttles at a preset speed when the lever is pulled towards operator. The throttle lock is disengaged by pulling out on the lever front side.

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OPERATOR'S SEAT The seat adjustment should be checked at the beginning of each shift and when Operators changed.

A. Forward-Backward adjustment

Lift lever (1) to move the seat to the desired position and release the lever. The Seat can be moved Forward or Backward within a range 180 mm in 15 steps.

B. Seat Height & Angle adjustment

Move the lever (2) set the Seat to the desired height and release the lever. The seat can be moved up and down within a range of 60 mm in 5 steps.

Move the lever (2) up, set the Seat to the desired angle, and release the lever. The seat can be tilted up or down in steps of 2.5.

C. Backrest adjustment

Press the lever (4) set the Seat to the desired angle and release the lever.

D. Weight adjustment

Rotate the Knob (3) set the Seat to the desired weight release the Knob. The seat can be adjusted within a range of weight from 50 kgs to 120 kgs.

SEAT BELT Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions.

Fasten the belt and remove it in the following manner.

1. Adjust the seat so that the brake pedal can be depressed all the way with the operator's back against the backrest.

2. Sit in the seat, Hold buckle (2) and insert (3) into the buckle (2). Check that the belt has locked by pulling it.

3. When removing the belt, raise the tip of the buckle lever to release it.

Fasten belt along your body without kinking it. Adjust the lengths of the belt on both the buckle and then insert sides so that the buckle is located at the mid-point of your body front.

Adjust the belt length in the following manner.

i. To shorten the belt, pull the free end of

the belt on either the buckle body or insert side.

ii. To lengthen, pull the belt while holding it

at a right angle to buckle or insert.

Inspect bolts and fittings on the chassis for tightness. Retighten any loose bolts to 2 to 3kgm torque.

If the seat belt is scratched or frayed or if any of the fittings are broken or deformed from long service, replace the same immediately.

14

INSTRUMENT PANEL AND CONTROLS

INSTRUMENT PANEL & CONTROLS

1. Trans. Oil Temp. Gauge 2. Water Temp. Gauge 3. Engine Oil Pressure Gauge 4. Air Pressure Gauge 5. Ammeter 6. Hour meter 7. Dash Board Lamp 8. Indicator Lamp, Left / Right Turn 9. Indicator Lamp, Engine Oil Pressure 10. Indicator Lamp, Parking Brake 11. Indicator Lamp, Reverse

12. Indicator Lamp, Air Pressure 13. Indicator Lamp, Battery Chare 14. Indicator Lamp, Preheat (Optional) 15. Parking Brake with indicator 16. Transmission Mode Switch 17. Rocker Switch, Engine Stop 18. Rocker Switch, Head Lamp 19. Rocker Switch, Work Lamp 20. Key Switch 21. Transmission Display Unit 22. Fuse Box (Shown separately)

1. Transmission Oil Temp. Gauge :

This indicates temperature of the transmission oil and temperature should be between 80 - 100 C.

2. Water Temperature. Gauge :

This gauge indicates temperature of the cooling water. If the temperature is normal during operation, the needle indicates green range. If the needle indicates the red range during operation, stop the machine and run the engine with

no load at midrange speed until the needle returns to the green range.

3. Engine Oil Pressure Gauge :

This gauge indicates the engine oil pressure.

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4. Air Pressure Gauge :

The gauge records amount of air pressure in the air tank. The gauge should read a minimum of 7kg/cm2.

5. Ammeter :

Records amount of current f low to and fro from batteries. Reading on (-) side shows discharge. Reading on (+) side records charging. At high idle and with no load on the electr ical system the ammeter should records a charge.

6. Hour meter :

This gauge indicates the total no. of hours the machine has worked. The hour meter advances while engine is running even i f the machine is not working.

7. Dash Lamp :

Provides illumination for night operation.

8. Indicator Lamp, Left / Right turn : Turn signal indicator lamps glow when turn signal switch is moved to either left or right by the operator.

9. Indicator Lamp, Engine Oil Pressure :

This indicator lamps glow when low engine oil pressure. If the alarm buzzer sounds and this lamp flash, the engine oil pressure is below the lower limit. Immediately stop the engine.

10. Indicator Lamp, Parking Brake :

This lamp lights up when the parking Brake is applied.

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11. Indicator Lamp, Reverse :

This lamp lights up when the vehicle is reversed..

12. Indicator Lamp, Air Pressure :

This indicator lamps glow when air pressure in the tank is low.

13. Indicator Lamp, Battery Charge :

The monitor indicates an abnormality in the charging system while the engine is running.

14. Indicator Lamp, Pre Heat (Optional) :

Indicates when Pre-heater is used.

15. Parking Brake : A 2 mode switch provides the operator control over parking brake.

Position ON : Parking brake is in applied condition. Parking brake indicator light on switch glows.

Position OFF: Parking brake is released. Parking brake indicator light goes OFF,

Keep the Parking Brake switch in ON position, before turning the key switch to on.

16. Transmission mode switch :

Auto shifting of a speed, keep the mode switch ON and rotate the speed lever to 4th Gear, give acceleration for Auto speed shifting operation.

17. Rocker switch, Engine stop : 18. Rocker switch, Head lamp : 19. Rocket switch, Work lamp : 20. Key Switch :

This is mounted on right side of the instrument panel. The switch is a locking device that prevents machine use by unauthorized persons. Key switch must be turned ON to complete the circuit to the starter control.

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21. Display unit (Transmission):

The following can be seen in the display Unit:

a. Display of the Driving direction (right side) V: Forward, N: Neutral, R: Reverse

b. Display of the engaged gear : Display 1,2,3,4

c. Waiting for Controller-Neutral Display: NN

d. Pre-selected Driving range: 1 Bar,2 Bars, 3 Bars & 4 Bars (All Manual Mode)

e. Display Manual/ Automatic (Arrows are indicate Automatic Mode: automatic up-and down shiftings)

f. Display of Cold-start phase : Transmission Remains in Neutral

g. Bars are flashing: Downshifting mode active

h. Error Display: Right side spanner symbol display

For more details contact Nearest BEML Office.

22. Fuse arrangement

Note: Fuse Box is fitted in side the Instrument Panel box.

Remove Cover

Replace a fuse with another of the same Capacity.

Before replacing a fuse, be sure to turn OFF the Starting switch. Lights, Back-up Horn a. Head Lights Front, Rear & Turn signal

indicator Lights on RH/LH b. Brake Lights on rear c. Reverse Lights on while reversing. d. Reversing Back-up Horn

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CHECK BEFORE STARTING


(Pre-operation checks forestall machine trouble. Never neglect them)

a. Walk around the machine and check for any trace of oil or water leakage. Remove radiator cap and check water level. Examine connections of high pressure hoses, hydraulic cylinders, final drive, radiator. If any leakage is evident, check for the cause and repair. If difficulty is encountered, consult your nearest BEML Office. Check tightness of bolts and nuts and retighten if required. Particularly checks are required for mounting of air cleaner and muffler. Check for broken electric wirings, short circuits and loose terminals. If any fault is detected, retighten/ repair / replace . In particular check for electric wirings of the battery, the starting motor and the alternator.

b. COOLANT

Remove radiator cap and check that coolant level is in the shaded area. If level is low, add water. To refill the radiator first stop the engine and pour in water until the water over flows the filler opening. Then, start the engine, check the water level again after five minute idling, and add water if necessary. If an excessively large quantity of water is required to correct the water level, leakage of water from somewhere in the cooling system is assumed. Inspect and remedy the cause of leakage.

To remove cap, release radiator pressure little by little by loosening cap slowly; then remove cap.

c. CHECK FUEL LEVEL AND REFILL FUEL IN THE FUEL TANK

1. Check the fuel level using fuel gauge/ dip stick.

2. Upon completion of work, pour in addition fuel from filler (F) until the fuel tank is full.

3. Fuel Capacity: 185 liters.

d. CHECK AND CORRECT OIL LEVEL IN

THE ENGINE OIL PAN Use the dipstick (G) to check the oil level. If necessary, add oil at the oil filler (F).

The type of lubricant used depends on the ambient temperature. Select according to the table "FUEL, COOLANT AND LUBRICANTS".

Make an oil level check before starting engine or 15 minutes or more after the engine is stopped. If oil remains at various portions of the engine, the correct oil level cannot be measured.

Stop the engine when checking the oil level. Checking the oil level with the engine idling may be allowed, if the following precautions are thoroughly satisfied:

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i. Check that the engine oil pressure gauge and water temperature gauge shows green ranges.

ii. Remove the oil filler cap. iii. Read the dipstick on its reverse

side where it is stamped, "ENGINE IDLING / STOPPED."

e. CHECK DUST INDICATOR When air cleaner element is clogged, the red piston of dust indicator (1) reaches service level and gets locked. In that case, clean element referring to section "WHEN REQUIRED".

After cleaning element, push button (2) to return red piston

f. CHECK FOR SEDIMENT & WATER IN THE WATER SEPARATOR. The water separator separates water mixed in the fuel. If the float (3) is at or above the red line (2), drain the water. For the draining procedure, see section "WHEN REQUIRED".

Even if a water separator is installed, be sure to check the fuel tank to remove water & sediment in the fuel.

g. HYDRAULIC TANK

Lower the Tyre Handler attachment horizontally to the ground and stop the Engine. Wait for 5 minutes, then check Sight Gauge (G). The oil should be visible in Sight Gauge (G).

Add Hydraulic oil from oil filler (F) if necessary.

The type of lubricant used depends on the ambient temperature. Select according to the table "FUEL, COOLANT AND LUBRICANTS".

When removing the cap (F), turn it slowly to relieve inner pressure.

Maintenance for every 50 hours should be carried out at the same time

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h. TRANSMISSION OIL LEVEL CHECK

All measurements must be carried out with low engine idling speed.

Park the equipment in horizontally standing.

Transmission in a neutral position. In the cold start phase, the engine

must be running about 2~3 minutes at idling speed, on the marking on the oil dipstick must then be lying above the cold start mark COLD.

At operating temperature of the transmission about 80 ~ 90 C

Loosen dipstick by counter lock rotation, remove and clean it.

Insert oil dipstick by slowly into the oil level tube until contact is obtained, and pull it out again.

On the oil dipstick, the oil level must be lying in the zone, hot.

Insert the oil dipstick again, and tighten it by clockwise rotation.

i. CHECK AND REFILL OF OIL IN

BRAKE OIL TANK

1. Check that the oil level in tank (1) at the right side of the operators seat in between the MAX & MIN marks.

2. Open cap (2) and refill SAE10W oil , if necessary.

The type of lubricant used depends on the ambient temperature. Select according to the table FUEL COOLANT AND LUBRICANTS.

Always use SAE10W oil to refill the brake oil tank.

j. Check that Parking Brake works properly

k. Check that Foot Brakes work properly l. Check that Horn sounds properly m. Check that Lamps flash properly.

Check for Dirt or Damage. n. Check direction of rear view mirror;

Check for Dirt or Damage. (Optional) o. Check that Engine Exhaust Gas color

and sound are normal. p. Check that Gauges and Instruments

work properly. (Refer Page No.14) q. Check Steering play. Check that

Steering works properly. r. Check that Back-up Buzzer sounds

properly.

s. CHECK ELECTRICAL WIRING Check for damage of the fuse and any sign of disconnection or short circuit in the electric wiring. Check also for loose terminals and tighten any loose parts.

Battery Starting motor Alternator

If the fuse is damaged or there is any sign of short circuiting in the electric wiring, always investigate the cause and correct it.

Please contact your nearest BEML Office for investigation and correction of the cause.

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OPERATING YOUR MACHINE

OPERATING YOUR MACHINE BEFORE STARTING THE ENGINE Before starting the engine, always check that the levers and pedals are in the correct positions.

1. Carry out an initial inspection. (For details of the inspection, see CHECK BEFORE STARTING).

2. With your back against the back rest of the Operators seat, adjust the seat position so that the pedals can be easily accessible and depressed.

3. Is work equipment control levers are in hold position.

4. Are the pilot lamps are working properly?

5. Do not start the engine while Dozer Blade control lever is in any position other than hold position.

TO START THE ENGINE

1. Keep gear shift / Forward & Reverse lever in N (neutral).

2. Depress accelerator pedal (1) lightly.

3. Turn the key of starting switch to the ON position to start engine.

4. If engine does not start, repeat the starting procedure after about 2 minutes.

5. When engine is started, release the key of starting switch and the key will return automatically to ON.

CHECK AFTER STARTING After starting, make the following checks. a. Depress accelerator pedal (1) lightly and

run the engine with no load at midrange speed for about 5 minutes.

b. After warm-up run is completed, check gauges and caution lamps for proper operation.

c. Confirm that the engine oil pressure caution lamp goes off when the engine is running at low idle.

d. Continue to run the engine at light load until the green ranges of the engine water temperature gauge and torque converter oil gauge are indicated.

e. Check if the exhaust color is normal or whether there is any abnormal noise or vibration.

f. Avoid abruptly accelerating the engine until the completion of warm-up.

TO MOVE THE MACHINE OFF 1. Check that the caution lamps are OFF. 2. Operate the Dozer blade control lever.

Bring the attachment in the traveling posture. 500 mm above the ground.

3. Depress right brake pedal (2), and turn

parking brake switch to OFF position to release the parking brake

4. Shift the gear shift lever to 1st or 2nd speed then shift Forward or Reverse direction as required.

5. Release brake pedal (2), then depress accelerator pedal (1) to move the machine off. If the machine has to be started on a

slope, always depress the left brake pedal. Then depress the accelerator pedal while releasing the left brake pedal to start the machine off slowly.

22


ZF CONTROLLER DW-3 After selecting the speed range release the Forward/Reverse lock lever. If lock lever is N position Forward/Reverse cant be operated. If the lock lever is switched to D position Forward/Reverse direction can be operated Please Note.

CHANGING GEAR SPEED By Rotative motion, the positions (speeds) 1 to 4 selected by rotating the lever (1) to the required gear speed (F1-F2-F3-F4) or (R1-R2-R3),

While changing speed use brake pedal before rotating lever.

CHANGING DIRECTION Reduce the speed and bring down to neutral before changing between forward and reverse direction. Place the directional lever to the desired position.

TURNING When traveling, use steering wheel (1) to turn the machine.

In this machine, the front frame is joined to the rear frame at center of machine by the center pin. The front and rear frame turn about this point, and the rear wheels follow in the same track as the front wheels when turning.

Turn the steering wheel lightly to follow the machine as is turns. When turning the steering wheel fully, do not turn it beyond the end of the stroke.

It is dangerous to turn the machine suddenly at high speed, or to turn on steep hills.

If the engine stops when the machine is traveling, the steering cannot be used. Since the machine is not equipped with emergency steering system.

This is particularly dangerous on hills, so never stop the engine when the machine is traveling.

23


TO STOP THE MACHINE 1. Release accelerator pedal (1) or release

Throttle Lock Lever forward direction and depress brake pedal (2) to stop the machine.

2. Place direction control lever in neutral.

3. Put parking brake switch to ON position.

4. Operate Dozer Blade attachment lever (3) and lower the attachment to ground.

Stop the machine in a safe place on firm level ground. If the machine has to be stopped on a slope, put blocks under the wheels. In addition to dig the attachment into the ground to increase the safety.

TO STOP THE ENGINE 1. Run the engine at low idle speed for

about 5 min. to allow it to cool down gradually.

2. Return starting switch to the OFF position and remove the key. (for Fig. see next page)

If engine is abruptly stopped before it has been cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency.

In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop it.

MAXIMUM DEPTH OF WATER

When working in water or on swampy ground, do not let the water come above the bottom of the axle housing.

After finishing the operation, wash and check the lubricating points.

IF WHEEL BRAKE DOES NOT WORK If the machine is not stopped by depressing brake pedal, use the parking brake to stop the machine.

PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES Lower the centre of gravity when turning When turning on slopes, lower the Dozer attachment to lower the center of gravity before turning. It is Dangerous to turn the machine with the Dozer Blade Attachment raised. BRAKING ON DOWN HILL SLOPES When driving down slopes put the speed

control lever in a low speed position and fully apply service brake. To apply the service brake, depress the right brake pedal.

If the speed control lever is not placed in proper speed position, the torque converter oil temperature may rise. If it overheats, place the speed control lever in the next lower speed to lower the oil temperature.

If the temperature gauge does not indicate the green range of the scale even with the lever in the 1st speed position, stop the machine, place the lever in neutral and run the engine at medium speed until the gauge indicates the green range.

IF ENGINE STOPS If the engine stops on a slope, depress the right brake pedal fully. Next lower the Dozer Blade Attachment to the ground and apply the parking brake. Then put the direction control and speed control levers in neutral, and start the engine again. (If the direction control lever is not in neutral, the engine will not start).

24

TOWING / TRANSPORTATION

TOWING

This machine must not be towed except in emergencies. When towing the machine, take the following precautions.

If there is a failure in the brake system, the brakes cannot be used, so be extremely careful when towing.

When engine can be used. Always keeps the engine running when

towing the machine. So that the steering and braking can be used.

When engine cannot be used. No lubrication oil flows in the

transmission, so disconnect the front and rear drive shafts before moving the machine.

The steering cannot be used, so disconnect the steering cylinder and steering linkage.

The machine should be towed only to the nearest place for inspection and maintenance. Do not tow the machine for long distance.

TRANSPORTATION When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc. it is a good idea to obtain a special platform for loading and unloading the machine. When it is unavoidably necessary to use a gangplank, however, at the very least observe the following for the sake of safety.

When loading the machine, park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine.

1. Correctly load the machine onto the specified part of the trailer.

2. Lower the Dozer Attachment and bring gear shift lever neutral lock .

3. Lock front frame and rear frame with safety bar provided on the equipment as shown in the figure.

4. Apply the parking brake on the trailer and insert blocks beneath the tyres to ensure that it does not move. Then fix the gangplank in line with the centers of the trailer and the machine. Make sure the gangplank has

sufficient width, length and thickness to enable the machine to be safely loaded and unloaded.

When transmission cut-off switch is put in OFF, the brake pedal and accelerator pedal are operated at the same time.

3. Determine the direction of the gangplank, then slowly load or unload the machine.

Do not on any account change the direction of the machine while it is on the gangplank. To change the direction of the machine, first take it down from the gangplank

4. When transporting the machine, place blocks underneath the front and rear wheels to prevent about. Also, hold it down with chains or wire ropes.

Determine the route for transporting the machine by taking into account the width, height and weight of the machine.

Before locking (Front & Rear frame)

After locking (Front & Rear frame)

25

COLD WEATHER OPERATION

COLD WEATHER OPERATION

PREPARATION FOR LOW TEMPERATURE

Replace lubrication oil by that with prescribed viscosity.

Fuel of low pour point shall be used. ASTM 0975 No.1 diesel fuel should be used at atmospheric temperature lower than -10 C.

Add antifreeze in the cooling water. When the atmospheric temperature drops lower than 0C while the machine is stopped, prevent freezing by adding antifreeze to the cooling water. The mixing rate of antifreeze is determined according to the expected minimum temperature. The following table shall be used.

Mixing rate of water and antifreeze

Min atmospheric temp (oC) -5 -10 -15 -20

Amount of antifreeze (litre) 38.5 49.5 59 68

Amount of water (litre) 126.5 121.5 106 97

Coolant capacity: 45 liters

Cautions for using antifreeze 1. Permanent type antifreeze shall be used.

2. Soft water (ex: city water) shall be used as mixing water.

3. Cooling systems must be thoroughly flushed before filling with antifreeze mixture.

4. When the climate becomes warmer and antifreeze (except permanent type) is not needed, replace with soft water (ex: City water), after thoroughly cleaning the cooling system.

Take care for fire as antifreeze is inflammable.

Care in using antifreeze Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc,) meeting the standard requirements as shown below, With permanent antifreeze, no change of coolant is required for a year, If it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for information,

Standard requirements for permanent antifreeze.

SA J1034 FEDERAL STANDARD O-A-548D Never use any antifreeze made from

methyl alcohol or ethyl alcohol which may be a cause of engine trouble.

Where no permanent antifreeze is available, ethylene glycol antifreeze without corrosion inhibitor may be used only for the cold season. In this case, coolant must be changed two times a year (at the beginning and at the end of the cold season).

Do not mix antifreeze with one of different brand.

Absolutely avoid using any water leak preventing agent irrespective of whether it is used independently or mixed with antifreeze.

Battery As ambient temperature drops, battery capacity will drop, and electrolyte may sometimes freeze if battery charge is low. Maintain battery at a charge level of approx. 100% and insulate it against cold temperature so that machine can be readily started the next morning.

Measure specific gravity of fluid and obtain rate of charge from the following conversion table:

Temp of Rate of fluid 20oC 0oC -10oC -20oC 100% 1.28 1.29 1.30 1.31 90% 1.26 1.27 1.28 1.29 80% 1.24 1.25 1.26 1.27 ch

ange

75% 1.23 1.24 1.25 1.26

When electrolyte level is low, add distilled water in the morning before work instead of after the day's work. This is to prevent fluid from freezing at night.

When temperature rises, change lubricating oil in each unit to that of recommended viscosity. Completely drain antifreeze from cooling system and fill with soft water (for example, city water) after thorough flushing.

26

OPENING AND CLOSING A LOCKING CAP / HANDLING OF BATTERY

OPENING AND CLOSING OF LOCKING CAP

A locking cap is available as a standard fitment for fuel tank cap or hydraulic tank cap. Open and close locking caps as follows:

1. To open the cap

Insert the key into the cap

Insert the key as far as it will go. If the key is turned before it is inserted all the way, it may break.

Turn the key counterclockwise and bring the rotor groove in line with the aligning mark on the cap. Turn the cap slowly until a "clicking" sound is made. This releases the lock and allows the cap to be opened.

2. To lock the cap

Turn the cap into place.

Turn the key clockwise and take the key out.

HANDLING OF BATTERY

PRECAUTIONS FOR CHARGING BATTERY 1. Before charging, disconnect the cable from

the negative (-) terminal of the battery. Otherwise an unusually high voltage will damage the alternator.

2. While charging the battery, remove all battery plugs for satisfactory ventilation.

To avoid gas explosions, do not bring fire or sparks near the battery

3. If the electrolyte temperature exceeds 45

C, stop charging for a while.

4. Turn off the charger as soon as the battery is charged.

Overcharging the battery may cause followings: a. Overheating the battery b. Decreasing the quantity of electrolyte c. Damaging the electrode plate

5. If the electrolyte gets on your skin or clothes, immediately wash with plenty of clean water.

6. Do not mix up cables (positive(+) to negative (-) or negative (-) to positive (+), as it will damage the alternator.

7. When inspecting or servicing a battery,

be sure to stop the engine and turn the starting switch key to (OFF) position.

8. When performing any service to battery besides checking the electrolyte level or measuring the specific gravity, disconnect cables from the battery.

REMOVAL AND INSTALLATION OF BATTERY

When removing battery, first disconnect the cable from the ground (normally, from the negative (-) terminal). If a tool touches a cable connecting the positive terminal and the chassis, there is danger of sparks being emitted.

27

HANDLING OF BATTERY

When installing battery, the ground cable should be connected to the ground terminal as the last step.

STARTING ENGINE WITH A BOOSTER CABLE When starting up the engine with a booster cable do as follows: 1. Before connecting the booster cable

a. Size of booster cable and clip should be suitable for the battery size.

b. Check cables and clips for breaks, corroded surfaces, etc.

c. Make sure cables and clips are, firmly secured.

d. Keep the starting switch key in (OFF) position.

e. The battery of the running engine must be the same capacity as that of engine to be started.

2. Connect the booster cables in the following manner.

a. Connect one clip of booster cable A to the positive (+) terminal of the engine to be started.

b. Connect the other clip to the positive (+) terminal to the engine which is running.

c. Connect one clip of booster cable (B) to the negative (-) terminal of the engine which is running.

d. Connect the other clip to the body of the machine to be started.

Make sure the clips are firmly connected to battery terminals. Then, start the engine.

When connecting the cables, never contact the positive (+) & negative (-) terminals

Make sure that the booster cable connections are correct. Connect the booster cable to the body as far as possible from the battery.

3. Starting the engine

a. Turn the starting switch key to START position and start up the engine.

b. If the engine doesn't start at first, try again after 2 minutes or so.

After the engine has started, the booster cables should be disconnected in the reverse order in which they were connected. 1. Disconnecting the booster cables.

a. Disconnect the clip of booster cable B from the body of the machine which was started.

b. Disconnect the other clip from the negative (-) terminal of the running engine

c. Disconnect the clip of booster cable A from the positive (+) terminal of the running engine.

d. Disconnect the other clip from the positive (+) terminal of the engine which was started

28

PRECAUTIONS FOR MAINTENANCE

PERIODIC MAINTENANCE

Proper lubrication and maintenance assure trouble-free operation and long machine life. Time and money spent for scheduled periodic maintenance will be amply compensated by prolonged machine operation and reduced operating cost.

All hourly figures given in the following descriptions are based on service meter readings. In practice, however, it is recommended to rearrange all of them into units of days, weeks and months to make the maintenance schedule more convenient. Under rough job site or operating conditions, it is necessary to somewhat shorten the maintenance intervals stated in this manual.

PRECAUTIONS FOR MAINTENANCE GENERAL

1. Wear well-fitting helmet, safety shoes and working clothes. When drilling, grinding or hammering, always wear protective goggles.

2. Fuel or oil is dangerous substances.

Never handle fuel, oil, grease or oily clothes in places where there is any fire or flame.

As preparation in case of fire, always know the location and directions for use of fire extinguishers and other fire fighting equipment.

3. When working with others, choose a group leader and work according to his

instructions. Do not perform any maintenance beyond the agreed work.

4. Do not handle electrical equipment while wearing wet gloves, or in wet places, as this can cause electric shock.

5. During maintenance do not allow any unauthorized person to stand near the machine.

6. Exhaust gas is dangerous. When working inside, be particularly careful to have good ventilation.

29

PRECAUTIONS FOR MAINTENANCE

7. Unless you have special instructions to

the contrary, maintenance should always be carried out with the engine stopped. If maintenance is carried out with the engine running, there must be two men present: one sitting in the operator's seat and the other one performing the maintenance. In such a case, never touch any moving part.

8. Always remember that the hydraulic oil circuit is under pressure. When feeding or draining the oil or carrying out inspection and maintenance, release the pressure first.

9. The procedure for releasing the hydraulic pressure is as follows: lower the dozer Attachment to the ground, and stop the engine; move the control levers to each position two or three times and then slowly loosen the oil filler cap.

10. Always use BEML genuine parts for replacement.

11. Always use the grades of grease and oil recommended by BEML. Choose the viscosity specified for the ambient temperature.

12. Always use pure oil or grease, and be sure to use clean containers.

13. When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into the oil.

DURING MAINTENANCE 1. Park the machine on firm, flat ground.

Lower the Dozer Attachment to the ground and stop the engine. Return the gear shift lever to "NEUTRAL", apply the brake lock and set each control lever to "LOCK". When maintenance has to be carried out with the Attachment raised, they must be securely supported by blocks.

2. Thoroughly wash the machine. In particular, be careful to clean the filler caps, grease fittings and the area around the dipsticks. Be careful not to let any dirt or dust into the system.

3. Hang a caution sign in the operator's compartment (for example "Do not start" or "Maintenance in progress").

This will prevent anyone from starting or moving the machine by mistake.

4. Flames should never be used instead of lamps. Never use a naked flame to check leaks or the level of oil, fuel, antifreeze or electrolyte.

5. Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine.

6. When check an open gear case there is a risk of dropping things in. Before removing the covers to inspect such cases, empty everything from your pockets. Be particularly careful to remove wrenches and nuts.

7. Before draining the oil, warm up it to a temperature of 30 to 40 C.

30

PRECAUTIONS FOR MAINTENANCE / BLEEDING AIR FROM CIRCUIT

8. Be particularly careful when removing

the radiator cap or the hydraulic oil tank filler cap. If this is done immediately after using the machine, there is a danger that boiling water or oil may spurt out.

9. After replacing oil, filter element or strainer, bleed the air from the circuit.

10. When the strainer is located in the oil filler, the strainer must not be removed while adding oil.

11. When adding oil or checking the oil level, check that the oil is at the correct level.

12. After greasing up, always wipe off the old grease that was forced out.

13. When changing the oil or filter, check the drained oil and filter for any signs of excessive metal particles or other foreign materials.

14. When removing parts containing O-rings, gaskets or seals, clean the mounting surface and replace with new sealing parts.

15. When the Tyres are removed, never put your fingers in the rim mounting holes.

16. Special measuring apparatus is needed for testing hydraulic pressure.

17. When changing the electrical circuit, adding additional or new equipment, or when replacing parts with parts which are not BEML genuine parts, please contact your nearest BEML office.

When carrying out other difficult maintenance works, carrying them out carelessly can cause unexpected accidents. If you consider the maintenance is too difficult, always request the nearest BEML office carry out it.

BLEEDING AIR FROM CIRCUIT BLEEDING AIR FROM HYDRAUILIC CIRCUIT After replacing oil, filter element of strainer, bleed the air from the circuit. To bleed the air from the hydraulic cylinders or hydraulic piping, run the engine at low idling and do as follows:

1. Operate each hydraulic cylinders 4 to 5 times, stopping 100 mm from stroke end.

2. Next, operate each cylinder 3 to 4 times to the stroke end.

If the engine is run at high speed at first, or if the cylinder is moved to the end of its stroke, the air in the cylinder may damage the piston packing, etc.,

BLEEDING AIR FROM THE BRAKE CIRCUIT Open the bleeder (B) as shown in the figure one by one .

slowly depress the brake pedal until oil flows out of the bleeder.

Close the bleeder again.

Slowly pressurize the brake and hold the pressure for some seconds.

Note: The brake piston extends and the cylinder chamber fills up with oil. The air accumulates in the upper section of the cylinder chamber.

Release the brake pedal and loosen the brake

Note: The reversing piston presses the air upper suction of the cylinder in to the brake line.

Open the bleeder plugs again

Slowly depress the pedal until oil flows out of the bleeder then close the bleeder plugs.

Repeat procedure as above from the beginning of the actuation no more exists from the bleeder.

31

MAINTENANCE TABLE

MAINTENANCE TABLE

No ITEM SERVICE PAGE CHECK BEFORE STARTING

a Walk-around check Check 18 b Coolant Check & supply 18 c Fuel tank Check & supply 18 d Engine oil pan Check & supply 18 e Dust indicator Check 19 f Water separator Check 19 g Hydraulic tank Check & supply 19 h Transmission oil Check & supply 20 i Brake oil tank Check & supply 20 j Parking brake Check function 20 k Foot brake Check function 20 l Horn Check function 20

m Lamps Check function 20 n Rear view mirror (Optional) Check 20 o Exhaust gas & colour Check 20 p Instruments Check 20 q Steering wheel Check play 20 r Back-up buzzer Check function 20 s Electric wiring Check & retighten 20

EVERY 50 HOURS SERVICE a Fuel Tank Drain water and sediment 33 b Tyres Check air pressure and damages 33

EVERY 100 HOURS SERVICE a Rear axle pivot pin Lubricate 2 points 33

INITIAL 250 HOURS SERVICE a Fuel pre filter and fine cartridge Replace cartridge 33 b Transmission oil cartridge Replace cartridge 33 c Engine oil pan and cartridge Change oil & replace cartridge 33 d Engine valve clearance Check and adjust 33

EVERY 250 HOURS SERVICE a Lubricating 34 -1 Blade Brace Screw Lubricate 2 point 34 -2 Blade cylinder pin Lubricate 2 point 34 -3 Cylinder Support / Yoke Lubricate 6 points 34 -5 Steering Cylinder pin LH&RH Lubricate 4 points 34 b Engine oil pan & cartridge Change oil & replace cartridge 34 c Fuel Strainer Check and clean 35 d Fuel pre filter and fine cartridge Replace cartridge 35 e Fan belt/ Compressor belt Check tension 36 f Wheel Nuts Check and retighten 36 g Battery Electrolyte level Check and supply 36

32

MAINTENANCE TABLE

No ITEM SERVICE PAGE EVERY 500 HOURS SERVICE

a Lubricating 37

-1 Center drive shaft (Engine & Trans.) Lubricate 3 points 37 -2 Center hinge pin Lubricate 2 points 37 b Transmission oil cartridge Replace element 37

EVERY 1000 HOURS SERVICE a Lubricating -1 Front drive shaft Lubricate 3 points 37 -2 Center Drive shaft Lubricate 3 points 37 -3 Rear Drive shaft Lubricate 3 points 37 -4 Intermediate drive Lubricate 3 points 37 -5 Damper Lubricate 1 point 38 b Transmission Change oil 38 c Transmission case breather Clean breather 38 d Hydraulic and steering filter Replace element 38 e Turbocharger clamping joint Check and retighten 38

EVERY 2000 HOURS SERVICE

a Front & Rear Axle Change oil 39

b Hydraulic tank & Breather Change oil & Replace element 39

c Engine breather Clean element 40

d Alternator and starting motor Check 40

e Engine valve clearance Check and adjust 40

f Turbocharger Check & clean 40

g Brake disc Check 40 EVERY 4000 HOURS SERVICE

a Water pump Check 41 b Vibration damper Check 41 C Air Compressor Check 41 d Damper (Chassis) Check 41

WHEN REQUIRED a Air cleaner element Check, clean or replace element 42 b Electrical intake air heater (Optional) Check 43 c Coolant Clean 43 d Transmission oil Check & refill 44 e Axle Oil / Case breather Clean, check and supply 44 f Lubricating

-1 Accelerator pedal linkage Lubricate 2 points 44 g Radiator fin Clean 44 h Water separator Clean drain water 45

33

EVERY 50 / 100 / INITIAL 250 HOURS SERVICE

EVERY 50 HOURS SERVICE a. FUEL TANK

Loosen drain valve on the bottom of the fuel tank, so that the precipitation and mixed water will be drained in accompaniment with fuel.

Maintenance Drain water before starting the engine.

b. TYRES

Measure the inflation pressure before operating the eqpt., when the tyres are cool

EVERY 100 HOURS SERVICE Apply grease to the grease fittings shown by arrows.

Maintenance for every 50 hours should be carried out at the same time.

Rear axle pivot pin ( 2 points)

INITIAL 250 HOURS SERVICE Perform the following maintenance after running the machine for the first 250 hours.

a. REPLACE FUEL PRE FILTER / FINE CARTRIDGE

b. REPLACE TRANSMISSION OIL & CARTRIDGE

c. REPLACE ENGINE OIL AND CARTRIDGE

d. CHECK ENGINE VALVE CLEARANCE For details of the method of replacing or maintaining, see the section on EVERY 250, 500 & 2000 HOURS SERVICE.

34


EVERY 250 HOURS SERVICE LUBRICATING a. Lubricating

Apply grease to the grease fittings shown by arrows.

Maintenance for every 50 hours should be carried out at the same time.

1. Blade Brace Screw (LH & RH) (2 Point)

2. Blade Lift Cylinder (2 Points)

3. Cylinder Support / Yoke (6 Points)

4. Steering Cylinder Pin LH&RH (4 Points)

b. Engine Oil Pan & Cartridge

Open oil filler (F) and remove drain plug (1) to drain oil. After draining, tighten the drain plug.

Using Filter wrench, remove engine oil cartridge (C) by turning it counter clockwise .

35


Apply a dab of oil to the gasket of the new cartridge, and contacts the gasket with the seal face.

To refit the cartridge, place the gasket face in contact with the seal face of the filter stand, then screw up the cartridge by hand 2/3 of turn (be careful not to tighten it up excessively).

After replacing the cartr idge, pour in the specif ied quanti ty of engine oi l from oi l f i l ler (F).

After pouring in oil, run the engine for several minutes, then once again check the oil level and ensure that it is correct.

For the method of checking the oil level, refer to CHECK BEFORE STARTING.

Refill capacity: 24 Liters. The type of lubricant used depends on the

ambient temperature. Select according to the table "FUEL, COOLANT AND LUBRICANTS".

Use a genuine BEML cartridge. Change the engine oil every 6 months or

every 250 service hours Before installing a filter cartridge, be sure

to fill the cartridge with engine oil. c. FUEL STRAINER

Remove the Strainer from the Strainer assy. (S) and clean the strainer and strainer case. The strainer is soldered on the cap.

d. FUEL PRE-FILTER & CARTRIDGE 1. Remove drain plug (P) on the bottom

of the Fine filter (F) and Cartridge (C) to drain fuel.

2. Using a filter wrench, remove cartridge (C) by turning it counter clockwise.

3. Fill the new cartridge with fuel and refit it after applying a dab of oil to the gasket face.

4. Remove the fine filter housing / inner element by removing the bolt on filter head, clean the housing and replace the inner element, fill the fuel and refit.

5. After fitment, both the filter / cartridge loosen the air bleed screws on top of the filter / cartridge housing, loosen and move the feed pump (1) up and down to bleed the air from the system. When no air bubbles comes out of the air bleeding screw / plug, tighten the screw/plug. Tight the knob (1)

36


e. Fan Belt

The Belt tension should normally deflect by about 5 to 10 mm when pressed with the finger at a point midway between the alternator pulley and the fan pulley (approx. 6 kg).

To adjust the belt tension, loosen bolt (B) and nut (N) and shift alternator (A) slightly.

After adjustment, tighten bolt (B) and nut (N) securely.

e. When adjusting the V-belt, do not attempt to push alternator (A) directly with a bar or the like, nut use a wood pad to prevent damage to the core.

f. Check each pulley for damage, and V-grooves and V-belt for wear. Particularly, check whether V-belt is in contact with bottom of V-groove through wear.

Replace belt if it has stretched, leaving no allowance for adjustment, or if there is a cut or crack on belt.

f. Wheel Nut

If wheel nut are loose, tyre wear and damage to rim will be increased and accidents may be caused. If any wheel Nuts are loose, tighten them to the specified tightening torque.

Tightening torque : 94.5 10.5 kgm If any wheel Studs are broken,

replace the Wheel Studs . Always rotate in the direction of

tightening when checking for loose bolt. g. ELECTROLYTE LEVEL IN BATTERY

If the electrolyte level is lower than the prescribed level (10 to 12mm above the plate), supply distilled water. Should any of the acid be spilt, have it replenished by the nearest battery shop with acid of the correct specific gravity. When inspecting electrolyte level, clean the air hole of the battery cap.

Never use metal funnel for electrolyte supply.

37

EVERY 500 / 1000 HOURS SERVICE

The maintenance for every 50, 100, 250 & 500 hours should be carried out at the same time.


a. LUBRICATING Lubricate grease to the grease fittings shown by an arrow.

1. Center Drive Shaft (3 point)

2. Centre hinge pin (2 points)

b. TRANSMISSION OIL CARTRIDGE

Park the equipment in level ground put of the engine and remove the cartridge by using cartridge remover tool.

g. Use a genuine BEML Supplied Cartridge

h. Replace the new cartridge by applying small qty of oil in the Gasket. Start the engine and check for any leakage.


a. LUBRICATING Apply grease to the grease fittings shown by arrows.

1. Front drive shaft (3 points)

2. Centre Drive shaft (3 points)

3. Rear Drive shaft (3 points)

4. Intermediate drive (1 point)

38


5. Damper (1 point)

b. TRANSMISSION

Park the equipment at level ground, bring the attachment to the ground level. Shift gear shift lever in Neutral. Stop the engine Clean the drain plug (D) and remove to drain the oil. After draining the oil install the plug with O-ring. Fill the oil through filler tube (F) as per the specific qty. start the equipment in idle speed check the oil level through dipstick, the oil level must be lying in the Zone HOT. Insert the dipstick again and tighten it by clockwise rotation.

c. TRANSMISSION CASE BREATHER Remove the breather, clean and refit.

d. HYDRAULIC AND STEERING FILTER ELEMENT

Remove the bolts and cover, take out the elements of Steering filter (S) and Hydraulic Filter (H). Clean the interior of the case as well as the disassembled parts, and fit the new elements and cover

Use genuine BEML elements.

After replacing the elements, start the engine and check the system for any leakage.

e. TURBOCHARGER Periodically inspect all joints for looseness. Tighten if necessary.

39


The maintenance for every 50, 100, 250, 500 & 1000 hours should be carried out at the same time.

EVERY 2000 HOURS SERVICE a. FRONT AND REAR AXLE

1. Remove Front and Rear Axle oil filler

plugs (1), then remove drain plugs (2) to drain the oil.

2. After draining the oil, clean drain plugs (2), then install them.

3. Add oil to the specified level through the oil filler ports of the axle housing (1).

4. Check the oil level and ensure.

Refill capacity 45 litres each axle.

The type of lubricant used depends on the ambient temperature. Select according to the table FUEL, COOLANT AND LUBRICANTS.

b. HYDRAULIC TANK AND

BREATHER 1. Lower the Dozer Blade attachment to

the ground and apply parking brake, then stop the engine.

2. Remove the oil filler cap (F) and replace the breather element (B) .

It is possible to replace the element with the breather installed in the tank. However, if the breather is removed, do not

wrap the taper thread of the breather with seal tape when assembling again, and be careful not to tighten too much.

3. Open drain valve (D) to drain oil. After draining, tighten the drain valve.

When removing the cap, turn it slowly to relieve inner pressure

4. Open the hydraulic tank strainer cover, remove the strainer clean and fit back.

Check that there is no foreign matter inside the tank before cleaning it.

5. Fill the specified quantity of hydraulic oil through filler (F). Check the oil level through gauge (G).

6. Start the engine and run at a low idle speed for 5 minutes, then operate the system 2 ~ 3 times and check the oil level, If required top up the oil upto gauge level.


Refill capacity: 195 litres. Check that there is no oil leaking

from the hydraulic tank components.

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c. ENGINE BREATHER

1. Loosen the clamp and remove the hose, then remove the breather from the cylinder block.

2. Put the breather in diesel oil and rinse.

3. After rinsing, pour in clean diesel oil through the hose. Then dry with compressed air & install.

4. Check the breather hose, if there is any sediment for deteriorated oil (sludge) inside, replace with a new hose.

d. ALTERNATOR & STARITNG MOTOR

As the hours of engine employment indicate that the brushes are already worn out, you should request repair from a BEML office.

They should be repaired every 1000 hours, if the machine is frequently operated at night.

e. ENGINE VALVE CLEARANCE

As special tool is required for removing and adjusting the parts, you shall request nearest BEML office for service.

f. TURBOCHARGER Excessive carbon or oil sludge adhering to turbocharger blower impeller may lead to deterioration of normal charger performance, and possible damage. Have turbocharger cleaned by BEML.

g. MULTI DISC BRAKE

(Wear measurement) A wear measurement has to be made on both output sides once a year or every 2000 hours.

If dimension X 3.5 mm, the lined discs on both output sides have to be replaced.

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The maintenance for every 50, 100, 250, 500,1000 & 2000 hours should be carried out at the same time.

EVERY 4000 HOURS SERVICE a. WATER PUMP

Inspect the water pump for play in the pulley, oil leakage and water leakage.

If any fault is detected, ask nearest BEML office to disassemble and repair or replace.

b. VIBRATION DAMPER

Check that there are no cracks in the damper. If there is any abnormality, contact your nearest BEML Office for repairs or replace.

c. AIR COMPRESSOR

Check the Compressor which produces air for operating, Brake system and Air horn .

d. DAMPER (Chassis)

Check for any leakage. If necessary contact your nearest BEML Office for repairs.

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WHEN REQUIRED

WHEN REQUIRED

a. CHECKING, CLEANING AND REPLACING AIR CLEANER ELEMENT

Checking

Cleaning or replacing outer element

Whenever the red piston in the dust indicator (1) appears, clean the air cleaner element. Stop the engine when cleaning the element.

1. Loosen wing bolt (2) and clamp (3) and remove cover (4). Loosen wing nut (5) with washer (6) and remove the outer element (7).

2. Clean the air cleaner body interior and the removed cover (4).

3. Clean and inspect the element. (See the next page for cleaning procedure.) Install the cleaned/new element (7) and tighten the wing nut (5) with washer (6). Fit the cover (4) and clamp (3)

4. Push the dust indicator (1) reset button to return the red piston to the original position.

When the dust indicator red piston appears soon even after installing the cleaned outer element, replace both the inner and outer elements (remove one sticker pasted on the element).

Replace the outer element, which has been cleaned 6 times repeatedly or used throughout a year. Replace the inner element at the same time.

Remove one sticker from the outer element. The number of times the outer element has been cleaned can be seen by the number of removed sticker.

Check inner element (10) mounting nut (8) with washer (9) for looseness and, if necessary, retighten.

Replace washer (9) or wing nut (8) if they are broken.

Replacing inner element 1. First remove the cover (4) and the outer

element (7), and then remove the inner element (10).

2. Place the cover over the air intake part to prevent dust entering.

3. Clean the air cleaner body interior. Remove the cover from the air inlet port.

4. Fit the new inner element (10) and tighten it with washer (9) and nut (8).

5. Install the outer element (7) and the cover (4). Push the dust indicator reset button.

NOTE: Do not attempt to reinstall a cleaned inner element.

Do not clean or replace the air cleaner element with the engine running.

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WHEN REQUIRED

Cleaning outer element with compressed air

Direct dry compressed air (less than 7kg/cm2) to element from inside along its folds, then direct it from outside along its folds and again from inside, and check element.

When using compressed air, wear safety glasses and other things required to maintain safety.

The following methods require spare parts.

With water : Dash city water (less than 3kg/cm2) on element from inside along folds, then from outside and again from inside. Dry & check it.

With cleaning agent : For removing oils and fats as well as carbon etc. attached on the element, the element may be cleaned in lukewarm solution of mild detergent, then rinsed in clean water and left to drip dry.

Drying can be speeded up by blowing dried compressed air (less than 7kg/ cm2) from the inside to the outside of the element. Never attempt to heat the element.

Using warm water (about 40C) instead of soapy water may also be effective.

If small holes or thinner parts are found on element when it is checked with an electric bulb after cleaning and drying, replace the element.

If element is usable, wrap it and store it in dry place.

Do not use element whose folds or gasket or seal are damaged.

When cleaning element, do not hit it or beat it against something.

b. CHECK ELECTRICAL INTAKE AIR HEATER (Optional)

Check electrical intake air heater once a year before commencing work in the cold season.

Remove electrical intake air heater from the engine intake connection, and check it for possible open-circuits and dirt.

When inspecting and replacing electrical intake air heater, replace the gasket with new one.

Ask your BEML distributor to check electrical intake air heater.

c. CHANGE COOLANT Perform twice a year in spring and autumn (when cleaning antifreeze solution).

In case antifreeze is not used, change coolant every 1000 hours.

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WHEN REQUIRED

d. CHECK AND REFILL TRANSMISSION OIL

(Measurements only with engine running)

Oil level check must be carried out as follows: 1. Park the equipment in level ground &

shift Gear shift lever to N, Start the engine and remove the oil filler (G).

2. Use dipstick (G) to check the oil level. 3. In the cold start phase, the engine must

be running about 2~3 minutes at idling speed, and the marking on the oil dipstick must, then be lying above the cold start mark, COLD.

4. Check at operating temperature transmission (about 80 ~ 90 C). on the oil dipstick, the oil level must be lying in zone HOT.

If the Oil level is dropped in operating temperature condition below the HOT zone, it is absolutely necessary to replenish the oil.

An oil level above the HOT marking,is leading to a too high oil temperature. . When checking the oil level, apply the parking brake.

e. CHECK AND REFILL AXLE OIL

Remove oil level plug (1), and check that the oil level reaches the bottom of the plug hole. If necessary, add oil through the hole of plug (2).


f. LUBRICATING Apply grease to the grease fittings by arrows. 1. Accelerator pedal linkage (1 point)

g. CLEAN RADIATOR FINS 1. Loosen bolt (1) and remove Radiator

grille (2). 2. Clean the Radiator fins and Oil

Cooler fins clogged with mud, dust and leaves with compressed air. Steam or water may be used instead of compresses air.

The rubber hose should be checked at the same time. If the hose is found to have cracks or to be hardened by ageing, such hose should be replaced by new one. Further, loosened hose clamp should also be checked.

45

WHEN REQUIRED

h. WATER SEPARATOR

When the Float (3) If it is at the above Red line (2) (Allowable water level) drain the water according to the following procedure:

1. Loosen either of the air bleeding (!) plug.

2. Loosen the drain plug (4) and drain the accumulated water until the Float (3) (Floats on water to indicate the water level) reaches the bottom.

3. Tighten the Drain plug (4) and Air bleeding plug (1)

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TROUBLE SHOOTING GUIDE


This guide is not intended to cover every conditions, however many of the more common possibilities are listed

ELECTRICAL SYSTEM The Ammeter is not stable while the engine is running at a constant speed. Lamp does not glow brightly even when engine runs at high speed. Lamp flickers while engine runs. Check for loose terminals and charging

circuit wiring. Adjust belt tension if necessary The Ammeter does not move even when engine speed rises. Replace the ammeter. Replace the alternator Check and repair wiring.

Starting motor turns the engine sluggishly. Charge the battery. Replace the starting motor. Starting motor disengages before the engine starts up. Check and repair wiring. Charge the battery. Starting motor does not turn when starting switch is turned on. Inspect and repair the wiring. Charge the battery. Replace the starting switch. Replace the battery relay switch. Put directional lever in neutral position. The heater signal glow white. Check preheating time. Replace electrical intake air heater. The engine oil pressure caution lamp does not light up when engine is stationary when the starting switch is in ON position). Replace the pressure switch. Replace the caution lamp switch.

ENGINE The engine oil pressure caution lamp does not go off immediately after starting engine. Add the oil to the specified level. Replace the oil element. Check oil leakage from the pipe or the

joint. Replace the lamp. Steam is emitted from the top part of the radiator (the pressure valve). The engine cooling water temperature gauge indicates red range. Supply the cooling water and check

leakage. Adjust fan belt tension. Wash out inside of cooling system. Replace the thermostat. Tighten the radiator cap firmly or replace

the gasket of it. Replace the gauge. The engine cooling water temperature gauge indicates red range. Replace the thermostat. Check or replace fan belt. Replace the gauge. The engine does not start when the starting motor is turned over. Add fuel. Repair air leaking into fuel system. Replace the injection pump or the

nozzle. Check valve clearance. Check engine compression pressure. Refer to the section of electrical system. The exhaust gas is white or blue. Add to specified oil quantity. Repair with specified fuel. The exhaust gas occasionally turns black. Clean or replace the air cleaner element. Replace the nozzle. Check engine compression pressure.

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Combustion noise occasionally changes to breathing sound. Replace the nozzle. Unusual combustion noise or mechanical noise. Replace with specified fuel. Check over-heating Replace with muffler. Adjust valve clearance.

CHASSIS Transmission Engine is running but machine will not move. Release parking brake. Put directional lever in position properly. Add oil to transmission case to the

specified level. Even at full throttle, machine moves slowly and lacks power. Add oil to transmission case to the

specified level. Oil overheats Add oil to transmission case to the

specified level or drain oil. Use a suitable gear speed. Reduce time using torque converter at

stall speed. Check engine. Abnormal noise is produced. Add oil to transmission case to the

specified level. Axle Abnormal noise is produced. Add oil to axle case to the specified level. Multi disc brake. Brake does not work when pedal is depressed. Check the multi disc brake. Wear and

replace if necessary. Add brake oil. Bleed air from brake system.

Brake drags or stays applied. Check the multi disc brake. Wear and

replace if necessary. Clean air vent of master cylinder. Brake slips. Replace disc. Parking brake. Brake does not work properly. Adjust clearance. Check brake pad. Steering Steering wheel is heavy. Check steering hydraulic system. Check for steering cylinder pins for

proper lubrication. Hydraulic system Tyre hand lacks lifting power. Tyre hand lifting speed is slow. Add oil. Replace filter in hydraulic tank.

Many bubbles from the oil.

Replace with specified oil. Add oil. Bleed air from hydraulic system.

Oil pressure is too low.

Add oil and bleed air. Check the pump pressure.

Cylinder vibrates when operating.

Add oil. Check the play in hing pins & cylinder

pins.

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STORAGE

STORAGE BEFORE STORAGE To place the machine in storage for an extended period of time, the following measures must be taken to insure that it can be returned to operation with minimum of service.

After every part is washed and dried, the machine shall be housed in a dry building. Never leave it outdoors.

In case it is Indispensable to leave it outdoors, lay wood plates on the ground, and park the machine on the wood plates and cover it with canvas etc.

Completely fill fuel tank, lubricate and change oil before storage.

Apply a thin coat of grease to metal surface (hydraulic piston rods

As to batteries, remove the terminals and cover them, or remove them from the machine and store separately.

When the ambient temperature is anticipated to drop below 0oC, always add antifreeze in the cooling water.

Set each control levers to neutral or hold position, lock them and apply the parking brake.

DURING STORAGE

Operate the engine and move the machine for a short distance once a month so that new oil film will be coated over movable parts and component surfaces.

Before operating the working equipment, wipe off the grease on the hydraulic cylinder piston rod.

If it is unavoidably necessary to carry out rust-preventive operation while the machine is indoors, open up doors and windows to improve ventilation and prevent the gas poisoning.

AFTER STORAGE After storage (when it is kept without cover or the rust-preventive operation once a month is not made), you shall apply the following treatment before operation.

Wipe off the grease on the hydraulic cylinder rod.

When using the machine without carrying out the monthly rust prevention operation, please contact your BEML office

After the engine is started, operate it until it is warmed up completely.

Engine with turbocharger only Remove the oil pipe flange on the turbocharger oil inlet, fill with 0.5 to 1l engine oil, and leave the flange lightly loosened. Then, rotate the engine by the starting motor without fuel injection, so that the discharge of oil is confirmed. Then, tighten the flange and start the engine.

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SERVICE METER / SERIAL NUMBER PLATE

SERVICE METER

Service meter indicates the integrated work hours. So, use it according to the following instructions.

Record the readings at the start and the end of work, this is the work record of the machine.

This record will indicate, when periodical maintenance is due.

It also indicates the integrated working hours when machine problems are encountered.

How the meter progresses

This meter shows the total operation hours of the machine.

The service meter progresses by 1 when the engine is operated for one hour, regardless of the engine speed.

Consequently, if the engine is running the service meter will advance even of the machine does not move.

While engine is running, green pilot lamp on the service meter flashes to show the service meter advances.

EQUIPMENT AND ENGINE SERIAL NUMBER

When calling for service of mechanic or when making replacement parts order, be sure to give your nearest BEML office the equipment and engine serial numbers as well as the service meter reading before mentioned. These

machine manual

Documents

new machine

safe machine operation

hours of operation

proper operation

actual operation

careful operation

air filter element kit

initial operation stage