1

ROAD MOBILE CRANE SERVICE MANUAL

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INDEX

Sr.No DESCRIPTION PAGE NO

1. SPECFICATION 04 2. GENERAL APPLICATION 07 3. INSTRUMENTS & CONTROLS 09 4. HYDRAULIC SYSTEM 11 5. PNEUMATIC SYATEM 16 6. ELECTRIC SYSTEM 20 7. ENGINE 23 8. CLUTCH 29 9. WHEEL ASSY 30

10. MAINTENACE SCHEDULE 31 11. LUBRICANT CHART 34 12. SAFE USE OF CRANE 35 13. TROUBLE SHOOTING 39 14. RECOMMENDED LUBRICATION 51

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SPECIFICATION TRANSMISSION Type : Sliding Mesh Spur type gear box. Six Forward and Two Reverse Speed with Hi & Lo Selector Switch. Speed : 25Km/hr on even metalled Road (without load). OPERATION TIMINGS: (NO LOAD AND RATED ENGINE RPM) Steering Lock to Lock : 8 Sec. Boom Rising : 20 Sec Boom Lowering : 16 Sec. Telescopic. Extension Out : 8 Sec. Telescopic extension In : 10 See. Hoisting : 24rn/min (Single) TYRES : Tyre From (4 Nos.) : 10.00 x 20-14 PR Tyre Rear (2 Nos.) : 13.00 x 24-12 PR Tyre Pressure - Front : 5.7-6Kg/Cm2

Tyre Pressure - Rear : 3.4 Kg/Cm2

Wheel Track - Front : 1880 mm. (Center of twin wheels) Wheel Track - Rear : 1570 mm. (Center of Wheels) STEERING Type : Hydraulically through two double acting cylinders. Turning Radius Approx. : 5.2 m Slew : 55° degrees either side. BRAKES : Front Wheels & Rear Wheels : Pneumatically assisted Hydraulic Brakes on Front & Mechanical shoe brake actuated through a hyd. Slave cyl. on rear.

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SPECIFICATION

LOAD CHART C8

5

SPECIFICATION

HYDRAULIC SYSTEM: Pump : Vane Pump directly driven from engine Crank pulley. Main Lift Cylinders : Two double acting tacks. Steering Cylinders : Two double acting tacks. Telescopic Cylinder : One double acting tacks. Hydraulic Filters : Micronic type in return line Hyd. Tank. HOIST MECHANISM : Four falls, hydraulic Winch, Rope DIA 13MM Winch Motor For Hoisting Up to 5MT. Control valve : Four spool, with relief valve set at 140 bar. Steering - Working Pressure : 90 bar. Capacities Fuel Tank : 45 Litres Hyd. Oil Tank : 90 Litres Engine Oil Sump : 8 Litres Transmission Housing : 27Litres Reduction Housing : 2.45 Litres each side. Air Reservoir :16 Litres Fuel Injection Pump :250 ml. UNLADEN WEIGHT Front Axle (Approx) :3250 Kgs. Rear Axle (Approx) : 495.3 Kgs. Shipping weight : 8200 Kgs.

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GENERAL APPLICATIONS

LOADING/UNLOADING/TRANSPORTING/STOCKING OF MATERIALS SUCH AS

Steel sections, Channels, Pipes, Plates, Bars, Ingots, Sheets etc.

Castings & forgings-compressors, machine tools and other heavy engineering manufacturers, foundry & forge shops.

General Stores-Defense, Projects, PWD’s irrigation departments, industry.

Transformers/Cables-Electricity boards, Thermal Power Stations.

Logs-Forest Departments, Paper pulp/Fiber Manufactures & Timber contractors.

Operation below ground level up to Six meters possible for pipe laying and for Accurate positioning of loads.

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INSTRUMENTS & CONTROLS

DASHBOARD

1. Fuse Box 8. Main Switch cum Parking 2. Water Temperature gauge 9. Head Lamp Switch 3. Ampere Meter 10. Horn 4. Hrs. / Rpm Meter 11. Indicator Light 5. Toggle Switch Indicator 12. Air Pressure Gauge 6. Toggle Switch Spot Light 13. Engine Oil Press Gauge 7. Hazard Switch

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INSTRUMENTS & CONTROLS Before putting the machine into operation, the Operator must be familiarize himself with the Following instruments/operating controls. The instrument panel is positioned in front of the operator which provides ready visibility and accessibility of instrument & controls during operation. Starting from left hand side, instrument / controls are explained below:-

3. AMPERE METER This gauge is provided in the battery charging circuit to indicate the rate at which the battery is being charged or discharged. Movement of needle towards the + ve side will indicates charging and towards the +ve side will indicate discharging.

Instrument 1. Fuse Box 2. Water Tamp Gauge 3. Ampere Water 4. Oil Press ire Gauge 5. Air Pressure Gauge 6. Engine Hour Recorder/Rpm Meter 7. Main Switch/cum Parking

4. OIL PRESSURE GAUGE The gauge indicates the pressure at which the engine lubricating oil is circulating through the engine.

1. FUSE BOX

5. AIR PRESSURE GAUGE The gauge indicates working pressure ( 0-10Kg /Cm 2) range for pneumatic brakes, the Working range being indicates the RED zone. Do not move the machine till such time 5 Kgs/cm2 pressure, is reached.

. 6. ENGINE HOUR RECORDER/RPM METER The meter records cumulative engine running hours up to 1/100 th of an hours. The needle in the gauge indicates the Rpm at which engine is running.

2. WATER TEMPERATURE GAUGE: The gauge indicates the temperature of the water. The needle position varies depending on load and ambient temp

7. MAIN SWITCH CUM PARKING: The main (ignition) switch has four position, (I) parking light (Anticlockwise direction), (ii) off, (iii) On & (iv) Start. The electric circuit becomes live when the key is turned clockwise to 'on' position. Instruments 5 & 6 become operative at this position further turning of the key to 'start' key should be released as soon as the engine cranks thereby protecting starter from burn out.

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INSTRUMENTS & CONTROLS

HAND OPERATED CONTROLSS

(I) HYDRAULIC CONTROL: These are basically hand operated control levers for the complete hydraulic system. These levers mounted towards R.H. side of the operator within

comfortable reach and hand movement, operate a direction control valve which regulates flow of hydraulic oil to various hydraulic actuation. Movement of these controls levers results in the

following movements for the hyd. Actuator: a. Steering control lever. b. Lift cylinder control leve. c. Telescopic cylinder control lever. d. Hoist control lever. Note: Movement of all levers while in operations

must be gradual, especially while operating.

(II) HAND BRAKE LEVER: This lever is used for parking brakes. Pulling the lever locks the brake with foot pedal in the “ Brake Applied” position.

Note: Parking brakes must always be applied in conjunction with the brake foot pedal with the machine in stationary position. (III) GEAR CHANGE LEVER: This lever is providing for selecting the road speed.

(IV) HI-LO Lever: This lever, located on the L.H side of the operator’s seat within convenient reach, enables operator to select the desired road speeds.

FOOT OPERATED CONTROLS. I. ACCELERATOR:

Desired engine RPM can be achieved by depression/ release of the foot accelerator. The pedal is spring loaded to return to the idling position automatically , Maximum engine speed can be achieved by full depression of the foot pedal. Since the pump RPM too are dependent on the engine speed, the accelerator is also used to achieve desired cycle timings for loading/unloading.

II. BRAKE PEDAL: Placed at comfortable operating position, depression of the single brake pedal operates both the front wheel pneumatically assisted hydraulic brakes as well as the rear wheel mechanical brakes through a slave cylinder. The braking distance depends upon the braking effort on the foot pedal.

The pedal retracts to neutral position as soon as pressure on it is released.

III. CLUTCH PEDAL: This is operated by the left foot. Depression of the pedal will disengage the heavy duty 11.2”single plate clutch through a linkage and vice versa.

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HYDRAULIC SYSTEM

HYDRAULICS DESCRIPTION The pump draws oil from the reservoir and feeds it to the Control' Valve (Spool type). So long as the Control Valve spools are in the neutral position. Oil flows freely through the control valve & to the reservoir. There is no load on the pump, at this stage. When any of the control valve spools are operated from the neutral to an operating position the flow of oil is direde.c1 to the associated cylinder or motor to get the desired motion. The Load on the pump directly dependent on the pressure developed to overcome the résistance offered by the Load. Since pump is directly coupled to the engine. The flow of oil through the actuators can be directly controlled by the throttle (Accelerator). Hence, Higher, engine RP1l's Result in faster cycle timings. Hydraulic actuators for performing other functions are a) Steering Cylinder - 2 Nos. b) Main Lift Cylinder - 2 Nos. c) Boom - Extension Cylinder -1 No. d) Winch Assy. - 1 No.

OIL RESERVOIR This is mounted on the Front of Can resulting dose to the hyd. Pump for better suction and reducing the length of suction pipes to avoid losses. Baffles provided in the tank offer better Cooling. A strainer provided at the suction inlet prevents dirt and Contamination from ententering the pump. A vent opening provided with a Larger capacity air breather. A Level pipe provided enables the operator to see the oil level in the tank. A magnetic plug has also been provided at the bottom to entrap ferrous particles in the tank.

HYDRAULIC PUMP This is a vane type positive discharge rotary pump; copied directly to the engine crankshaft through a coupling the engine imparts a rotary movement to the rotors of the pump. The design of the pump forces oil 00 through the outlet due to the rotary motor of the vanes in the pump. The pump provides constant flow of to the desired actuator. (Through control valve). The pressure developed in the line depends upon the load connected writ the particular actuator and seeing of the relief valve i.e. the pressure developed in the system is a direct function of the load applied

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HYDRAULIC SYSTEM

HYDRAULIC CIRCUIT-C8

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HYDRAULIC SYSTEM MAINTENANCE OF HYDRAULIC SYSTEM it is crucial that complete hydraulic system be maintained in tip top condition; since all the actives being performed by the crane are hydraulically controlled, For this it is important that the following points be Strictly adhered to :

1. OIL USED Use to hydraulic oil Specified by the manufactures only. Any change In make/ grade/viscosity of oil substituted by the user will have adverse effect on the performance of the machine. Different oils have different activities some of which may be harmful to the oil seals used throughout the hydraulic Circuit. Different oils also have deferent lubricating properties. This could result in excessive temperature rise. This is very harmful for various hydraulic components. Other oils have varying viscosity characteristics at different temperatures. This will again result in improper performance of the machine if the recommended oils are not used.

2. FILTRATION Oils have two types of impurities soluble & insoluble. Oil should always be procured from standard source so that the soluble impurities are kept within allowable limits To move the insoluble impurities the hydraulic oil must always be poured in through 20 G sieve before adding to the tank. The machine must never be left with the filler cap of the hydraulic tank removed. Abrasive sand particles can cause great deal of harm to hydraulic pump and motor.

3. INTERNAL LEAKAGE IN HYDRAULIC DISTRIBUTOR

After a long use the spools may get worn out and oil may leak past them. To diagnose the internal leakage through the distributor valve. Proceed as follows

A. Raise Boom about 2 meters above the ground level. B. Shut Off engine end disconnect oil line from the distributor valve to the reservoir. If oil is leaking through the disconnected line, it indicates internal leakage & may call for change of control valve. 4. INTERNAL LEAKAGE IN HYDRAULIC JACKS During the course of use of the equipment these cylinders may develop internal leakage due to normal wear on the seals etc. The internal leakage will reduce the sensitivity and lifting capacity of the equipment. It is therefore necessary to check the cylinder for internal leakage as follows : Checking the internal leakage in lift cylinder 1. Lower the boom to the lowest position. 2. Disconnect the pipe connecting the full bore end chamber of the main. lift Cylinder, 3. Operate the main cylinder “lift' lever, further to forward position for a few seconds. Till the relief valve blows. 4. In case of internal leakage the cylinder oil will flow out from the disconnected end of the Chamber. 5. Repeat the same procedure to check the leakage from the other cylinder, In case, any Internal leakage is observed the jack. should be dismantled according to proper laid down procedure all the hyd. Seals replaced and reassembled. Special care must be taken against any ingress of dirt / abrasive particles.

NOTE : Before removing the cylinders for repair. Be sure the boom is lowered fully and that engine is stopped before disconnecting the hydraulic hoses.

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HYDRAULIC SYSTEM

5. FILTER : A fine {25 Micron) filter is provided in the return line of the main hydraulic circuit. The entire amounts of oil going to reservoir get filtered here.

CAUTION :- Do not tighten fittings too tight. Make them just enough to eliminate leaks. Regular attention to the maintenance of the hydraulic system will result in increased efficiency and longer life.

Fitter element should be changed at the intervals mentioned in the periodical maintenance schedule.

Following points need special attention. 1. Repair hydraulic oil leaks promptly to avoid loss of oil and possible damage to the damage to the system.

For removal of filter element unscrew the 4 Screws. Filter body along with the element and replace with new element

2. A leaking or damaged hose must immediately be replaced by a new one.

6. OIL LINES AND HOSES Check all oil lines and connections periodically for leaks and dents. Oil leaks in pressure lines can be located by carefully inspecting the external area of tie system.

3. Bleed air from the system any time a hydraulic hose is removed, a tube disconnected or the system is opened to the Atmosphere. After reassembly, bleed the system by running the engine and operating the distributor valve levers (with no load in the boom) a couple of times. After bleeding the system, shut off the engine and close the hydraulic jacks. Check oil level and add fresh oil in necessary.

To check for air leaks in suction lines or pump shaft packing Open top plate of oil reservoir while under operation and check for foaming. Presence of air bubbles in oil indicates intake of air from suction.

This can damage the pump in shorter period. When tightening connections two wrenches should always be used to prevent twisting or breaking tubing.

7. BOOM TELESCOPIC :

90orn Telescoping lever is located on RHS of operator seat The telescoping is by the double acting hydraulic jack. Dented tubing should be replaced as the

restriction causes cal foaming and faulty crane operation. Wash oil lines with clean solvent to remove dirt from inside & outside before installing on crane.

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HYDRAULIC SYSTEM

The Telescopic speeds can be achieved by file angina throttle. 1. For "telescoping out the control lever is pushed forward, thus supplying hydraulic oil under pressure to the rear end of the cylinder.

4. When. load has been raised to the required height, natural slowly and release pressure on the accelerator pedal.

2. For telescoping" in the control lever is pulled back, thus reversing the hydraulic oil. Supply to the other end of the cylinder.

B. Lowering the load : With the engine idling, carefully push the hoist lever, forward to lower the load. Avoid jerky control valve movement.

8. HOISTING Hoisting is accomplished by a winch mounted on the main boorn. The winch is powered by a variable speed drive hydraulic motor connected to the drum through a constant reduction (1:107) Constant mesh gear box. A40 meter wire rope using 4 fall pulley block arrangement is used to hoist loads. Actuation of the hoist is controlled directly by means of a hand'. Speeds can be controlled directly by means of A hand Operated control valve. Hoisting speeds can be controlled directly by engine throttle or throttling the oil flow motor from the Control valve layer.

2. Adjust position of accelerator to acquire required lowering speed level, allow the hoist control to return to neutral and release pressure an accelerator pedal, after the load is lowered.

A- 'Raising the load 1. Check that the load is within the maximum safe specification for the working radius,

CAUTION :

a. Avoid' stopping the load suddenly as this imposes unnecessary' .strain on the crane.

b. Avoid travelling at over 4 Krnph with the load hoisted.

c. Always rower the load to the ground before shutting down the engine or leaving the crane unattended.

d. While lowering the hoisted load, avoid lowering the Boom since it may increase the load overhang beyond the safe load radius and thus include instability.

2. With the engine running at low RPM. Carefully pull back on the hoist/lower lever so as to take up the Load without jerking. Once load is off the ground, the lever Can e pulled right back to raise position. 3. Adjust engine speed with the accelerator piedal, 10 regulate hoisting speed.

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PNEUMATIC SYSTEM

1. BRAKES: The crane is provided with pneumatically assisted hydraulic brakes on the front & rear (traction) wheels . Both systems are operating through a common foot pedal & have been synchronized to provide best result. The braking system not only reain the inherent ruggedness and dependapility of the mechanical baking system, but also incorporates the numerous advantage of the pneumatic system as well as the reliability & positive action of the hydraulic system. The following are some of the high lights of brakes on the crane:

- The braking is through a pressurized reservoir of air so that braking force is available to the service brakes even when the engine is shut off.

- Pneumatic assistance provided for reduced padal effort which reduces operator’s fatigue.

- Synchronizing of the front & rear brakes enables application of the rear brakes a fraction of a second before the front brakes, thus providing additional safety.

- Parking brakes are applied on the rear wheels simultaneously by a single lever which will hold the crane stationary, Application is through a cable mechanism which will lock the brakes in the applied position as & when desired.

- The system meets all SAE requirements for braking for this category of equipment.

2. AIR RESERVOIR: The function of reservoir is to store compressed air so that there will always be an ample supply available for immediate use in brake operation. It also provides storage for sufficient compressed air to permit several brake applications even after the engine has stopped. Another function of reservoir is to provide place where the air, heated during compression, may cool and water vapour condense. The total reservoir volume (15 Liters)

3. BRAKE ADJUSTMENT: REAR This primary setting is followed by testing simultaneous braking of both wheels, performed at as stand, or over a smooth surface during the machine riding. The brake which acts with delay on pressing of the brake pedal, has the control rod due for shortening in length, by screwing it further into the fork and piece. After adjustment tighten lock firmly.

FRONT To adjust the front brakes: 1. Jack up the front wheels. 2. Unlock nut of the adjusting cam on one

wheel. 3. Rotate the cam till the wheels are fully

jammed. 4. Slowly rotate the cam in the opposite

direction till the wheels are just free. 5. Lock the cam by locking nut.

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PNEUMATIC SYSTEM

Repeat the same for adjusting brakes on IInd Wheel. Check the oil level in the master cylinder. Bleed the brake system. 4. BRAKE FLUID FILLING

The level of brake fluid in the container should be checked from time to time and topped up if necessary, Only the recommended brake fluid should be used for dependable operation oxidations. Do net overfill. Mixing of efferent brands of fruits in the system should be avoided. If the brake pedal gets spongy, this may be due to air in the braking system. This defect can be rectified by bleeding the system. Whenever any repairs/overhaul or disconnecting of any brake pipe is done, it is imperative to bleed the system to remove any air trapped in it. It is vital that the absolute deadliness is maintained throughout the entire bleeding operation. All equipment to be used must be entirely free from petrol kerosene or arty form of mineral oil, as mineral oil contamination spread rapidly in the braking system. causin9 a dangerous deterioration of the rubber seats. During filling Operation, keep the following points in mind: 1. Ensure that the fluid level in the container do not

fall low enough to cause air to be drawn into the system.

2. Never, under any circumstances, use the fluid which has been bled from the system to lop up the container. It may be aerated, have too much moisture content, and/or contaminated.

5. BLEEDING : 1. Remove filler cap and fill the brake fluid container

with fresh brake fluid up to indicated level. 2. Remove the dust cap from the left front Cylinder

bleeds screw and clean it thoroughly. Attach the bleeder tube to the breed screw and place the other end of the tube in a clean glass jar containing sufficient brake fluid to submerge the end of the tube.

3. Pump the brake pedal twice/thrice slowly Throughout stroke and by Wang the pedal , loosen the bleed screw and watch the air bubbles in the glass jar. 4. Re-tighten the bleed screw and release the brake pedal. Repeat the same operation until air bubbles cease to appear of the end of the bleed tube Mowing only fluid to flow. 5. Repeat the same procedure from step f to 4 for front right wheel cylinder, & rear left and right slave cylinder. 6. If the pedal feel is spongy even after initially bleeding, the brakes should be vigorously pumped and then the bleeding operation repeated. 7. Fill the brake fluid container up to indicated level.

NOTE : While doing bleeding of hydraulic brake system,

the engine should be running and also the parking brake should be released.

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PNEUMATIC SYSTEM

PNEUMATIC CIRCUIT

18

BRAKE CIRCUIT SCHEMATIC

19

ELECTRIC SYSTEM

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ELECTRIC SYSTEM

DESCRIPTION The following components essentially constitute the electrical system i.e. starting and lighting. I) 12 Volt Battery ii) Alternator iii) Starter In order to have trouble free stalling of the engine and maximum availability of machine for use, it is always advisable to pay attention towards the maintenance of electrical system Following few points if adhered to will avoid Problems of the system. BATTERY When the atmospheric temperature is below the freezing point. special attention should given to hydrometer readings of the battery. A specific gravity of 1.270 to 1.215 at 80 F is considered satisfactory for continued use Specific gravity readings without correction or temperature are practically meaningless. For each 10 degrees that the temperature of electrolyte is above of 80° F add 4 points to hydrometer reading and for each 10 degrees below 80 F subtract 4 points to get true specific gravity. For example if hydrometer reading is 1.250 and electrolyte temperature is 20''F, (60° below 80F) 1.250 minus 24 points equals 1.226 the true specific gravity.

If corrected readings ale below 1.215 the battery is not receiving sufficient charge. This might indicate that the alternator or alternator regulator requires attention. If these units prove satisfactory inspect system for short circuits and for loose or corroded connections In zero weather there is danger of battery freezing. If specific gravity is 1.100 it will freeze at 18 F battery with a specific gravity of 1.220 will freeze at 31 , below zero, F. During freezing weather, any addition of water to cells should be made after engine is started at beginning of an operating period to make certain that water and electrolyte solution will be thoroughly mixed; otherwise it may freeze. The fitter caps must be kept tight at all times and top of the battery kept clean and dry. Check the Wired of electrolyte in the battery after every week of operation or as often as operating conditions prov., it necessary Maintain level of solution 10 mm above plates of battery by addition of clean distilled water. Keep battery and cable terminals tight & cleaned. To prevent possibility of electric short circuit always disconnect the Battery before attempting any repair or while cleaning. If corrosion occurs. clean battery Post and terrnina.ls with a strong soda solution and coat terminal's lightly with petroleum jelly.

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ELECTRIC SYSTEM

Before connecting them again. The petroleum jelly will prevent further corrosion. In case the battery run down is fast, check for :

1. Loose or corroded wire Connections. 2. Broken wires. 3. Worn generator brushes. 4. Oily Alternator brushes or commutator. 5. Fan belt loose. 6. Faulty voltage regulator.

PRECAUTION : 1. Do not bring lighted matches or on open flame

of any kind within the proximity of battery cell. 2. Keep the battery clean by using a stiff bristle

brush. If terminals are corroded of if the battery is acid slacked mash with hot water or soda solution. Vent plugs are open.

3. Ensure tightness of alt patter, Connections. 4. in the event of long storage of machine, it is

advisable to remove the battery and keep it in a cool dry covered place.

5. It is advisable to get the battery trickle charged at least once in a month if the machine is kept idle for a long period.

Testing and adjustment of the alternator should not be. Attempted without dependable testing equipment, therefore it is recommended that these units be taken to a dependable electrical repair shop when service is required. IMPORTANT Whenever the Alternator has been removed for repairs or replacement when Alternator regulator leads have been disconnected and reconnected, the Alternator must be polarized. it causes current to flow in normal direction through the field coils and will prevent vibration, arcing, burning and sticking of regulator points. CAUTION : Never operate the starter motor for more than 10 seconds at a time If the engine does not start in first instance, wait for 2-3 minutes before making next attempt for startling. if the engine fails to start within 3 to 4 attempts. find out the cause and rectify the same, If the starter fails the crank the engine , check the following parts 1. Broken wires or loose connections. 2. Faulty starting switch. 3. Exhausted battery. 4. Worn out pinion teeth. 5. Damaged winding,

Note:- Put off all the lights while using the starter to avoid heavy damage of battery power.

22

ENGINE

The performance of the high compression Diesel Engine depends upon the supply of clean fuel in the form of a fine spray to the engine cylinder. This is achieved through precision parts such as the fuel injection pump and injection nozzles aided by the filtering system. The working parts are manufactured to extremely close tolerance. If particles of dirt air even the finest are allowed to flow in between these precision working parts, wear takes place rapidly and consequently the pump unable to develop 'the required pressure for spraying the fuel into the cylinder A high rate of fuel injection equipment wear is attributable to dirt and foreign matter in the fuel. Many replacement expenses can be saved and engine reliability enhanced if meticulous care is taken while handling engine fuel. Only high speed diesel Should be used as fuel for the engine. An inferior fuel will prove expensive In the long run. LUBRICATENG SYSTEM The lubricating oil is used in the engine to reduce the friction at the bearing surface providing a film of oil between them It also keeps temperature of the moving surfaces within limits. The effective film can be maintained between the surfaces, only if the recommended grade of oil is used. The system of lubricated comprises of pressure feeds to main & big-end bearings to No 2 cam shaft bearing rocker shaft & auxiliary drive. pump draws oil through the strainer, from the sump and delivers it by an internal drilling within the crankcase to the oil relief valve cover on the side of the

Cylinder block, From the oil pressure relief valve cover, the oil flows through an external pipe to the full flow lubricating oil filter. At the outlet this filter flow passes along a further pipe to the pressure rail. The outlet union on the filter is drilled to allow for the connection of the oil pressure gauge pipe. The pressure rail is an internal passage within the crankcase. Holes drilled in the crankcase webs, leads from this pressure rail to the crankshaft carry thee oil to the big end bearings. Surplus oil is returned to the sump. An Oil Seal prevents oil from leaking along the crankshaft. At its rear end & any oil thrown from the oil filter head. One pipe carries oil at full pressure to the auxiliary drive body. The other pipe carries oil to the lower of the two drilling in the camshaft tunnel on the central line of No 2 camshaft bearing. As the camshaft revolves, oil is picked up and carried round in the narrow slot machined on no 2 camshaft journal unit it escapes through the upper drilling in the camshaft tunnel. The Oil then flows through the pipe to the cylinder head where as another pipe conveys it to the hollow rocker shaft which feeds oil to the rocker bushes etc. The overflow of oil from the rocker shaft from the head into camshaft tunnel and from the front of the tunnel on to the timing gear and drive sprockets and then returns to the pump.

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ENGINE (A) MAINTENANCE OF AIR SYSTEM: Dusty air if sucked in the Combustion chamber forms an abrasive paste with the lubricating oil and accelerates wear on the engine components. It is therefore, suggested that utmost care should be emphasized on the maintenance of air System. AIR CLEANER Tice dry type air cleaner is mounted on the engine. 1. Maintenance procedure : Regular check up & maintenance of the air leaner is essential to ensure maximum protection to the engine from the dust. 2. Daily check the connection of Rubber hose and the hose clips between the manifold and the air cleaner before starting the engine. Damaged hose/clips must be replaced immediately. Any by-passing of unfiltered air through cracks in the hose/loose hose will quickly lead to serious damage to the engine, CAUTION : Since this is a dry type air cleaner, do not fill a single drop of oil in it.

3. The pre-cleaner should be cleaned to remove the accumulated dust, after each day’s work, when the engine is stopped. This cleaning can be done by removing the top cover of the pre- cleaner. 4. The restriction indicator, mounted on air cleaner near the hose, indicates the conditions a red signal will be seen through the transparent window on the indicator when the engine is running and will disappear when engine is stopped, However, if the element is choked, then the red signal will remain ON even after engine is stopped. This is an indication that element must be removed and cleaned or replaced.

Notes : a) if engine performance is poor, but restriction is still within limits, don't change the element. The air cleaner is probably not at fault b) To get those extra service hours out of air cleaner element, make sure the air inlet is away from any heavy dust clouds caused by operation.

5. Make sure the vacuator valve is not damaged or plugged is the cup joint sealing This should take care of most air cleaner related performance problems. 6. Cleaning Of Filter Element When restriction indicator readings finally indicate a change, loosen the mounting band of dust cup, remove the wing nut of the element and take out element for checking and cleaning. a) Use a damp cloth to wipe out all excess dust in the air cleaner. Similarly clean the dust cup. b) Thorough cleaning with compressed air is recommended. CAUTION : 1. Too much pressure can break the filter paper and destroy the element (Max. air pressure 50psi (3.5 Kgcm 2) 2. Rapping , lapping or pounding dust out of them is dangerous. Severe damage to the filter will result.

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ENGINE

C) Carefully check new or properly clean elements for damage before installing. Conduct light test by passing the light through element, the light will pass through it. In that case replace the element. D) Replace the cleaned or new element in the air cleaner body and re-install the dust cup, making sure it seals 360 around the air cleaner body. Reset the restriction indicator to green. AIR INTAKE PIPES & CONNECTIONS All the connections leading to the air inlet Manifold Should be kept air tight air tight and free of restriction. There Should not be any crack is war- page on the hose/pipes. If any crack is noticed, replace the hose immediately with a new one.

NOTE Timely maintenance of air cleaner will ensure trouble free service and increase the life of the engine.

B) MAINTENANCE OF FUEL SYSTEM Only high Speed diesel should be used as fuel for the engine, An inferior fuel will prove expensive in the long run. NOTE:- Only astutely dean fuel should be al allowed to flow in the fuel injection system. This could be achieved only if the following care is taken in handing fuel

1. Funnels or cans used for fuel oil should be kept absolutely clean.

2. The fuel tank should be filled only through strainer-fitted funnel.

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ENGINE

TO CHECK TAPPET CLEARANCE

1. Turn crankshaft in clockwise direction and set No, 1 inlet valve in full open position. Set tappet clearance No. 2, 3, 5 & 8 valves 0.012” in cold and 0.010” in hot

2. Again turn crankshaft in clockwise direction and set No. 8, inlet valve in kr31 on position. Set tappet clearance on No. 7, 6, 4 & 1 valves 0.012” in cold and 0.010” in hot.

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ENGINE

LUBRICATING OIL FILTERS

The importance of using dean lubricating oil in the first place, and providing the means to ensure that it is always dean in uses hardly second to the importance of cleanliness in respect of the fuel. It is imperative, therefore that lubricating oil filters be not neglected. Moreover if the periodical attentions Derain recommended are carried out and the correct grade of dean oil used, a very long life can be obtained from the engine. To ensure cleanliness, two filters are incorporated---- 1) Sump strainer 2) Main filter

SUMP STRAINER The sump strainer consists of a perforated container which is welded to suction pipe of the oil pump. After a time there may be a tendency for sludge to collect and restrict the supply of (A to the pump. This strainer with pipe should therefore be removed and thoroughly washed with fuel oil.

MAIN (CANESTAR TYPE FILTER

TO RENEW ELEMENT IN LUBRICATING OIL FILTER.

1) Remove titter by unscrew in anti lock. Direction & renewed with new one and destroy old one ensure that there should riot be any leakage and filter should not be over tightened. The lub. Oil filter element is a throve-away type and it should not be cleaned but replaced every 250 hours. CAUTION If the fitter is not changed as recommended. The flow of ail through the filter is resisted. This does not, however. Prevent oil passing to the engine. For when restriction on take place. A by-pass valve opens and permits unfiltered oil to continue to flow round the engine. The consequences of this need not be described. Do not therefore; omit to change the filter as prescribed.

27

ENGINE FAN BELT ADJUSTMENT Check that the belts are properly positioned

and adjusted for this, proceed as follows: a) Pass a string, light over the face of the belt, with the help of a marked straight edge. Press the belt inward as far as possible. The reading coinciding with the undisturbed string should be 8-10 mm. b) If belt tension is not within. Limit, adjust it with tension adjusting lever on the alternator. When desired tension is achieved, firmly clamp. The alternator in position by tightening already loosened nuts.

TO ADJUST FAN BELT TENSION The tension of the belt should be such that it is not loose to a degree that it can slip at the crankshaft pulley, thus preventing the full Operation of the water pump and also not turning the dynamo at sufficient speeds to Charge the battery. If the belt is over tightened this can cause overloading of the bearings fitted in the water pump and Alternator. The bolt itself can be damaged internally creating an early failure conditions.

When fitting a belt never place it onto a pulley by using a lever, always close in The adjustment on the Alternator and place. The belt in position. At least wind" the belt over the pulley by turning belt and pulley together by hand. The method of tensioning belts by the practical way as installed, is to decide which is the longest run of belt between any two pulleys and apply pressure in the center of the run and adjust the tension the belt deflects about 3/8 in {10mm} as shown in Fig. When making adjustment loosen all the setscrew and/or nuts securing the Alternator to its brackets as well as both ends of the adjustable linkage. On obtaining the correct tension, retightened all the securing points. When a new belt is fitted, it is necessary to recheck tale adjustment after a short running period when the belt will have settled into the grooves of The pulleys and the initial stretch, if any, will have been completed.

28

CLUTCH

CLUTCH PEDAL FREE PLAY

The clutch pedal free pedal play is to be maintained to ¾’' or 20mm. The play can be adjusted by adjusting the linkage.

29

`WHEEL ASSEMBLY To assure maximum life and satisfactory performance, inspect tyres once every day and keep them properly inflated. Recommended tyre pressure are: Front tyres 5.7-6 Kg/CM2 Rear tyres 3.4 Kg/CM2 Over inflation results is rapid wear at the centre of the tread, tread cracking, excessive strain on the side walls, beads and rims and tyre failures due to sudden application of brakes. Under inflation causes rapid wear on outer edges of the tread and excessive internal heat due to flung which may result in blowouts. Never release built-up pressure in tyre, such as encountered extremely hot days. pressure built up on a hot days actually protects the tyres by avoiding excessive side wall flexing and heat which are both detrimental to tyre life. Venting tyres will also result in under inflation when the tyre cools. Mis-alignment of the tyres also cause rapid & uneven wear of tyres.

Tyres should always be kept free from oil, paint & grease, because they are very harmful to life of tyres, During long storage of machine the wheels should be jacked up so that tyres do not touch the ground. This Is to avoid wear on bottom portion of tyres due to constant weight of machine acting downwards.

Replacement of split rim rear tyres :

1. Remove the wheel rim assembly by loosening eight central nuts retaining the wheel rim with wheel reduction gear hub.

2. Loosen wheel weight clamping bolts.

3. Deflate the tyres.

4. Loosen 16 nuts holding the two halves of split rims.

5. Part of the two halves using a tie rod lever.

6. Replace tyre, inflate the tube a Little and refit the two split halves using a torque wrench adjusted to specified torques.

7. Tighten wheel weight clamping bolts.

8. Mount the wheel rim assembly on wheel reduction hub.

30

MAINTENANCE SCHEDULE PERIODICAL LUBRICATION SCHEDULE Lubrication is an essential part of preventive maintenance, controlling to a great extent the useful life of the unit. Different lubricants are needed and some components in the unit require; more frequent lubrication than others. Therefore it is important that the instructions regarding types of lubricants and the frequency of their application, as given in this manual, be explicitly followed. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures. To prevent minor irregularities from developing into serious condition that might involve shutdown and major repair, several other services or inspections are recommended for the same intervals as the periodic lubrication. The purpose of these service or inspections, which require only a few minutes, is to assure the uninterrupted operation of the unit by revealing the need for adjustment caused by normal wear. The need for some minor adjustment, if neglected, could result in failure and shutdown. Refer to the periodical Maintenance Schedule and the Lubrication.

IMPORTANT: Thoroughly clean all lubrication fittings, caps, filter and level plugs, and their surroundings surfaces before servicing. Prevent dirt from entering the lubricant The lubricant should be warn (operating temperature)

when draining at oil change intervals. The intervals given in this guide are based on normal operation ; perform these services, inspections, etc more often (as necessary) for operation under abnormal and severe conditions. When checking oil level of systems equipped with a gauge rod having 'Operating Range marks the system has adequate oil for safe operation when the oil level is anywhere within the 'Operating Range" marks, the system has adequate oil for safe operation when the oil level is anywhere within the "Operating Range" marks.

31

MAINTENANCE SCHEDULE DAILY EVERY 10 HOURS OPERATION CHECK RADIATOR WATER LEVEL CHECK ENGINE OIL LEVEL CHECK HYDRAULIC OIL LEVEL CHECK FUEL LEVEL CHECK AIR CLEANER CHOKE INDICATOR CLEAN PRE AIR CLEANER WEEKLY (EVERY 50 HOURS) CHANGE ENGINE OIL & FILTER (NEW ENGINE) CLEAN AIR FILTER ELEMENT GREASE ALL POINTS CHECK GEAR BOX OIL LEVEL CHECK REDUCTION OIL LEVEL CHECK BATTERY ELECTROLYTEC LEVEL DRAIN AIR PRESSURE FROM THE AIR RESERVOIR CHECK BRAKE MASTER CYLINDER OIL LEVEL CHECK TYRE PRESSURE CHECK WINCH OIL LEVEL (8100) CHECK FOR LEAKAGE OF FUELENGI NE OIL HYD. OIL AND RECTIFY CHANGE HYD. RETURN FILTER (NEW MACHINE) MONTHLY (EVERY 250 HOURS) CHANGE ENGINE OIL a FILTER CHECK & ADJUST BRAKES CHECK WHEEL NUTS TIGHTNESS CHECK AXLEIENGINE MOUNTING BOLTS & NUTS-TIGHTNESS CHECK CLUTCH PEDAL FREE PLAY & ADJUST CLEAN ALL THE AIR BREATHER EVERY THREE MONTHS (500 HOURS) CHANGE HYD_ RETURN FILTER CHANGE FUEL FILTER-PRIMARY CHECK FRONT WHEEL BEARINGS S REPLACE EVERY YEAR (1000 HOURS) CHANGE HYD. CHANGE GEAR BOX OIL CHANGE REDUCTION OIL CHANGE FUEL FILTM-SECONDRY

32

CRANE MAINTENANCE QUICK GUIDE

33

LUBRICATION CHART

GREASING POINTS

LEGEND

POINTS DESCRIPTION OF POINTS

NO. OF PTS. POINTS DESCRIPTLON OF

POINTS NO. OF

PTS. A MAIN FRAME PIVOT 1 H CLUCTH SHAFT 1

B BOOM PIVOT PLN 2 I PULLEY' JIB HEAD 1

C LIFT JACK PIVOT PIN 2 J PULLEY BLOCK 2 D FRONT WHEEL HUB 2 K 'A" FRAME PIVOT PIN 1

E STEG. JACK FRONT 2 L PROP SHAFT 3

F STRG. JACK REAR 2 M LIFT JACK 2 G CAM SHAFT LH & RH 4 N BOOM ASSY 1

34

SAFE USE OF CRANE

OPERATION TECHNIQUES For the safe use of crane, which is important for both human & material safety the following points should be kept in mind. (A) GENERAL : 1. The crane driver should nave a slinger to

assist him. 2. The Operate must to Over 18 years of age,

medically fit and should be authorized to operate the crane.

3. He should have sufficient knowledge & training in the working of the crane to enable him to carry out routine checks. He should also understand the duties of the stinger & be familiar with the signal code.

4. The stinger should be aligle, have the physique to enable him to handling lifting equipment & trackle, should be trained to accurately judge distances, heights & should be thoroughly familiarly with the signal code.

(B) TERRAIN : 1. The terrain should be reasonably hard

should be able to bear the load of the crane. Soft marshy land is likely to bog down the crane.

2. Tyre protection chains should be used when operating over jagged, rocky terrain.

3. Terrain with gradients Larger that 10 % should be avoided.

(C) OPERATI NG I NSTRU CTIONS 1. The operator should not operate the crane

unless he has thoroughly familiarized himself with the controls.

2. Carry out all routine pre operation checks. 3. The operator should only more the crane

when it is in the correct traveling position.

WITHOUT LOAD Boom in horizontal position with telescopic.

Extension fully retracted and pulley block fully

WITH LOAD The bottom of load should be approx 300-500mm above ground, if load is suspended from pulley block should be fully raised. The boom should be in its lowest convenient position. 4. Always approach the load in the Load On position. Loads should tic lifted with the boom in the central (unslewed) position. 5. Before lifting load. Check if connecting Strings/tackle are properly hooked and are Strong enough to take the load. 6. while travelling, consideration should be given to the presence of proximity hazards such as overhead cables, telephone lines, nearby structure or other cranes, public access areas, etc. Many fatal accidents occur due to crane touching, or even coming to close to overhead transmission cables, If at any time the machine makes electrical contact with a line OHT line observe the following rules.

1. Remain inside the cab. 2. Tell all other personnel to keep away from the

machine & not touch the crone or load. 3. Try unaided to back off the crane unit it is well

clear. 4. If this is not possible inform the electricity board

& wait till line is made dead. 5. If it is essential to leave the cabin (due to fire

etc.) jump clear. Do not touch the machine & ground at the same time.

6. Do not leave the crane unattended.

35

raised. DO'S DONT'S AND SAFETY PRECAUTIONS

DO'S : 1. Keep all nuts and bolts tight. 2. Use only the approved grades of lubricating

and fuel oils. 3. Attend immediately to all fule and oil leakages. 4. Drain air-reservoir regularly. 5. Keep a stock of recommended preventive

maintenance spare parts. 6. Apply the parking brake when the machine is

parked. 7. Keep the battery terminal covered with

petroleum jelly and rubber terminal covers. 8. Ensure that the gear selector lever is in neutral

position before starting the engine. 9. Use low gear while carrying loads. 10. keep the boom as low as possible white

transporting. 11. Lift loads as far as possible with crane in

unslewed position.

DON'TS :

1. Do not change selector gear while in motion. 2. Do not interfere with factory adjustment. 3. Do not neglect maintenance at specified

periods. 4. Do not over load the machine. 5. Do not drive with your foot resting on the clutch

pedal. 6. Do not allow the machine to be operated by an

untrained operator. 7. Do not coast down a gradient in NEUTRAL gear. 8. Do not guess. Consult your hand book and be

sure. 9. Do not exceed road speeds of 4KM PH while

carrying loads. 10. Do not forget to release parking brake lever

before moving the machine. 11. Do not disconnect battery while engine is

running,

SAFETY PRECAUTIONS

1. Allow only the trained operator to operate the crane. 2. For safety. Always park your crane with the gear lever in the neutral position and the parking brake

locked. 3. Never leave the crane seat with the load raised and never leave the crane unattended while engine is

running. 4. A careful operator is the best insurance against an accident. 5. never attempt to clean, oil or adjust a machine while it is in motion. 6. Never drive the crane too close to the edgy if a ditch or excavation. After engine has started observe the

following during operation. 7. Do not drive the crane faster than 15 Kmph with load, Reduce speed when going over uneven ground

and always keep the loads near the ground. 8. Always keep the loading area as level as possible. 9. Do not try to repair or lighten hydraulic hoses which are under pressure, when the engine is running or

when the boom is raised. 10.In ease of bursting of any hydraulic hose or pipe, slap the engine immediately and lower the boom. 11.Do not operate the crane if any hydraulic joint is leaking. 12.Whenever crane is to be left unattended always ensure parking brake is on.

36

OPERATION CHECKS BEFORE STARTING

1. Water level in the radiator. 2. Oil level in the engine oil sump. 3. Oil level in the transmission and

differential housing. 4. Level in the reduction housing both LH

& RH. 5. Oil level in the fuel infection pump

housing. 6. Fuel in the fuel tank. 7. Oil level in the master cylinder. 8. Electrolyte level in the battery. 9. Tyres for proper inflation pressures. 10. Oil level in the hydraulic reservoir. 11. All grease points for proper lubrication. 12. All nuts, bolts & screws for proper

tightness, preferably with torque wrench.

13. All electrical connections for contacts. AFTER STARTING 1. Check that a l lights are switched off. 2. Insert the key in the starting switch and rum it

clockwise to 'on' position. 3. Press the throttle pedal approx half throttle

position and turn the key further clockwise till the engine starts cranking.

4. Alter the engine has made few revolutions, release to key to 'on' position and increase throttle slowly.

5. Once the engine has started, allow it to warm up for a few minutes till the water temperature gauge indicates in the green gone.

14. All hydraulic connections for tightness. 15. Fan belt for proper tension. 16. Ensure all pins are properly secured. 17. If all systems are operative. 18. Wire rope & clamps for damage. 19. Structure for cracks/dame. 20. General cleanliness.

(B) RECTIFY LEAKAGE IF ANY : NOTE

a) Replenish the oil level wherever is necessary with clean recommended grade of oil.

b) Add pure distilled water in the battery.

c) Add clean soft water in the radiator it required.

After starting the engine observe the following during operation :

1. Engine Oil Pressure Gauge: The gauge should register minimum 0.5 Kg/cm2 at idling and 0.5 to 4.5 Kg/cm2 during operation.

2. Water Temperature Gauge: The pointer should be in green zone.

3. Air Pressure Gauge: Needle should cross to the red zone within a minute of starting engine.

4. Ampere Meter: The pointer should be in the positive zone indicating charging.

5. Speedo-Cum-Hour-Recorder: Should start working as soon as the engine is started.

37

OPERATION CHECKS

MOVING THE MACHINE 1. Check the brakes for its proper function before

putting the machine to actual use. 2. Remove the parking brake lock. 3. To move the machine, first press the clutch pedal,

engage the HL gear lever in either high or low position & put the gear selector in the desired speed.

4. Release the clutch slowly & accelerate the engine speed simultaneously.

CAUTION A. If the engine does not start in first attempt, wait

for a minute before making next attempt to start the engine and in case engine fails or start even after 2-3 subsequent attempts. Investigate the fault & rectify the same before making further attempt to start the engine. (Refer Trouble &looting Chart).

B. Do not use the starter for more than 10 seconds at a One and allow a minimum time gap of two minutes between two consecutive starting attempts.

C. Do not worry if during the initial starting of the engine, oil pressure gauge needle registers in the green zone.

D. Do not worry if during the initial starting of the engine, oil pressure gauge needle indicates in the extreme red zone, it should stay within green zone after engine gets warmed up.

E. The movement of water temperature gauge needle in the extreme reed zone indicates overheating of engine, investigate the fault and rectify the same.

F. Ensure refueling before fuel level indicates 1/4 tank level.

NOTE Run in the new unit for 50 hrs, of initial

operation at half loads and change engins oil fitter 50 hours with filters.

C) STOPPING & PARKENG THE CRANE

For stopping the crane, proceed as follows: 1. Release the accelerator pedal and apply

Brakes gradually. 2. Put the gear selector lever in the neutral

position. 3. Lower the load to rest on ground. 4. Idle the engine for 15-20 seconds. 5. Pull up-wards the fuel cut off knob till engine

stops. 6. Put ignition off and remove key. 7. Apply parking brake before leaving the

operator's seat. CAUTION : The crane should not be operated with

engine speed more than 2000 r.p.m.Excessive speeds are dangerous and maycause unnecessary strain on the components.

38

TROUBLE SHOOTING

Trouble shooting is an organized study of a problem, then a planned procedure for investigating and correcting the problem. Anyone familiar with constructional details & Operating principles of particular equipment/components, can trouble shoot The failure without much difficulty. The serviceman responds to a complaint by getting the furl story from the operator, by observing the machine and making necessary investigation and test which will reveal about the cause of failure. The first act of the trouble shooting is to understand the problem very precisely. For this purpose following questions are suggested to diagnose the trouble properly. A) OPERATING CONDMONS 1. Did any unusual noise precede the failure? 2. Was the crane under specified load or over

loaded? 3. Did any unusual dusty or smoky condition persist

for long time? 4. Did oil pressure or oil temperature very? 5. What were weather conditions? 6. How trouble was first noticed? 7. What was the consumption rate for fuel or

lubricant?

8. What was the condition of exhaust? 9. Was the engine starting & shutdown

satisfactory? 10. Did the engine run at idle for long period? 11. Was there any smoke from any part other

than exhaust? B) OBSERVATIONS

1. Is the crane clean on dirty?

2. Is there any leakage of Oil or fuel, extremely visible?

3. Are there any nuts, bolls, screws found lose?

4. Are there any modifications done on the by removal or replacements of parts?

5. Is there any misalignment of wrong adjustment?

6. Is there damage of parts due to accident?

7. Is there any part fouling?

8. Is there any symptom of burning or overheating of a part?

39

TROUBLE SHOOTING

CAUSES 1. ENGINE DOES NOT TURN :

1. Battery weak. 2. Starter or starter switch inoperative. 3. Engine is locked or seized.

4. Hydro-static lock 2. ENGINE OVEREATING : 1. Slow cracking speed. 2. Insufficient supply of fuel to fuel injection nozzles. 3. Fuel injection nozzles not operating properly. 4. Fuel injection pump improperly timed. 7. ENGINE HARD TO START 1. Battery weak. 2. Insufficient fuel in fuel tank. 3. Incorrect grade of fuel.

4. Fuel injection nozzles not operating. 5. Air in fuel system. 6 Insufficient supply of air to cylinders. 7. Fuel injection pump improperly timed. 8. Incorrect tappet clearance. 9. Piston rings or cylinder lines worn out. 10. Valve wrapped or pitted.

REMEDIES 1. Recharge or replace battery. 2. Repair or replace affected parts. 3. This can be due to extended idle or storage periods or to improper preparation of the engine for storage, in which case the parts may be rusted or corroded & seized, Broken piston rings, gear etc. may also cause locking. The engine should be disassembled to determine the cause & the necessary parts to be replaced. 4. this can be due to rain water entering uncovered exhaust pipe, leaking cylinder head. The engine should be dissembled to determine the cause & the necessary parts be replaced. 1. The specific gravity of the battery may be too low or the starter may not be delivering its maximum torque to provide adequate cranking speed. Replace the affected parts. 2. Check fuel system & rectify. 3. Test & repair /replace nozzles. 4. Time fuel injection pump 1. Recharge or replace battery 2. Check fuel level in tank. Fill the tank with high speed diesel. 3. Drain Fuel system. Fill the tank with high speed diesel. 4. Test & repair /replace nozzles. 5. Correct air leaks in suction side of fuel system & bleed fuel system. 6. Clean air system. 7. Time fuel injection pump. 8. Check & adjust Tappet clearances. 9. Replace affected parts. 10. Recondition or replace valves and/or valve

40

TROUBLE SHOOTING CAUSES 4. ENGJNE STOPS FREQUENTLY :

5. Idling speed too low. 6. Restricted fuel supply.

5. ENGINE STOPS SUDDENLY 1 No fuel in the tank. 2. Restricted fuel supply. 3. Broken or loose fuel lines. 6. ENGINE OVEREATING : 1. Coolant levels less in Radiator. 2. Radiator fins blamed. 3. Fan belt looses I broken. 4. Improper engine lubrication, 5. Fuel in pump improperly timed. 6. Water pump failed 7. ENGINE SHOWS LOSS OF POWER 1. Insufficient supply of air to cylinders. 2. Insufficient supply of fuel to fuel injection nozzle. 3. Governor not operating properly. 4. Air in fuel system. 5. Clogged fuel filters. 6. Improper valve. Clearance. 7. Fuel injection pomp improperly timed. 8. Inoperative fuel injection pump or fuel injection nozzles. 9. Valve leaking. 10. Worn out piston rings & liners.

REMEDIES 1. Adjust low idling speed. 2. Check fuel system & rectify. 1. Fill fuel lank with High Speed Diesel and Need

the fuel system. 2. Check fuel system & ramify. 3. Correct or replace affected parts. 1. Top up 2. Clean 3. Adjust/Replace 4. Check and rectify lubrication system. 5. Time fuel injection pump. 6. Check & Repair if Replace. 1. Clean air system 2. Check & rectify system. 3. Contact nearest concerned dealer. 4. Check for air leaks on suction side of fuel

pump & bleed fuel system. 5. Change filter element. 6. Cheek & adjust. 7. Time fuel injection pump. 8. Repair or replace affected parts. 9. Recondition or replace the affected parts. 10. Replace the affected parts.

41

TROUBLE SHOOTING

CAUSES 8. ENGINE EMITS BACK SMOKE FROM EXHAUST 1. Air system dogged. 2. Improper grade fuel 9. ENGINE EMITS BLUE SMOKE FROM EXHAUST : 1. Fuel injection nozzle not operating Properly. 10. ENGINE NOT ATTANING THE GOVERNED SPEED : 1. Throttle linkage defective. 2. Restricted fuel supply. 3. Restricted air intake. 4. Poor quality of fuel.

12. EXCESSIVE FUEL CONSUMPTION 1. External or internal leakage. 2. Faulty nozzles. 3. Engine overloaded. 4. Fuel pump defective. 5. Poor quality of fuel. 6. Restricted air intake.

REMEDIES 1. Check and clean engine air intake system. 2. Drain fuel system and refill with fuel of recommended specifications. 1. Test and adjust nozzles. 1. Adjust throttle linkage. 2. Clean change fuel filter and check for any restriction in the fuel line. 3. Clean air cleaner and refill oil to the required level. 4. Drain the system arid refit' dean High Speed Diesel. 1. Check for leakage and rectify. 2. Get the injectors tested and replace if Necessary. 3. Do not overload the engine. 4. Repair fuel pump. 5. Drain the system & refill dean High Speed Diesel. 6. Clean air intake system, air cleaner and fill fresh oil.

42

TROUBLE SHOOTING CAUSES 12, EXCESSIVE LUBRICATING OIL CONSUMPTION ; 1. External oil leaks. 2. Wrong grade of oil used. 3. Valve guide worn out. 4. Oil rings stuck in piston ring grooves. 5. Pistons, rings, liners, worn out. 6. Engine overheating. 13. NO OR LOW LUBRICATING OIL PRESSURE: 1. Pressure gauge defective. 2. Oil lines loose/broken inside. 3. Wrong grade doll used. 4. Insufficient oil in the crankcase. 5. Cooling system defective. 6. Main or connecting rod or crankshaft bearings worn out. 7. Lub. Oil pump defective, 8. Lub. Oil pump suction strainer chocked. 9. Oil pressure valve defective. 14. EX ES-BRIELUBRICATING OR PRESSURE ; 1. Pressure gauge defective. 2. Pump defective. 3. Wrong grade of oil used. 4. Oil pressure valve sticking. 15. CLUTCH OPERATING HARD OR STICKY 1. Clutch not adjusted properly. 2. Clutch linkage or pedal fouling. 3. Clutch linkage parts rusty. 4. Release bearing failure.

REMEDIES 1. Check leakage and rectify. 2. Drain the oil arid refill with proper grade of oil. 3. Replace the valve guide. 4. Replace affected parts. 5. Replace affected parts. 6. Clean Air Cleaner, intake system & fill with fresh oil. 1. Replace oil pressure gauge. 2. Repair or replace affected parts. 3. Drain oil and refill with the proper grade of oil. 4, Fill crankcase to proper level. 5. Rectify cooling system. 6. Replace affected bearings. 7. Repair or replace the pump. 8. Clean strainer. 9. Clean strainer. 1. Check & replace pressure gauge. 2. Repair/ replace pump. 3. Drain and refill with proper grade of oil. 4. Clean/replace relief valve. 1. Adjust the clutch. 2. Rectify. 3. Clean & lubricate the joints. Check clevis pin for free rotation. 4. Replace the bearing.

43

TROUBLE SHOOTING

CAUSES 16. CLUTCH SUPPING 1. Clutch out of adjustment. 2. Worn clutch plate. 3. Spring tension poor. 17. GEARS NOT ENGAGING I SLIPPING : 1. Clutch not disengaging. 2. Fork/lever/ shaft bent. 3. Interlock jammed. 4. Springs broken or lost tension. 5. Worn gear teeth. 6. Fork locks Loose. 18. UNUSUAL SOUND FROM GEAR. BOX 1. Incorrect lubricants & level too low. 2. Worn Of broker' goon teeth. 3. Warn bearings. 19. DIFFERENTIAL NOSILY 1. Incorrect lubricants & level too low. 2. Worn or broken gear teeth. 3. Crown wheel & pinion unmatched or not property adjusted. 20. DIFFERENTLAL OVERHEATS 1. Incorrect lubricants or Level too low. 2. Bearing adjusted too light. 3. Excessive wear on gear.

REMEDIES

1. Adjust clutch. 2 Replace clutch plate. 3. Replace springs. 1. Adjust the clutch. 2. Replace or repair Fork/lever/ shaft. 3. Rectify. 4. Replace springs/or add washer. 5. Replaces gears. 6. Tighten the lock.. 1. Fill with oil recommended grade of oil and Check for leakage. 2. Replace gears. 3. Replace bearings. 1. Check level, use recommended oil and check for Leakage. 2. Replace-worn out parts. 3. Adjust back lash/replace with matched set. 1. Check level, fill with correct recommended grade. 2. Re-adjust properly. 3. Check, gear for excessive wearing scoring Replace if necessary.

44

TROUBLE SHOOTING

CAUSES REMEDIES 21. NOISE IN REDUCTION HOUSING 1. Incorrect lubricants a low oil level. 2. Bearings worn Out. 3. Gear & pinion teeth worn out/broken. 4. Splines on Axle/wheel shaft worn out. 22. BRAKES NOT EFFECTIVE:

1. Check level. Fill recommended grade of oil &check for leakages.2. Replace bearings. 3. Replace worn out/broken parts. 4. Replace worn out part.

Type of fault Possible causes

Recommended action

A. Brake pedal Hard to operate a) Reservoir Drain plugs

open. b) Trailer brakes shutoff cock left open.

Make a complete check of pipelines, hoses, connections. Reservoir r and trailer couplings.

1. Compressed Leakage

Fault in Air Compressor such as: i) Defective or worn Compressor. ii) Leaking delivery valve. iii Leaking inlet valve. iv) Defective unloaded valve. v) Leakage at Tyre inflator.

Service the Compressor Unload. Valve Tyre inflator as per manufacturers Recommendatior.

2. Wheel brakes or pedal

a) Brake pedal, relay lever or brakes shoe binding. b) Glazed Linings Reline or clean linings. c) Grease or brake fluid on linings. d) Corrosion in master cylinder. e) Restriction or damage to hydraulic fines to wheel cylinder.

Inspect pedal linkage or shoe assemblies for tightness. Reline or clean lining-s and adjust brakes. Inspect master cylinder. Check operation of wheel cylinders/slave cylinders.

3.Hydraulic System Trouble

a) Corrosion in wheel cylinders/slave cylinder. b) Residual check valve not opening in master cylinder. c) Incorrect brake fluid.

Inspects wheel cylinders/slave cylinders. Remove master cylinder outer connections and inspect valves. Flush out system and refill with correct fluid.

45

TROUBLE SHOOTING

Type of fault Possible causes

Recommended action

B. Brakes fail to release : 1. Wheel Brakes or pedal Trouble

a) Shoe linkage seized. b) Weak or broken shoe return springs. c) Brake pedal or linkage binding d) Weak of broken pedal return spring. e) Broke linkage incorrectly adjusted. Preventing servo returning to 'off' position.

Check brake assemblies for seizing and weak or broken. Check pedal and linkage for correct alignment and freedom movement. Lubricate pedal pivot and linkage. Adjust brake linkage so that both pedal and servo are in 'off position.

2. Hydraulic System Trouble

a) Faulty adjustment of slave Cylinder push rod. b) Faulty adjustment of slave cylinder push rod. c) Corrosion in master cylinder. d) Restriction or damage to Hydraulic lines to wheel cylinders/slave cylinders. e) Corrosion in wheel cylinders. f) Incorrect brake fluid. a) Lever assembly not functioning correctly. b) Exhaust valve sticky c) Release breather filler obstructed. d) Power piston not returning due to dirt corrosion or lack lubrication. e) Reaction piston not returning due to dirt or lack of lubrication due to dirt or lack of lubrication due to dirt or lack permanently set. f) Power piston or Reaction piston springs or broken or permanently set.

Check that the servo output rod stand out in correct. If not adjust by internal shimming. Check & set it right. Inspect master cylinder. Check operation of wheel cylinder/slave cylinders and inspect pipes. Inspect wheel cylinders slave cylinders. Flush out system and refill with correct fluid. Remove lever housing and check lever operation. Check exhaust valve. Remove wire mesh filter and clean. Remove power piston. Examine and re-lubricate. Remove reaction piston. Examine and re-lubricate. Examine springs and if faulty replace.

46

TROUBLE SHOOTING

Type of fault Possible causes

Recommended action

C. BRAKE PEDAL HAS EXCESSIVE TRAVEL : 1. Wheel Brakes or Pedal Trouble

a) Brake shoes in need of adjustment. b) Excessive wear in brake pedal linkage. c) Shoe linkage seized. d) Cracked drums or distorted brake shoes.

Adjust brake clearance. Inspect pedal and linkage. Examine brake assemblies.

2. Hydraulic system Trouble

a) Low fluid level in master cylinder reservoir. b) Air in system. c) Defective seals in master cylinder. d) Leakage in pipelines to wheel cylinders. e) Defective seals in wheel cylinders/ slave/ cylinder. f) Incorrect brake fluid.

Check level of fluid and top up to correct level. Bleed the system. Examine master cylinder. Inspect pipes and fittings for loose Connections replenish fluid. Check seals in wheel cylinders/ slave/ cylinder. Flush out system and refill with correct fluid.

D. BRAKES GRAB : 1. Wheel Brakes

or pedal Trouble:

a) Grease or break fluid Linings. b) Broken shoe return springs. c) Pedal linkage binding. d) Distorted brake shoes. e) Brakes out of adjustment. f) Pedal linkage binding. g) Loose brake flange plate. h) Stack hub bearing.

Reline shoes or clean linings. Examine brake assemblies and brake drums. Adjust brakes as necessary. Check and lubricate pedal linkage. Examine brake assemblies.

2 Hydraulic system Trouble:

a)Leakage of fluid at wheel cylinder/slave cylinders. b) defective seals in wheel cylinder/slave cylinders.

Examine assemblies. Inspect wheel cylinder/slave cylinders

47

TROUBLE SHOOTING

CAUSES REMEDIES 23. VEHICLE DRAGGING TO EITHER SIDE : 1. Brakes unequally adjusted. 2. Worn out lining. 3. Tyre pressure unequal. 4. Defective wheel brake cylinder/slave cylinder. 5. Brake shoe return spring damaged.

1. Adjust brake properly. 2. Replace lining. 3. Inflate all the tyres to recommended pressure. 4. Replace defective parts. 5. Replace defective parts.

24. UNEQUAL STEERING TURNS ON TWO SIDES : 1. Steering geometry distributed. 2. Stopper's not set properly. 3. Unequal tyre pressure.

1. Check and rectify. 2. Check and rectify. 3. Inflate all the tyres to recommended pressure.

25. STEERENG WRONG DERECTION: 1. Incorrect plumbing of steering unit to steering lines.

1. Check steering line plumbing.

26. HYDRAULIC RESPONSE POOR : 1. Cold hydraulic oil. 2. Oil of high viscosity. 3. Insufficient engine speed. 4. Air leak in section line. 5. Pump worn out. 6. Oil Leaking past 'O' rings and seals actuators. 7. Oil Leaking past distributor. 8. Restriction in suction line. 9. Clogged breather in hyd. Oil reservoir. 10. Mechanical linkage joints jammed. 11. Load exceeding specified lift capacity. 12. Checked or partially clogged strainer in Oil reservoir.

1. Allow hyd. oil to warm up the slow engine speed. 2. Use recommended oil. 3. Press foot-accelerator to increase speed. 4. Check & rectify Add Hyd. Oil if necessary. 5. Get pump repaired/replaced. 6. Check & replace affected parts.

7. Get distributer valve repaired or replaced. 8. Check clean and reassemble suction line strainer & hyd. oil filter. 9. Clean breather. 10. Clean and lubricate. 11. Reduce load. 12. Remove, clean & refit.

48

TROUBLE SHOOTING

CAUSES REMEDIES 27. HYDRAULIC SYSTEM NOT RESPONDING : 1. Insufficient oil in reservoir. 2. Foreign matter lodged under seat of relief valve or in line check valve. 3. Insufficient relief valve pressure. 4. Pump badly worn out or damaged. 5. Broken oil line. 6. Obstruction in oil lines or valves. 7 Worn distributor valve. 8. Pump gears worn out. 9. Pump shaft, key or propeller shaft sheared. 28. BOOM FAILS TO HOLD UP : 1. Leaking or broken oil lines from distributor valve to lift cylinders. 2. Internal leakage in hit cyl. Past of rings & seals. 3. Internal leakage past distributed spool. 29. HYDRAUIJC OIL OVERHEATING : 1. Operator holds distributor valve open too long causing roller valve to open. 2. Incorrect relief valve pressure setting. 3. Incorrect grade of oil used. 4. Dirty oil. 5. Insufficient oil in hydraulic reservoir. 6. Dirty breather on hydraulic oil reservoir. 7. Suction fine restricted. 8. Worn pump valve or cylinder. 9. Air in the system.

1. Add oil. 2. Check and clean relief valve. 3. Get relief valve reset to recommended pressure. 4. Get pump repaired replaced. 5. Check for leakage and repair oil. 6. Check flow of oil through the hydraulic circuit and remove obstruction. 7. Get distributor valve repaired or replaced. 8. Check for dirt or metal chips. Clean the parts thoroughly and replace the affected parts. Flush with hyd. Oil if necessary. 9. Check & replace affected parts. 1. Check for leaks. Tighten or replace lines. 2. Check & replace affected parts. 3. Get distributor spool repaired/replaced. 1. Release control handle when not in use. 2. Get relief valve reset to recommended oil Pressure. 3. Use recommended oil. 4. Drain and refill with recommended oil. 5. Fill tank to proper level. 6. Clean or replace breather. 7. Clean suction line/strainer. 8. Replace affected parts. 9. Check hydraulic system suction lines.

49

TROUBLE SHOOTING

CAUSES REMEDIES 30. OIL FOAMING 1. Kink or dent in oil lines. 2. Worn seal on the pump shaft. 3. Incorrect grade of oil. 4. Low oil level in reservoir 5. Oil contaminated with water. 31. NOISY HYDRAULIC OPERATION : 1. Partially clogged suction line 2. Sludge and dirt in pump. 3. Reservoir breather clogged. 4. Oil viscosity high. 5. Pump worn out. 6. Low hydraulic oil level. 7. Engine speed too high. 8. Air in system. 32. STEERING RESPONSE POOR ON ONE OF THE SIDE 1. Internal leakage in steering jack 2. Piston rod bend. 3. Blocked hose/pipe lines. 4. Flow cum pressure relief valve defective..

1. Replace oil lines. 2. Get pump repaired or replaced. 3. Use recommended oil. 4. Add recommended oil to proper level. 5. Drain hydraulic oil and refill recommended oil. 1. Remove & clean suction line between reservoir and pump.

2. Get the pump cleaned thoroughly. 3. Remove breather cap. Flush and clean. 4. Use recommended oil. 5. Check and repair the pump.

6. Add hydraulic oil to proper level. 7. Always maintain the recommended speed. 8. Check hydraulic system for air leaks in the suction lines.

1. Check and replace. 2. Replace jack.

3. Clean/replace. 4. Rectify/replace the assembly.

50

RECOMMENDED LUBRICANTS

LUBRICANT MANUFATURER

ENGINE, AIR CLEANER & F. P. I REDUCTION GEAR STEERING

GEAR BOX & DIFF. HOUSING

HYDRAULIC RESERVOIR GREASE POINT TEMP

0-270 C TEMP ABOVE 270

C

INDIAN OIL SERVO PRIDE 20 20W/40

SERVO PRIDE 30 20W/40

SERVO GEAR HP- 90 SERVO SYSTEM 68

SERVO GREASE MP

BHARAT PETROLEUM

BHARAT ACTUMA ALTRA SUPER

OIL-30

BHARAT ACTUMA ALTRA SUPER OIL-

30

BHARAT SPIROL 90-EP

BHARAT HYDROL-68

UNIVEX A

HINDUSTAN PETROLEUM

(H.P.C.) HYLUBE MILCY 20 HYLUBE MILCY 30 H.P. GEAR OIL

ST-90 ENKLO 68

H.P.MULTI PURPOSE

CASTROL DEUSAL SUPER CRD 20W-40

DEUSAL SUPER CRD 20W-40 HYPOY 90-EP CASTROL HYSPIN

AWS 68

BALL BRG. EPL-2

GULF GULFSUBE MOTOR OIL XHD- 20

GULFSUBE MOTOR OIL XHD- 30

GULF TRANSMISSION

90

GULF HARMONY 68

GULFSIL MULTI PURPOSE

TIDE WATER VEEDOL HDC 20 OR 20W-20

VEEDOL HDC 30 OR 20W-40

VEEDOL T & GEAR 90 VEEDOL ATLINE-68

VEEDOL ALL PURPOSE GREASE

51

KNOW YOUR MACHINE – C8