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7/21/2019 BG825 OM 27.02.15


BG825

MOTOR GRADER

OPERATION & MAINTENANCE

MANUAL

BEML LIMITED

INDIA

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OPERATION & MAINTENANCEMANUAL

BG825 MOTOR GRADER

EQPT.SL.NO.25044 & UP

BEML LIMITED

INDIA

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Unsafe use of this machine may cause serious injury or death. Operators and maintenancepersonnel must read and understand this manual before operating or maintaining this machine. Thismanual should be kept in or near the machine for reference, and periodically reviewed by allpersonnel who will come into contact with it.

The Company reserves the right to make changes or add improvements at any time without incurringany obligation to install such changes on products sold previously. Because of continuous researchand development, periodic revisions may be made to this publication. Customers should contact theirlocal BEML Service Manager for information on the latest revision.

BG825 OPERATION & MAINTENANCE

MANUAL

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FOREWORD

This Operation & maintenance manual is written for use by the operator and/or the service

technician and is designed to help these persons to become fully knowledgeable of the MotorGrader and all its systems in order to keep it operating safely and efficiently. All operators andmaintenance personnel should read and understand the materials in this manual beforeoperating the Motor grader or performing maintenance and/or operational checks on the Motorgrader. All safety notices, warnings and cautions should be understood and followed whenoperating or accomplishing repairs on the Motor grader.

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 intopersonal habit.

This manual describes the basic techniques. Skill is performed as the operator o r anyoneget the correct knowledge and performance of the machine.

Operation, inspection, and maintenance should be carefully carried out, and the safetymust be given the first priority.

The safety information contained in this manual is intended only to supplement safety

cords, insurance requirements, local laws, rules and regulations.

Some photographs and illustration pictures are different from your machine as technicalimprovement is continuous ly reflected on it. Revision to up-to-date manual's content isperformed in later editions.

NOTE: The specification contained in this manual is subject to change at any timewithout notice. Contact your BEML Representative for the latest Information.

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!This “ ALERT ” symbol is used with words “ CAUTION ” ,

“ DANGER ” ,“ WARNING ” and “ IMPORTANT ” in this manual

to alert the reader to hazards arising from improper operating

and maintenance practices.

Indicates the potential hazard which may result in personal injury or

death if proper precautions are not taken.

Indicates the potential for equipment damage. This is a general

reminder of proper safety practices.

Indicates a specific potential hazard which w ill result in either personalinjury or death if proper precautions are not taken.

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BREAKING IN YOUR NEW MACHINE

Each machine is carefully adjusted and tested before shipment. However, a new machinerequires 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 ofperformance will prematurely deteriorate and the service life will be reduced. A new machinemust 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 toactual operation.

Avoid operation with heavy loads or at high speeds.

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

With increase in ambient temperature, Change lubricating oil and fuel to that ofrecommendation and add ACF ( Anti Corrosion Fluid ) in premixed condition to thecoolant.

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

1 Changing all oil, filter elements and cartridges.

2 Checking and adjustment of engine valve clearance.

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. Ifheavily collected, check for possible cause before starting operation.

Hours of operation are indicated by the service meter.

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TABLE OF CONTENTS

Sl.no. Subject Section

1 OPERATIONS A

2 MAINTENANCE B

3 SPECIFICATION C

4 FUEL AND LUBRICANTS D

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SECTION - A

OPERATION

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BG825 A1

Section AOPERATION

INDEX

Sl.no. Section reference no. and Description Page no.

1. 1. SAFETY HINTS A5

1.1. General A5

1.2. Safety Rules A7

1.3. Safety features A7

1.4. Unauthorized modification A7

1.5. Before starting operation A7

1.6. After starting engine A8

1.7. During operation A9

1.8. Parking A12

2. 2. GENERAL LOCATIONS A13

3. 3. DASH BOARD SYSTEM A14

3.1. Introduction A14

3.2. Power supply A14

3.3. PV750 Murphy display A14

3.4. Transmission controller A18

3.5. Inspection chart for transmission control module (Table-I) A19

3.6. Solenoid combination – Check as per table -II A20

3.7. Trouble shooting A21

3.8. Precautions for welding on machines with electronic

controls A23

3.9. Steps for improving the reliability of Murphy dash board

System A26

3.10. Emergency steering system on motor grader A33

3.11. Starting motor trouble Shooting A36

3.12. Alternator wiring test A37

3.13. Batteries A37

3.14. Care of the battery A38

3.15. Battery and charging System A40

3.16. Servicing battery A40

3.17. Recharging batteries A41

3.18. Starter motor A43

4. 4. INSTRUMENTS AND CONTROLS A53

4.1. Work equipment control lever A53

4.2. Steering wheel tilt lever A534.3. Steering post tilt pedal A53

4.4. Work equipment control lever safety lock A54

4.5. Fuel control lever A54

4.6. Gear shift lever (& parking brake) A54

4.7. Inching pedal A55

4.8. Brake pedal A55

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BG825 A2

Sl. no. Section reference no. and Description Page no.

4.9. Accelerator pedal A56

4.10. Dust indicator A56

4.11. Articulate lock pin A56

4.12. Operator’s seat A57

4.13. MCB A58

5. 5. CHECK BEFORE STARTING A595.1. Check and refill coolant A59

5.2. Check and refill fuel tank A59

5.3. Drain water and sediment In fuel tank A60

5.4. Drain water from air tank A60

5.5. Check oil level in engine oil pan A60

5.6. Check electrical wiring A61

5.7. Check dust indicator A61

5.8. Check and adjust tire Pressure A61

5.9. Check and adjust Steering wheel A61

5.10. Is rise in air pressure Normal? A62

5.11. Other check points A62

5.12. Check the windshield Wiper, window washer and

Defroster for normal Function. Check for Sufficient washer

fluid Level.

A62

5.13. Check for sediment and Water in the Water Separator A62

6. 6. OPERATING YOUR MACHINE A63

6.1. Before starting the Engine A63

6.2. To start the engine A63

6.2.1 Special starting A64

6.3. Check after starting A64

6.4. To stop the engine A64

6.5. To move the Machine off A65

6.6. Changing gear speed A65

6.7. Forward-reverse shifting A66

6.8. Turning A66

6.9. To stop the machine A67

6.10. Cautions for operating hills A67

6.11. Slopes, steep hills A67

6.12. Precautions when stopping or parking Machine A67

7. 7. COLD WEATHER OPERATION A68

7.1. Preparation for low temperature A68

7.2. Fuel and lubrication A68

7.3. Coolant A68

7.4. Battery A687.5. Starting in cold weather A69

7.5.1 To start the engine A69

8. 8. CAUTIONS AFTER COMPLETION OF WORK A70

9. 9. AFTER COLD WEATHER A70

10. 10. WORKS TO BE CARRIED OUT BY A MOTOR GRADER A70

11. 11. JOBS EFFECTUATED WITH ARTICULATED FRONTFRAME A73

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BG825 A3

Sl. no. Section reference no. and Description Page no.

12. 12. OPERATING OF WORK EQUIPMENT A73

12.1 Operation method of the work equipment control lever A73

12.2 Cautions in operation of work equipment A74

13. 13. ADJUSTMENT IN SHIFTING OF WORK ATTACHMENT A74

13.1 Blade projection A74

13.2 Propulsion angle of blade A75

13.3 Adjustment of blade cutting angle A75

13.4 Bank-cutting posture (right side) A75

13.5 Shoulder reach posture (right side) A76

13.6 Operation of the blade accumulator A77

13.7 Features of the blade accumulator A77

14.14. REVERSING AND REPLACEMENT OF CUTTING EDGE

AND END BITA78

14.1 Turning and replacing A78

14.2 Replacing ripper point A78

15. 15. CHANGING TIRES A79

15.1 How to changes tires A79

16. 16. HOW TO USE LEANING STOPPER A79

17. 17. DRIVING ALONG ROAD A80

17.1 Position of blade when traveling A80

17.2 Way to insert shack when transporting A80

17.3 Articulated operations A80

17.4 Precautions when travelling on road A81

18. 18. HANDLING OF BATTERY A81

18.1 Precautions for charging battery A81

18.2 Removal and installation of battery A82

18.3 Starting engine with a booster cable A82

19. 19. TOWING A83

19.1 Towing the machine A8319.2 Releasing parking brake A83

20. 20. TRANSPORTATION A84

21. 21. EMERGENCY STEERING SYSTEM A85

21.1 Function A85

21.2 Checks A85

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BG825 A4

NOTES:

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BG825 A5

OPERATION

1. SAFETY HINTS:

1.1. GENERAL

Safety records of most organizations willshow that the greatest percentage ofaccidents is caused by unsafe acts of thepersons.

The remainders are caused by unsafemechanical or physical conditions. Reportall unsafe conditions to the properauthority.

Read and follow all safety precautions.Failure to do so may result in seriousinjury o r death.

Wear well-fitting helmet, safety shoes andworking clothes. If the nature of the workrequires safety, wear protective goggles ormask, thick gloves, ear plugs or otherprotection as shown in the Figure 1-1.

FIGURE 1-1. SAFETY ACCESSORIES

Trained and authorized personnel shouldoperate and maintain the machine.

Accidents or injuries are liable to occurwhen the operator is careless or slack. Itis most important to bear safe operation inmind at all times as shown in Figure 1-2.

When working with another operator or aperson on worksite traffic duty, be sure allpersonnel understand all hand signals thatare to be used.

FIGURE 1-2. OPERATOR’S SAFETY

Take care of your health. Do not drive

when tired, or after drinking.

Learn the prohibitions, cautions, and rulesabout work procedures in the work site.

When there is a leader, fix standardsignals and always follow these signalswhen operating.

If there should be an accident or fire orany other such unexpected mishap, dealwith it quickly, using the nearest apparatusas shown in the Figure 1-3.

FIGURE 1-3. SAFETY APPARATUS

Be sure fire extinguishers have beenprovided and know how to use them.

Provide a first aid kit at the storage point

as shown in the Figure 1-4. Be sure you

know the phone numbers of persons you

should contact in case of an emergency.

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BG825 A6

FIGURE 1-4. SAFETY FROMFIRE HAZARD

Learn before and the locations of the firstaid boxes and fire extinguishers and howto use them. It is also important to knowthe emergency contact system.

Learn about the safety devices on yourown machine and about how to use them.

Confirm that they are correctly attached inthe prescribed position.

Such safety devices include:

Guards

Canopies

Protective Devices

Roll-Over Protective Structures

Seat Belts, etc.

Take care not to get caught by protruding

parts of the machine. Do not wear oil-tainted clothing because it is likely to catchfire.

Keep fire away from stored fuel, lubricantsand anti-freeze.

Thoroughly remove wood chips, leaves,paper and other flammable thingsaccumulated in the engine compartment.These could cause a fire.

Check fuel, lubrication, and hydraulic

systems for leaks. Have any leaksrepaired. Wipe up any excess oil, fuel orother flammable fluids.

Be sure a fire extinguisher is present andworking.

Do not operate the machine near anyflame as shown in Figure 1-5.

FIGURE 1-5. FLAME RESTRICTED

Exhaust gas dangerous. When runningthe engine for long periods in a poorly

ventilated area, there is a danger of gaspoisoning, so open the windows or doorsto ensure a good supply of fresh air asshown in the Figure 1-6.

FIGURE 1-6. AVIOD FUMES

Read Operation and Maintenance Manualcarefully as shown in the Figure 1-7.

FIGURE 1-7. READ MANUALCAREFULLY

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BG825 A7

Learn how to use the control devices,gauges and warning devices. Be sure youunderstand the meaning of the Cautionplates. Remember the check points andchecking method for engine oil, fuel,cooling water and hydraulic oil levels.

When working on a road, pay attention tothe safety of passing vehicles andpedestrians. If necessary, assign asignalman or provide temporarybarricades.

Before starting the machine, perform allnecessary checks as stated in theOperation and Maintenance Manual.

1.2. SAFETY RULES

Trained and authorized personnel should

operate and maintain the machine.

Follow all safety rules, precautions andinstructions when operating or performingmaintenance on the machine.

When working with another operator or aperson on worksite traffic duty, be sure allpersonnel understand all hand signals thatare to be used.

Check the Machine - Before you beginyour workday, you should inspect your

machine and ensure that all systems ingood operating condition. Do not operatethe machine until all deficiencies arecorrected.

1.3. SAFETY FEATURES

Be sure all guards and covers are in theirproper position. Have guards and coversrepaired if damaged.

Learn the proper use of safety features anduse it properly.

NEVER remove any safety features. ALWAYS keep them in good operatingcondition.

Improper use of safety features couldresult in serious bodily injury or death.

1.4. UNAUTHORIZEDMODIFICATION

Any modification made to this vehiclewithout authorization can possibly createhazards.

Before making any modification, consultthe authorized BEML service personnel.

1.5. BEFORE STARTINGOPERATION

Examine the lay of the land and the kindof soil at the work site to determine thedangerous points and the best method ofoperation.

Proceed with the work only after makingsafety arrangements about the dangerous

points else it may be threat to operator asshown in the Figure 1-8.

FIGURE 1-8. ENSURE SAFETY ARRANGEMENTS

Inspect leakages from the fuel, lubricatingand hydraulic systems. Check that tireinflation pressure is standard, that hubnuts are not loose, and that no other partsare damaged or missing. Machines havingsuch failures should not be operated.

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

Do not leave parts or tools lying around inthe vicinity of or on the floor of theoperator's compartment. Keep everythingin its proper place. If the tools arescattered here and there it can be aproblem for the operator while moving asshown in the Figure 1-9.

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BG825 A8

FIGURE 1-9. TOOLS TO BE INPROPER LOCATION

Wipe off thoroughly any grease, oil or mudon the step, handrail, floor or controllevers. Failure to do this may cause you toslip.

Check the level of the fuel, lubricants andcooling water. Extinguish cigarettes beforechecking or replenishing. Check that theradiator cap and each oil filler caps orplugs are firmly tightened.

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

If the belt is damaged or worm, replace it

with a new one.

To ensure the safety of the workers nearthe machine, always sound the horn towarn them before starting the engine andmoving the machine. Be particularlycareful to check that the road is clearbefore backing the machine as shown inthe Figure 1-10.

FIGURE 1-10. HORN BEFORE MOVING

Inspect the inside of the engine room andremove any dead leaves or paper. Deadleaves or paper are highly inflammableand can cause fires as shown in theFigure 1-11.

Before starting the engine, confirm that all

control levers are in "Neutral” or "Hold”.

FIGURE 1-11. INSPECT THE M/C

1.6. AFTER STARTING ENGINE

Confirm that all gauges and warningdevices are functioning correctly, and thatthe gauge readings are within theprescribed range.

Check the play and travel of each leverand pedal before giving the clearance foroperation as shown in the Figure 1-12.

FIGURE 1-12. CHECK FORCLEARANCE BEFORE OPERATION

Operate the blade to confirm that they arefunctioning normally.

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BG825 A9

Move the machine slowly and listencarefully to the engine or gears to confirmthat they are not making any unusualnoises.

Operate the gear shift lever to confirm thatthe travel speeds for forward and reverse

are functioning normally. Also carry out abrake test at each travel speed.

Choosing a safe place, turn the machineto the left and right to confirm that thesteering devices are functioning normallyas shown in the Figure 1-13.

FIGURE 1-13. TAKE TURNCAREFULLY

If these tests reveal anything wrong,however slight it may be, contact the manin charge of the machine and operate themachine only after obtaining hispermission.

1.7. DURING OPERATION

Always concentrate. It is extremelydangerous to allow yourself to bedistracted or to think of other things whenoperating a machine.

In dangerous places, or where there is

restricted visibility, it is important to getdown from the machine and confirmwhether it is safe before continuing work.

The work area should be made as flat aspossible. If the work area is flat operationis made much easier and this reducesoperation fatigue.

The machine should always be operatedat the speed where it can be controlled.

Never do the following.

Speeding

Sudden starting, sudden braking,sudden turning.

Snaking

Coasting

Before, careful of those around you, andalways confirm that there is no person orobstacle in the way before driving orturning the machine as shown in theFigure 1-14.

FIGURE 1-14. AVOID OBSTACLES

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

Raise each work piece of equipment ashigh as possible and keep the blade within

the machine width while traveling.Maintain the specified traveling posture.

Do not control the vehicle speed bypressing the brake as it will overheat thebrake lining.

Do not allow unauthorized persons intothe work area as shown in Figure 1-15.

FIGURE 1-15. DON’T ALLOWUNAUTHORISED ENTRY

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BG825 A10

Always be aware of the operating capacityof the machine. Using the machine to dowork beyond its capacity will not onlydamage the machine, but may even causeunexpected accidents.

The machine condition can be judged

from many factors. Changes in thegauges, sound, vibration, exhaust gascolor or response of the control levers canindicate the occurrence of some disorder.If any disorder occurs, park the machineimmediately in a safe place to takeappropriate action. Be especially careful inthe case of a fuel leak as there is dangerof fire.

If the machine breaks down and needs tobe towed, first confirm that the brakes areworking properly, and then tow, using a

wire rope or any other suitable towingequipment as shown in Figure 1-16.

FIGURE 1-16. USE SUITABLE APPARATUS FOR TOWING THE M/C

When parking the machine afterdiscontinuing work, put the gear shift leverinto "Neutral" apply the brake lock, lowerthe blade and scarifier (option) to theground, and put all safety levers into the"LOCK" position.

FIGURE 1-17. PROPER PARKING OFTHE M/C

Never leave the operator's seat withoutswitching the engine off as shown inFigure 1-17.

When continuing operations after rain,remember that conditions will havechanged from those before the rain

started, so proceed with caution. Beparticularly careful when approaching theshoulder of the road or cliffs, as they mayhave been loosened by the rain.

Check the load limits of bridges beforecrossing otherwise it will lead to accidentsas shown in Figure 1-18.

FIGURE 1-18. CHECK LOAD LIMIT OFTHE BRIDGES BEFORE CROSSING

When operating on uneven ground, driveat as low speed as possible and avoidsudden changes in direction.

When operating at the edge of a cliff or atthe shoulder of a road, remember thefollowing points:

When operating in a place where there isdanger of the machine falling over theside, be doubly careful. Do not approachthe edge of the cliff or road shoulder bymistake.

When working on river embankmentsor other places made of piled soil,there is danger that the weight orvibration of the machine may causethe machine to sink into the piled soil,so be extremely careful whenoperating in such places.

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BG825 A11

When operating on slopes, rememberthe following points :

When driving on a slope, always drivedirectly up or down it. Never drivehorizontally or diagonally across theslope, as this may cause the machine

to roll over or slip sideways.

When going down a slope, use theengine as a brake. If this is not enoughto control the speed of the machine,use the service brake as well. Nevercoast down a slope with gear shiftlever in "Neutral" or with clutchdisengaged.

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

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

If the engine stalls on a slope, first usethe brake to stop the machine, andthen return the gear shift lever to"Neutral" before staring the engineagain. See the Figure 1-19. Whileoperating in the slope.

FIGURE 1-19. OPERATING IN SLOPE

When using the articulation system, beparticularly careful not to let the bladedamage the rear tire. (In articulate framemodel):

Operating articulation system when

traveling at high speed may cause themachine to overturn. Always perform thisoperation at the speed below 10 km/hr. (Inarticulate frame model).

Always observe the traffic regulations andleave margin for emergencies.

When operating in a city area, be sure tolocate underground pipes and cablesbefore starting the machine to preventthem from being broken.

When operating inside a building alwaysbe sure of the clearance of the ceiling,entrances, aisles, etc. and the load limit ofthe floor else it will lead to accidents asshown in the Figure 1-20.

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BG825 A12

FIGURE 1-20. OPERATING INSIDEBUILDING

Never allow other person than theoperator to ride on the machine duringoperation.

When passing through a narrow space, becareful of the side and overheadclearances. Take special care not to touchany obstacles on either side or overhead.If necessary, have someone outside themachine call out instructions.

When operating at night, remember thefollowing points:

Be sure to arrange an adequatelighting system.

At night it is very easy to makemistakes in assuming the distance andheight of objects and land.

When operating in fog, mist or smoke,where visibility is bad, be careful toconfirm first whether operation is safe.

When visibility drops below safety level,stop work and wait for the visibility toimprove.

When operating in snow, or cleaningsnow, remember the following points:

Even sight slopes can cause expectedside slipping, so in such places,operate with extreme caution.

Never use the service brake to stopsuddenly on slopes. Lowering the

working equipment is a far moreeffective way of stopping.

Operating in snow should be donecarefully as shown in the Figure 1-21.

FIGURE 1-21. OPERATING IN SNOW

During operation, use seat belt .

1.8. PARKING

When parking the machine, park it in asafe place outside the working area, or inthe specified place as shown in the Figure1-22. The following factors should beconsidered when choosing a parkingplace: it should be on flat, firm groundwhere there is no danger of rock falls,landslides or floods. If the machine has tobe parked on the slope, it should beparked facing directly up or down theslope and chocks should be placed under

the tires. When the machine is facingdownhill, lower the blade so that it cutsslightly into the ground to further increasethe safety.

When parking the machine, return thegear shift lever to "Neutral", apply thebrake lock, lower the blade the scarifier(option) to the ground, and put all safetylevers in the "LOCK" position. Switch offthe engine and remove the key.

FIGURE 1-22. PARKING THE VEHICLE

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BG825 A13

2. GENERAL LOCATIONS

1. Head lamp

2. Turn signal lamp

3. Blade lift cylinder

4. Ripper

5. Rear tire

6. Blade

7. Front tire

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BG825 A14

3. DASH BOARD SYSTEM

The Equipment vital parameters are

monitored using Murphy PV750 Display

mounted on front console as shown in

figure 3-0.

FIGURE 3.0. MURPHY DISPLAYSCREEN

3.1. INTRODUCTION

The BG825 Dash board instrumentation

consists of I/O module and LCD (Liquid

Crystal Display) PV750Murphy display for

real time monitoring of vehicle critical

parameters and also to provide audio and

visual warnings to alert the operator about

impending breakdown. In addition to this,

various switches are mounted on the dash

board for system controls.

The Murphy Controller accepts On/off and

analogue signals from electro-mechanical

switches and sensors fitted on the

equipment sub systems and send the

information to the LCD display via CAN

and also provide audio & visual alarm

whenever any vehicle critical parameter

crosses its safe operating point.

LCD Murphy Display consists of followinggauges, pilot indicators & warningmessages.

Engine oil pressure gauge : 0-10 bar

Engine Water temp gauge: 40-120 º C.

Fuel level gauge

Voltmeter

Tachometer

Air Pressure gauge (2 nos.)

Engine Oil temp Gauge 40 -120 ºC

Transmission oil temp gauge

40-160ºC

Speedometer

3.2. POWER SUPPLY

The unit will work on the alternator –

battery supply of 18 –32 VDC, available

on the equipment and it is protected

against reverse polarity, and electrical

noise caused by switching of starting

motor, horn, wiper, solenoids, etc.

3.3. PV750 MURPHY DISPLAY

LCD Murphy Display accepts the analog

and digital signals from I/O Module

through CAN and displays the real time

value of critical parameter on Murphy

screen and also gives the warning

messages if vehicle critical parameter

crosses its safe operating point.

Murphy PV750 Display screen front panel

first screen is shown in the Figure 3.3a

Murphy PV750 Display screen secondpanel first screen is shown in the Figure

3.3b

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BG825 A15

FIGURE 3.3a MURPHY PV750

DISPLAY-FRONT PANEL

(FIRSTSCREEN)

FIGURE 3.3b MURPHY PV750

DISPLAY-FRONT PANEL

(SECOND SCREEN)

Type of Sensors using for the variousparameter are as follows:

Fuel Level: Fuel level is sensed using

resistive type sensors.

Temperature gauges: Temperature

sensors are thermistor type.

Pressure gauges: Pressure sensors are

current output type .

Warning indicators

Check before starting

The following parameters are to bechecked before the Engine start.

Radiator water level

Engine oil level

Hydraulic oil level

All indicator will be switched ON once the

key switch is turned ON and goes OFF

after few seconds (System check). If any

one of the above parameter is abnormal,

then the particular warning symbol

indication on Murphy display along with

text message and buzzer is displayed.

Battery charge and other parameters

All indicator will be ON once the key

switch is turned ON and goes OFF after

few seconds (System check). The battery

charging indication will go OFF when

engine is started and 24V received from

alternator ’I/WL’ point. If 24V is not

received, battery charging indication will

indicate on Murphy display along with

buzzer.

Pilot indicators

The following indicators are only for givingpilot indication when operated.

Differential lock

Lift arm lock

Absorber(optional)

Preheat(optional)

High beam

Turn signal (Right, Left)

Engine oil level(optional)

Final drive oil temperature

Coolant level

All indicators will be switched ON once the

key switch is turned ON and goes OFF

after few seconds (System cheek). If any

one of the parameter is operated

/abnormal then the indicator will be ON aslong as the parameter is operated /

abnormality present.

PV750 Murphy Navigation buttons

To see all the parameters press the button

and navigate to the next screen as shown

in the Figure 3.3c

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BG825 A16

FIGURE 3.3c MURPHY PV750

NAVIGATION BUTTONS

Once Warning Symbol is appears on the

screen, immediately stop the vehicle and

press the Button (shown in fig.) to see thewarning messages and read the warning

messages on Murphy display by

pressing the key as show below.

RH Panel

RH panel assy. consists of following

switches and key-switch as shown in the

Figure 3.3d.

FIGURE 3.3d RH PANEL

Lifter arm lock switch Starter switch

Head lamp switch

Differential lock & unlock switch

Dust indicator

Work lamp front and rear

Engine shut off switch

Wiper Motor Switch(Front & Rear)

Wind Shield Washer Switch (Front

& Rear)

Rear/Reverse lamp switch

LH Panel

LH panel assy. consists of Emergency

Steering switch, Rops lamp switch (front

& rear) and roof lamp switch and fan

switch. Emergency Steering switch can

be actuated in case of regular steering

pump fail. When this push bottom switch

is actuated emergency steering motor will

be “ON” and the lamp in the steering

switch goes ON when pressed. Details as

shown in the Figure 3.3e.

FIGURE 3.3e LH PANEL

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BG825 A18

3.4. TRANSMISSION CONTROLLER

BG825 Transmission consists of

electrically operated solenoids for gear

shifting. The shift tower is used to select

the required gear position manually to

operate the equipment at appropriate

speed. The shift tower consists of 8

forward, 8 reverse, neutral and parking

brake position.

Engine start: The equipment will start

only when shift lever is in parking brake

position. Other than parking brake

position, the Engine will not start.

Forward and reverse gear posi tion :

The forward and reverse gear position will

be sensed by two proximity switches

mounted on the shift tower. Based on the

actuation of proximity switch,

forward/reverse gears will be engaged.

Shift lever position sensing :

Non contact type Hall Effect sensors are

used to sense the shift lever position.

Details as shown in the figure 3.4. below

FIGURE 3.4. TRANSMISSION CONTROL

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BG825 A19

3.5. INSPECTION CHART FOR TRANSMISSION CONTROL MODULE :BG825(Table-I)

SL.

NO.CONDITION ACTION REMARKS

01 Power supply Should operate between 18-32v DC

02 Reverse polarityprotection

Should not affect the controller

03

Gear shift lever

a) Operating force

b) Lever position

2-4 kg

Centre of knob and graduation on FRP

console should coincide for every range.

04Engine start

Put shift lever in ‘P’ position. Check for

actuation of start relay coil (CNRST) and

ground signal from this relay to starting

circuit

Engine should not

start other than

‘P’ position &

check the same.

05 Reverse alarm

Put shift lever in ‘R’ position. Check for thefollowing

a) Proximity switch (CNSWR) get ‘on’(red LED on)

b) Relay (CNRTR) coil to beenergized and provides groundsignal to backup alarm relay.

c) Backup relay (CNRBB) coil getenergized and provides 24v powerto buzzer to drive alarm.

Check power to

backup alarm in

reverse gear

position (N to 8)

06

Shift lever position

i) Neutral forward

j) Neutral reverse

i) Proximity (F) switch get ‘on’ (red

LED on)

Relay (F) coil will be energized and

provides ground to forward solenoid

ii) Proximity (R) switch get ‘on’ (red LED

on)

Relay (R) coil will be energized and

provides ground to reverse solenoid

Check the

forward solenoid

energized in all

gear position

(F1-8 )

07 Differential relay

When shift lever position is between 1 to 4gear the differential relay (CNRD1) coil isenergized and provides ‘NC’ contact

Both in forward &

reverse direction

08 Mechanical lock forgear shifting

Check shifting of shift lever by pressingknob

Shifting from ‘n’ to ‘p’ position(N P)

a) Shifting from ‘5’ to ‘6’ gear during bothforward & reverse position.b) Shifting from ‘7’ to ‘6’ gear during downshifting in both forward & reverse position.

Both in forward &

reverse direction

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BG825 A20

3.6. SOLENOID COMBINATION – CHECK AS PER TABLE-II

NOTE: 1. (*) Indicates solenoids are energized

2. All solenoid will be driving in sinking mode

SHIFT LEVERPOSITION

SOLENOID COMBINATION

F R L H 1 2 3 4

P

N-

FORWARD

*

N-REVERSE *

F

1 * * *

2 * * *

3 * * *

4 * * *

5 * * *

6 * * *

7 * * *

8 * * *

R

1 * * *

2 * * *

3 * * *4 * * *

5 * * *

6 * * *

7 * * *

8 * * *

Shift leverposition

Ground details @ CNT 02 connector

PPin 2

1. The ground signal is same forboth forward & reverse range.

2. Check ground points withrespect to +24v using multimeter.

3. In neutral position both reverse& forward solenoids get groundsignal through respective relays.

1Pin 4&6

2Pin 4&7

3Pin 4&8

4Pin 4&9

5

Pin 5&6

6Pin 5&7

7Pin 5&8

8Pin 5&9

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BG825 A21

3.7. TROUBLE SHOOTING

Supporting tools required

Multimeter & circuit diagram

Shift tower - The shift selector is arange selector, which is used to selectthe range of maximum permitted gear.The sensing is based on the non-contact sensor to ensure long life andtrouble free operation. Mechanical lockis provided to avoid accidental shift to'p' position, up shifting from 5 to 6 gearand down shifting from 7 to 6 gear.

A) Shift tower position check as pertable - II

B) Functional checking as pertable - I

C) Engine not starting

Probable fault

Shift tower @ 'P" position no groundsignal

Starting relay (CNRST) notfunctioning

Remedy

Check shift tower ground signal atpin-2 of cnt 02 connector. (no roundsignal w.r.to +24v replace thecontroller).

Check starter relay function &wiring(replace relay if found faulty)

D) Parking brake not working

Probable fault

Shift tower @ 'P’ position no groundsignal

Parking brake not working

Remedy

Check shift tower ground signal at pin2of CNT 02 connector (no ground signalw.r.to +24v replace the controller)

* Check parking brake relay (CNRPB)function & wiring replace relay if foundFaulty.

Measure the parking brake solenoidresistance (if found open circuitreplace Parking brake solenoid).

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BG825 A23

3.8. PRECAUTIONS FOR WELDING ON MACHINES WITH ELECTRONIC CONTROLS

As with all machines with Electronic

Controls, special care should be taken

when welding on the machine. Here aresome tips to keep in mind when

performing welding on the Dump truck and

Motor Graders. For additional details,

review the Operation and Maintenance

Manual.

General Warnings & Tips

Always wear proper personalprotective equipment.

Before welding around electronics,Remove the electronics in that area toreduce or eliminate heat damagecaused by the welding process.Remove the controller unit if welding isto be done within 10” of it.

Lock-out and Tag-out the machine.

Clamp the ground cable from thewelder to the component that will bewelded and place the clamp as closeto the weld as possible. Attach the

welder ground cable no more than 2feet from the part being welded. Ifgrounding cable is connected nearinstruments, connectors, etc., theinstruments may malfunction.

Do not use electrical components(ECM or ECM Sensors) or electricalcomponent grounding points forgrounding the welder.

Do not weld in wet areas or in therain.

Always weld in a well ventilatedarea.

Keep your work area clear ofanything flammable

Do not use cables that are frayed,cracked or have bare spots in theinsulation

Never connect the ground cable ofthe welder to the ECM. Welding on

the engine or engine mountedcomponents is not recommended.

Do not apply more than 200 Vcontinuously.

Always avoid laying welding cablesover or near the vehicle electricalharnesses. Welding voltage couldbe induced into the electricalharness and possibly cause damage to components.

Always fasten the welding machineground (-) lead to the piece beingwelded.

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BG825 A24

Welding instructions:

a) Turn off the Ignition switch.

b) Turn –off Battery disconnect switch

c) Remove Both positive(+) and the

negative (-) terminal of the battery tostop the flow of current when carryingout electrical welding.

d) Before welding on truck, be certainthat each of these components arecompletely disconnected:

• Transmission and brake controllers

• Engine ECM

• Batteries

e) Cover all electronic controllers forprotection from sparks.

f) Engine must never be used as agrounding point.

g) Ensure the connection of automaticCAN grounding circuits for protectionof CAN bus lines. If it is notconnected/provided, all CAN bus linesare to be disconnected from thecontroller (Engine, transmission, Brake

and Murphy modules) and Murphydisplay units.

Jump Starting and Battery Charging

Do not connect the jumper starting orbattery charging cables to any part ofthe Engine / Transmission / otherECMS.

When using jumper cables to start theengine, make sure to connect thecables in parallel: Positive (+) to

positive (+) and negative (-) tonegative (-).

When using an external electricalsource to start the engine, turn thedisconnect switch to the “OFF”position before connecting the cablesto the battery.

Do not exceed 36 volts. Removethe key from the key switch beforeattaching jumper cables to thebattery.

When jump starting, make sureyou choose the right size of cable

for vehicle. Always connectpositive cable first and negativecable last. Disconnect the negativecable first and reconnect it last.

Handling controller

1) The controller contains amicrocomputer and electroniccontrol circuits. These control all ofthe electronic circuits on themachine, so be extremely carefulwhen handling the controller.

2) Do not place objects on top of thecontroller.

3) Cover the control connectors withtape or a vinyl bag. Never touchthe connector contacts with yourhand.

4) During rainy weather, do not leavethe controller in a place where it isexposed to rain.

5) Do not place the controller on oil,

water, or soil, or in any hot place,

even for a short time. (Place it on a

suitable dry stand).

6) Precautions when carrying out arc

welding when carrying out arc

welding on the body disconnect all

wiring harness connectors

connected to the controller. Fit an

arc welding ground close to the

welding point.

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BG825 A25

Points to remember when

troubleshooting electric circuits

1) Always turn the power OFF beforedisconnecting or connectingconnectors.

2) Before carrying out troubleshooting,check that all the related connectorsare properly inserted. Disconnect andconnect the related connectors severaltimes to check

3) Always connect any disconnectedconnectors before going on to the nextstep. If the power is turned ON withthe connectors still disconnected,unnecessary abnormalitydisplays/error codes will be generated.

4) When carrying out troubleshooting ofcircuits (measuring the voltage,resistance, continuity, or current),move the related wiring andconnectors several times and checkthat there is no change in the readingof the tester. If there is any change,there is probably defective contact inthat circuit.

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BG825 A26

3.9. STEPS FOR IMPROVING THE RELIABILITY OF MURPHY DASH BOARDSYSTEM

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BG825 A27

Noise Source

Effect of Noise on twisted pair

The total Effectis 14-14-0

Shield: BraidedSilver Plated Wire

Conductor: SilverPlated Copper or Alloy

Insulation: PTFE

over e PTFE

Jacket:: ETFEFluro ol mer

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BG825 A28

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BG825 A29

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BG825 A30

Single point Grounds

Once all the major components are fitted with their own return wire, by collecting all thereturn wires at a common point, the single point ground(SPG) works to get the entire

electrical system” singing of the same sheet of music”. It does this by simply making sure

that every electron has a clear path back to its source, whether it’s the alternator or the

batter .

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BG825 A31

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BG825 A32

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BG825 A33

3.10. EMERGENCY STEERING SYSTEM ON MOTOR GRADER

The emergency steering system is

supplementary steering system, to operate

the steering system in case of failure /

malfunctioning of steering pump / Engine

while equipment is in moving condition.

The emergency steering system is

consists of electrically operated DC motor

to drive the pump to provide the required

flow to steering system.

Manually operated Emergency steering

system :

The operator has to press the switch to

operate Motor and pump incase of failure

of steering system.

A switch mounted on the console next to

the operator can be used to activate the

emergency steering system if necessary

to steer the equipment when the engine is

not operable.

Note: Use of the emergency steering

system should be limited to a

maximum of 90 seconds.

The manual steering system intent to use

in case of failure of main steering system

to move the equipment to safer side. The

system should not be operated more than

90 seconds. The continuous operation ofemergency steering Motor leads to failure

of Motor and Pump.

In order to avoid the Motor failure due to

inadvertent operations, ON-Delay timer is

being provided to cut-off power to Motor

after 90 seconds, details are as follows.

On-Delay Timer: The On-Delay timer is

allows the Motor to operate for 90

Seconds and switch off the motor after

specified time. If operator wants to operate

the Motor for More than 90 seconds, the

Steering switch mounted on the dash

board to be operated once again.

The emergency steering system is a

safety system. The system should be

checked daily to ensure the proper

functioning of system. The procedure for

checking emergency steering system is

explained below.

Emergency steering system of BG825 Motor grader is shown in the Figure 3.10.a below.

FIGURE 3.10.a. EMERGENCY STEERING SYSTEM

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BG825 A34

Manual Emergency steering system

Check:

1. Turn the starting switch key to the ONposition.

2. Start engine and run for one minute.

3. Switch off the engine and switch ‘ON’emergency steering switch, and check

that the steering wheel can beoperated for 10 seconds.

The Circuit for Manual Emergency steering is shown in the Figure 3.10.b.

FIGURE 3.10.b CIRCUIT FOR MANUAL EMERGENCY SYSTEM

From Circuit

Breaker

EmergencySteering Motor

Emergency

Steering Relay

Emergency

Steering Switch

Battery

Buzzer

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BG825 A35

Preventive Maintenance Procedures:

The object of preventive maintenance is to

identify and correct potential problems

before they occur.

Wires and cables:

For any type of vehicle electrical system,

it‘s important to keep all connection Points

clean. Road dirt and grease create

resistance that interferes with electrical

current flow. In order to get the necessary

power from a unit , there must be little or

no resistance between the batteries and

the motor. In the same vein, you need to

make sure that wires and cables are

clean, properly tightened, and of the

proper size. Any loss of current due to

poor connections will reduce power to

motor.

Clean all connections on a periodic basis.

Also check for tension on terminals due to

improper routing.

Battery :

A battery having a low / poor state of

charge will place abnormal stresses on

the system. When measuring battery

voltage, make sure voltage is 24 V or

greater.

Excessive heat:

A motor can become damaged if it

operates too long at high temperatures.

Excessive heat is generally due to

continuous engagement of the Motor.

Damage to Motor system components canoccur when the motor is operated for long

periods. Motor should not be operated for

more than 90 seconds and allow Motor to

cool down for 3 minutes after operation.

Corrosion, dirt, and dust:

The Motor operates less efficiently when

corrosion forms or dirt particles build up

around wire and cable connection points.

Corroded and dirty connection points

impair the flow of electrical current. Clean

all connections on a periodic basis.

Timely preventive maintenance of the

system provides smoother operation and

long life for Motor and pump components.

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BG825 A36

3.11. STARTING MOTOR TROUBLE SHOOTING

SYSTEM

The heavy-duty electrical system is madeup of the starting system and the charging

system. These systems are, in turn,comprised of batteries, the starter, thealternator, the interconnecting wiring andelectrical and mechanical switches. Formaximum operating efficiency, all parts ofthe system must be functioning properly.

DIAGNOSIS:

Diagnosis is the three part process that

begins when a problem is perceived and

ends when the equipment is confirmed as

serviceable. The process can be

described by using three questions thatmust be answered to assure completion.

What are the symptoms? This is what

has been observed (seen, heard, felt

or smelled) that indicates a problem.

What caused the symptoms? This

involves using diagnostic procedures

to identify the root cause of the

problem.

How do we fix it? Usually this involves

the adjustment, repair or replacement

of some part or parts.

The Circuit connection for starting motor

with Alternator is shown in the Figure 3.11below.

FIGURE 3.11 STARTING MOTOR TROUBLE SHOOTING

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BG825 A37

3.12. ALTERNATOR WIRING TEST

This procedure is the first step in checking

out the charging system. The output of the

alternator, the batteries and the accessory

loads with a minimum of voltage loss. Any

loss slows the rate of charge to thebatteries and could cause the batteries to

be partially discharged. Discharged

batteries can result in starter damage. Low

output voltage can cause improper

performance of other vehicle electrical

components.

MAGNETIC SWITCH CONTACTOR

TEST

The figure for Magnetic Switch Contactortest is shown below.(Figure 3.12.)

FIGURE 3.12. MAGNETIC SWITCH

CONTACTOR

With carbon pile connected as for previous

Starter Solenoid Circuit Test, proceed as

follows:

Connect

1. Digital voltmeter set on low scale

across large terminals of magnetic

switch. Battery voltage will show

immediately.

Test

1. Push starter button with key on. Voltagewill read zero.

2. Turn on and adjust carbon pile to 100amp load (60 amp if 24 volt system).

3. Read and record voltage (V11) across

magnetic switch on voltmeter then release

starter button.

4. Magnetic switch contactor voltage loss

(V11) shall not exceed 0.2 volts for 12 or

24 volt system.

5. Replace magnetic switch if contactor

voltage loss is excessive.

3.13. BATTERIES

Batteries are perishable devices that wear

out at some point in time. With use they

deteriorate and eventually become

incapable of performing their important

job. In addition, new, good batteries may

become discharged for various reasons.

Neither worn out nor discharged batteries

can supply the power necessary for

cranking. Thus the battery check becomes

the starting point for diagnosing electrical

system problems.

Because of vibration, corrosion,

temperature changes or damage, the

performance of wiring, connections, and

secondary components as well as the

function of the starter and alternator can

deteriorate. This in turn can cause

malfunctions within the starting andcharging systems. For the purpose of

testing, wiring and components are broken

down into four circuits that must be tested.

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BG825 A38

Cranking Circuit

This consists of the large cables that carrythe high starter current. Excessive losshere causes slow cranking speeds,especially in cold weather. Inability to startfrom slow cranking can lead to starterburn-up if the starter is cranked over 30seconds. Deeply discharged or worn-outbatteries can also cause the sameproblem.

Solenoid Circui t.

This consists of the wiring from the battery,through a push button or magnetic switch,to the “S” terminal of the starter solenoid,and back to the battery. Excessive losshere can cause the solenoid to shift in andout (chatter) resulting in a no startcondition. This can cause a burnedcontact disc and terminals of the startersolenoid. Deeply discharged batteries canalso cause this problem.

Magnetic Switch Circuit

(When Magnetic Switch Used). This ismade up of the wiring from the batterythrough a key switch and/or start button tothe coil of the magnetic switch and back tothe battery. Excessive loss here can

cause a “no start” complaint.

Charging Circuit.

This consists of the wiring between the

alternator and the battery and back to the

alternator. Excessive loss here can cause

the batteries to not charge properly. As

noted above, discharged batteries will

cause other problems.

3.14. CARE OF THE BATTERY

When handling a battery, the following

safety precautions should be followed

Hydrogen gas is produced by the

battery.

A flame or spark near the battery may

cause the gas to ignite.

Battery fluid is highly acidic.

Avoid spilling on clothing or other fabric.

Any spilled electrolyte should be flushed

with large quantity of water and cleaned

immediately.

To remove or replace a battery, alwaysdisconnect the cable first, then the positive

cable. After installing battery, connect

battery cables and make sure to properly

tighten all terminals.

Keep the battery cable connections

clean.

The cable connections, particularly at the

positive (+) terminal post, tend to become

corroded. The product of corrosion, or

rust, on the mating faces of conductorsresists the flow of current. The inability of

the starter motor to crank the engine is

often due to the rust formation in the

battery cable connection. Clean the

terminals and fittings periodically to ensure

good metal-to-metal contact, and grease

the connections after each cleaning to

protect them against rusting.

Be always in the know as to state of

charge of the battery.

The simplest way to tell the state of

charge is to carry out a hydrometer test.

The hydrometer is an inexpensive

instrument for measuring the specific

gravity (S.G.) of the battery electrolyte.

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BG825 A39

Why measure the S.G.?

Because the S.G. of the electrolyte isindicative of the state of the charge. Thedirect method of checking the battery forstate of charge is to carry out a high ratedischarged test, which involves a special

precise voltmeter, an expensiveinstrument used generally in the serviceshops but no recommendable to the userof the machine. At 20 degree centigrade ofbattery temperature (electrolytetemperature).

The battery is in FULLY CHARGEDSTATE

if the electrolyte S.G. is 1.280.

The battery is in HALF CHARGEDSTATE

if the S.G. is 1.220.

The battery is in NEARLYDISCHARGED STATE

if the S.G. is 1.150 and is in danger offreezing.

The following information is basic in natureand is nothing new; it is merely a

reiteration of what every service shoppersonnel knows about the automotivestorage battery. The information isintended to serve as a reminder to thereader, with a hope that he will, in turn,reminded each final user of the importantbasic facts about the battery wheneveropportunity permits him to engage in aconversation with the final user in the shopor out of the shop.

The battery is a very reliable

component, but needs periodical

attentions. Keep the battery containerclean; prevent rust formation on the

terminal posts; keep the electrolyte up

to the upper level uniformly in all cells;

and try to keep the battery fully

charged at all times.

Preserve the capacity of the battery.

There is a limit to the ability of the

battery to hold electricity is store. This

limit is called “capacity”.

WAYS FOR THE BATTERY TO LOWER

IT'S CAPACITY

Loss of electrolyte, or fall in electrolyte

level.

When this happens, the battery cannot

hold so much electricity as it originally

could. Handle the battery with care when

you take it down. Barring the loss of

electrolyte by careless spilling or

otherwise, the electrolyte level goes down

gradually in the battery at work because

the water content of it evaporates.Periodically refill distilled water to each

cell, as necessary, so that the electrolyte

is always up to the specified level. Never

allow its surface to fall so much as to

expose the cell plates.

Overcharging the battery in place or off

the machine.

In recharging the battery off the machine,

caution must be exercised so as not to

overcharge it. Over charging give rise to

several complexities. For one thing, it

heats up the battery to deform the battery

container to result in a destroyed battery.

Overcharging could occur in a battery in

place if the voltage regulator is in mal

condition to allow the alternator (or

dynamo in other machines) to develop too

high an output voltage. For another thing,

“gassing” occurs in a battery being

overcharged to result in a loss of water

content. One of the most serious

consequences of overcharging is the

swelling of positive-plate grids, causing

the grids to crumble and the plates to

buckle.

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BG825 A40

Undercharging the battery in place.

Regulator malfunctioning is usually the

cause of the battery remaining in a state of

charge far below its capacity. This

condition is very undesirable in freezing

weather, for the electrolyte in such abattery can easily freeze up to result in a

destroyed battery. Moreover, an

undercharged battery is an easy prey to a

greater evil sulfation.

Sulfation

Let us recall the electrochemical reactions

that take place in the battery during

charging and discharging. As the battery

gives out its energy (discharging), the

active materials in its cell plates areconverted into lead sulfate.

During recharging, this lead sulfate is

reconverted into active material. If the

battery is allowed to stand for a long

period in discharged condition, the lead

sulphate becomes converted into a hard,

crystalline substance, which will not easily

turn back to the active material again

during the subsequent recharging.

“Sulfation” means the result as well as theprocess of that reaction. Such a battery

can be revived by very slow charging and

may be restored to usable condition but it

is a damaged battery and its capacity is

lower than before.

3.15. BATTERY AND CHARGINGSYSTEM

Located on the battery box, this warningdecal (WA 3101) stresses the need tokeep all spark producing materials awayfrom the battery. When another battery or24V DC power source is used for a jumpstart, all switches must be off prior tomaking any connections. Whenconnecting jumper cables, maintaincorrect polarity, connect positive poststogether and then connect the negativelead of the jumper cable to a good frameground.

Do not connect the negative posts ofthe vehicle batteries.

This hook up completes the circuit but

minimizes the danger of sparks near the

batteries.

Sulphuric acid is toxic and corrosive, use

proper safety gear - goggles, rubber glove

and rubber gloves when handling and

servicing batteries.

If sulphuric acid is spilled on the skin,

immediately flush the area with large

amount of running water for at least 15

minutes, and get medical attention at

once.

Counteract swallowing of acid by drinkinglarge amount of water or milk, followed

with mild of magnesia, beaten eggs or

vegetable oil. Get medical care promptly.

3.16. SERVICING BATTERY

Proper servicing will increase the life ofthe batteries. Checking electrolyte leveland cleaning are the two most importantitems in servicing.

Service the electrolyte level with distilled

water or water approved by the

manufacturer. Hard water will cause

mineral deposits on the cell plates and

decrease battery life. Add water until the

top of the plates are covered. Over filling

will weaken the battery electrolyte and

cause corrosion of battery connections.

Batteries can be cleaned by using soda

solution or ammonia, and rinsing with

clear water.

The decal for battery is pasted on thevehicle as follows:

When washing batteries, make sure

that cell caps are tight to prevent

cleaning solution from entering the

cells.

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BG825 A41

When installing the batteries, check all the

connections for corrosion. If corrosion is

present, clean the terminal or clamp and

apply coating of petroleum jelly to prevent

further corrosion.

3.17. RECHARGING BATTERIES

LEAD ACID BATTERIES

(RE-CHARGING)

1. Prior to operating battery charger,

make sure that leads are connected to

the corresponding terminals.

2. In case if the voltage is low or shelf life

is more than 60 day, then subject the

battery for refresh charging with the

help of battery charger @ 16

Volt/battery and 10% (1/10) rated

capacity of battery (AH) Charging

current . Example: for 100 Ah battery

charging voltage will be 16 Volts and

charging current will be 10% of AH- 10

Amps.

NOTE: During charging process

vent caps should be kept open for

venting and premises should beproperly ventilated.

3. A battery is consider fully charge when

its CCV (Closed circuit voltage)

reached 15.6 to 16.00 Volts and

Specific gravity of electrolyte

measuring 1.250 (±0.005).

4. All the cells of battery should gas

freely and three hourly consequently

reading shows constant reading ofvoltage and specific gravity.

5. Make sure the charging system of the

equipment to which battery is fitted

deliver required charging voltage (15

Volts-CCV) and charging current of

10% rated capacity of battery AH.

6. Continue charging till

a) The battery voltage reaches about15.8 to 16.6 volts.

b) All the cells are gassing freely.

c) The voltage and specific gravityreadings remain constant for 3consecutive hours.

Once the battery has been fully

recharged, the specific gravity of the

electrolyte should be 1.250 + 0.005 @

27 Deg. C.

7. If the specific gravity is lower than that

specified above, adjustment should be

made by removing the requisitequantity of acid form the cell and

replacing with acid of 1.300 specific

gravity. If the specific gravity is higher

that the specified value, requisite

quantity of acid should be removed

and replaced with distilled water. The

battery should then be given a charge

of 2 to 3 hours to allow the electrolyte

to mix thoroughly. This adjustment

should be done only in a cell which

gasses freely on charge.

8. Once the battery is fully recharged and

the specific gravity adjusted, switch off

the charger. Fix the vent plugs tight

and wash the battery with plenty of tap

water. Wipe the battery with clean

cotton waste and smear the terminals

with petroleum jelly/Vaseline.

9. In case the battery has been subject to

a very deep discharge (specific gravity

absolutely zero), then the battery

should be drained completely and

filled with electrolyte of 1.150 specific

gravity it should then be charged at

50% of the recommended charging

current for 3 to 4 days and then

increased to 100% charging should be

continued till the conditions as per

point no. 2 above are met. The specific

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BG825 A42

gravity will be above 1.250 and this

should be adjusted to 1.250.

10. It should be ensured that the

electrolyte temperature does not

exceed 50 Deg C during charging at

which time charging should be

discontinued and temperature allowed

to drop to 40 Deg C.

NOTE : The time of recharge

is solely dependent on State of Charge

and State of Health of battery.

DO Not Smoke or allow open flame

around a battery or during re-charging!

DO Not attempt to charge a frozen

battery, Serious Injuries may occur!

Precaution dur ing Charging

1. Use Rubber gloves while handlingsulphuric acid.

2. On body contact with acid, use watergenerously and contact a physician ifnecessary.

3. Keep constant watch on thetemperature of electrolyte and reducecharging current if temperaturecrosses 50⁰C.

Prior to operating battery charger, makesure that leads are connected to thecorresponding terminals, and remove cellcaps to dissipate any gas accumulation.The battery charging system process can

be monitored by checking specific gravity.To check specific gravity level of a cell,use Hydrometer.

Specific gravity reading of 1.270 to 1.215

@ 27 degree centigrade indicates that

battery is fully charged. A reading below

1.215 @ 27 degree centigrade is

considered as uncharged and is

unsatisfactory for use.

Note: The specific gravity reading will vary

with ambient temperature, and may needcorrection. Correction can be made by

adding 4 gravity points for every 3.4

degree centigrade or by subtracting 4

gravity for every 3.4 degree centigrade

below 27 degree centigrade.

A voltage reading may also be taken

across each of the individual cells. The

voltage reading across each individual cell

should be approximately 24 V DC.

SEQUENCE OF PROCEDURES

It is important that the procedures in the

manual be followed in the exact sequence

specified. Batteries, wiring and

connections should be checked and

corrected to the specifications given. If

cranking problems still occur, then

connecting cables should be checked

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BG825 A43

before replacing the starter with a known

good unit. Similarly, in the charging circuit,

batteries wiring and connections should be

thoroughly checked and corrected to the

specifications given. Only then should the

alternator be checked and replaced if

necessary.

NOTES :

The use of digital voltmeters is highly

recommended for the following reasons:

Digital voltmeters are generally more

accurate than analog (needle

movement) instruments.

Digital readings need no interpretation;

everyone sees the same number.

Digital instruments are generally auto

ranging; they automatically select the

proper range for the value of the

reading

Reversing polarity with a digital

instrument will simply result in a

negative reading (minus sign) whereas

with an analog voltmeter, reversing

polarity could damage the meter.

If analog meters are not read directly

facing the meter, inaccuracies may

result.

3.18. STARTER MOTOR

Diagnostic - Fault finding chart

Chart - 1 @ STARTER MOTORINACTIVE

The solenoid valve cannot be heardclicking.

NOTES :

Check

– The condition and voltage of thebattery

– The condition of the batterywiring and terminals

– The condition of the earth straps

– The condition of the power fuse (iffitted).

Repair or replace the faulty

components, if necessary.

– Check the presence and the conditionof the fuses.

Replace if necessary.

– Check, on the starter motor, theconnection and the condition of thecontrol terminal.

Repair if necessary.

– Check, with the ignition on, that theimmobilizer is inactive.

In the event of a problem, use theimmobilizer fault finding procedure.

– Check, using an ammeter that thevehicle's consumers have not short-circuited.

If there is a problem, carry out a faultsearch (damaged wiring, relayssticking, etc.).

– Check, with the ignition on and withthe starter motor operational, for thepresence +24 Volts on the startermotor control line.

If not correct:

If the vehicle is fitted with a circuitbreaker or additional alarm:

– Check if it is acting on the startermotor control line.

– Check the insulation and condition ofthe connections with the circuitbreaker or the alarm.

– Ensure that these are both operatingcorrectly.

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BG825 A44

– Check if 12 Volts is present before theignition is switched off; replace thecircuit breaker or alarm.

If the model is controlled by the startermotor switch:

– Check the line between the switch andthe control terminal.

– Check that the rotary switch isoperating correctly.

– Check the supply to the rotary switch.

If the model is controlled by theimmobilizer:

– Check the line between the switch and

the control terminal.

– Carry out a fault finding procedure onthe immobilizer.

Repair or replace the faultycomponents, if necessary.

If everything is correct, replace thestarter motor.

AFTER REPAIR

– Check that the starter motor isoperating correctly.

CHART - 2 @ STARTER MOTORBLOCKED

The solenoid clicks, but the starter motordoes not run.

NOTES :

Check

– The condition, the voltage andconformity of the battery,

– The condition of the battery wiring and

terminals,

– The condition of the earth straps,

– The condition of the power fuse (if

fitted).

Check for the presence of + 24 volts at the

starter motor power terminal.

Repair or replace the faultycomponents, if necessary.

If not correct,

– Check the insulation and the continuityof the power line between the batteryand starter motor.


Put the vehicle in neutral (also neutralon automatic gearboxes) and try toturn the starter motor by hand.

If not correct, check

– If there is oil in the engine (seizure),

– The timing adjustment,

– That no auxiliary is slowing down themotor,

– That the gearbox and its control arenot faulty,

– That there are no objects which couldbe blocking the free movement of the

motor at the flywheel end,

– That the engine is not flooded and thatthere is no object (dropped valve...) inthe cylinders.


Check, using an ammeter that the

vehicle's consumers have not short-

circuited.

If there is a problem, carry out a fault

search (damaged wiring, sticking relays,

etc.).

If everything is correct, replace the starter

motor.

AFTER REPAIR

– Check that the starter motor isoperating correctly.

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BG825 A45

CHART - 3 @ UNDERPOWERED

STARTER MOTOR

The starter motor is not turning the engine

over quickly enough.

NOTES

Check

– The condition, the voltage andconformity of the battery,

– The condition of the battery wiring andterminals,



Repair or replace the faulty components, if

necessary.

Check, using an ammeter that the

vehicle's consumers have not short-

circuited.

If there is a problem, carry out a fault

search (stripped wiring, sticking relays,

etc.).

Check the insulation and continuity of thestarter motor power wiring to the battery.


Put the vehicle in neutral (also neutral on

automatic gearboxes) and try to turn the

starter motor by hand.

If not correct, check

– If there is oil and water in the engine(seizure),

– That no other auxiliary is slowing downthe motor (coolant pump, airconditioning compressor, etc.),

– The adjustment and condition (tensionwheel sticking...) of the timing system,

– That the gearbox and its control arenot faulty,

– That there are no objects which couldbe blocking the free movement of themotor at the flywheel end,

– That the engine is not flooded and thatthere is no object in the in the intakes,

– The valve clearances.


If everything is correct, remove the starter

motor and check for signs of wear.



motor.

CHART - 4 @ INTERMITTENT

OPERATION

The starter motor does not operate during

all the starting sequences.

NOTES

Check

– The condition, the conformity and thevoltage of the battery,

– The condition of the battery wiring and

terminals,




necessary.

Check that the immobilizer is not faulty

and that it becomes inactive each time the

ignition is switched on.

Perform a fault finding procedure on the

engine immobilizer system if necessary.

Check the condition and the connection of

starter motor control circuit terminal.


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BG825 A46

Check if the vehicle is fitted with circuit

breaker or an additional alarm.

Check they are working correctly.

Check the condition and insulation of

starter motor control circuit line.


Check that the starter motor switch is

operating correctly.

Repair or replace it, if necessary.

Connect the diagnostic tool and check

that the immobilizer is operating correctly

(vehicles with immobilizer controlling the

starter motor).

Perform a fault finding procedure on the

engine immobilizer system if necessary.

Remove the starter motor and check that

there are no bad contacts (contact brush).



motor.

CHART - 5 @ NOISY STARTER MOTOR

The noise is only present during the

starting phase and afterwards.

NOTES

Check

– The condition and voltage of thebattery,





necessary.

Check the mountings securing the starter

motor to the engine.

Reaffix if necessary.

Check the condition of the flywheel ring

gear.

Repair or replace it, if necessary.

Check the condition of the starter motor

drive pinion.

Check that the centering pin is present.

Replace the starter motor if necessary.

If the noise persists after starting:

– Check that the control circuit is no

longer being supplied.

If necessary, check the insulation of the

control line (short circuit to + 12 vol ts ), the

operation of the rotary switch and the

immobilizer (if the starter motor is

controlled by the engine immobilizer).

Repair the faulty components.

– Check that the solenoid is operating

correctly and the starter motor fork is

returning.

Replace the starter motor if necessary.

AFTER REPAIR

– Check that the starter motor is


CHART - 6 @ STARTER MOTOR

OVERHEATING

Odour / smoke coming from under the

bonnet during the starting sequence.

NOTES

Check

– The condition and voltage of thebattery,

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BG825 A47





necessary.

Check the condition of the starter motor:

– Label showing signs of peeling,

– Blue annealing at terminals,

– Wiring has melted,

– Paint melting / or odour of paint

melting.

Before replacing the starter motor, check

that there is no external cause for this

fault (water or oil leak from above, motor

seized or abnormally difficult to turn, short

circuit, etc.).

AFTER REPAIR

– Check that the starter motor is


The Primary Causes of Starting System

Malfunction:

Before discussing the preventive

maintenance and diagnostic procedures

for the starting system, we are going to

cover certain environmental and product

application factors that can cause the

starting system to malfunction.

Battery charge

A battery having a low / poor state of

charge will place abnormal stresses on

the starting system. When measuring

battery voltage, make sure voltage is 24 V

or greater.

Excessive heat

A starter motor can become damaged if it

operates too long at high temperatures.

Excessive heat is generally due to

continuous engagement of the starter.

Damage to starting system components

can occur when the starter motor is

cranked for long periods (often due to cold

weather starts etc.). Starter should

operate for 30 seconds maximum then let

to cool down for 2 minutes.

Excessive vibration.

If starting system components are poorly

or loosely mounted to the vehicle’s

engine, the resulting vibration can

damage sensitive internal components.

Corrosion , dirt, and dust.

Starting system components operate less

efficiently when corrosion forms or dirt

particles build up around wire and cable

connection points. Corroded and dirty

connection points impair the flow of

electrical current.

Defective solenoid.

If the starter fails to engage or fails to stayengaged, the pull-in or holding coil may be

defective, or the wiring to the solenoid is

bad. You need to check the wiring to the

solenoid. If the wiring is ok then the coil is

defective and you will have to replace the

solenoid.

Commutator Problems

Starter motors rely on commutators, or

switches that reverse the direction of

current between the external circuit and

rotor, to contact the motor's brushes and

generate electrical power. Commutators

can wear down over time, or accumulate

dirt or other sediment that can impede

operation. Cleaning or replacing the

commutator typically corrects the problem.

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BG825 A48

Worn Bearings

Motor bearings, or devices in a motor that

allow rotational movement between parts,

can also fail due to normal wear and tear.

Worn bearings can cause the armature, or

coil that generates electrical energy via a

magnetic field, to drag on the stator, or

stationary component of the motor,

resulting in a short circuit and starter

motor failure. Replacing the bearings

typically restores normal motor function.

Jammed Gear

A jammed Bendix gear, or gear used to

press into the flywheel ring gear to crank

the engine, often results in a "clunking"

noise when attempting to start the engine.The jammed Bendix gear, along with the

ring gear and, if damaged, the starter

motor, may need replacement to start the

engine.

Battery cable and its routing :

The battery cable connected to Starter

motor solenoid “B” point should be flexible

and tension should not be there on

terminal. If Battery cable connected withheavy tension on the terminal leads to

short circuit of terminal, since the terminal

comes out and touches to the solenoid

body. Also it leads to burnt of solenoid

terminal.

Preventive Maintenance Procedures:

The object of preventive maintenance is to

identify and correct potential problems

before they occur. There are two preventive maintenance

procedures that can greatly enhance the

efficiency of the starting system’s

functions.

These two procedures also represent the

initial steps one should take when fully

diagnosing (i.e. troubleshooting) a

problem in the vehicle’s starting system.

Engine operating condit ion.

Keeping the engine in good running

condition is essential to ensure efficient

operation of the starting system. Simplyput, an engine in poor condition is harder

to start, and this shortens the life of the

starter motor. An engine that starts easily

results in fewer turns of the starter motor,

and therefore, a longer life for the starter.

Wires and cables.

For any type of vehicle electrical system,

it‘s important to keep all connection points

clean. Road dirt and grease create

resistance that interferes with electrical

current flow. In order to get the necessary

power from a unit the size of a starter

motor, there must be little or no

resistance between the batteries and the

starter motor. In the same vein, one need

to make sure that wires and cables are

clean, properly tightened, and of the

proper size. Any loss of current due to

poor connections will reduce power of the

starter motor.

Clean all connections on a periodic basis.

Also check for tension on terminals due to

improper routing.

Employing the preventive maintenance

steps we've outlined will be extremely

beneficial to the starting system. There's

also another way to save oneself a lot of

time and wrench work:

Visually inspecting the starting system’s

components for signs of damage.

Diagnostic / Troubleshooting

Procedures

Timely preventive maintenance of the

starting system should keep it running

smoothly.

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BG825 A49

However, if the starter motor is cranking

slowly, or not at all, it’s time to diagnose

(i.e. Troubleshooting) the starting system.

Any discussion about the electrical system

must begin with the batteries. Before one

begin analyzing, the starting system, one

must be sure the batteries have been

properly tested and are at least 75%

charged. Otherwise, any electrical tests

conducting on the starting system will be

inaccurate.

One must also be aware that if the

batteries aren't being recharged, there

may be a problem in the charging system,

which will lead to starting system

problems Once verified that the batteries

and charging system are working, one canbegin testing the starting system.

When troubleshooting, you always want to

strive for the most easily obtainable

solution and progress toward the most

difficult problems to address.

And remember, when replacing

electrical equipment, always

disconnect all battery ground cables at

the batteries.

Ignition / Run switch test

Begin by determining whether the problem

is in the ignition switch, Safety relay and

associated wiring or if it’s in the solenoid

and starter motor.

We will begin with the ignition switch

circuit. Connect a voltmeter between the

4ST switch terminal of the starter solenoid

and ground see Figure below.

Have someone attempt to crank the

engine and record the voltage. You'll get

either no voltage, low voltage, or normal

voltage, with slow cranking or no cranking

at all.

IGNITION TEST

First, troubleshoot the switch circuit. You

can test it by connecting a remote start

switch between the battery positive and

the switch terminal on the starter solenoid.

When you close the switch, the starter

should engage and start the engine.

Again, record the voltage while cranking

and compare it to your first reading. A

difference of less than one volt is not

enough to indicate a problem. If there is a

difference of more than one volt, however,

then there is a problem in the switch

circuit.

Use the voltmeter to check each

connection, moving backward through theswitch circuit. If your first test of the

ignition switch had shown low voltage,

that may indicate a shorted starter motor,

which would have to repaired or replaced.

If the voltage in your first test was normal,

but there was slow cranking or no

cranking at all, that would indicate a

problem related to the batteries, battery

cables, or a damaged starter.

4ST Relay / Magnetic switch

The magnetic switch is a sealed unit and

not repairable. For testing of 4ST relay

Disconnect cables from the switch

terminals and wires from coil terminals.

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BG825 A50

Coil Test

Using an ohmmeter, measure the coil

resistance across the coil terminals.

The coil should read approximately

10-15 Ohms at 72°F (22.2° C).

If the ohm meter reads Infinity (∞), the

coil is open and the switch must be

replaced.

If the ohmmeter reads 0 Ohms, the

coil is shorted and the switch must be

replaced.

Place one of the ohmmeter probes on a

coil terminal and another on the switch

Mounting bracket. If the meter displays

any resistance reading, the coil isgrounded and the switch must be

replaced.

The ohmmeter should display ¥ when

the probes are placed across the

switch terminals.

NOTE

The switch terminals should show

continuity when 24 VDC is applied to the

coil terminals, however high resistanceacross the internal switch contacts due to

arcing etc. could prevent the switch from

delivering adequate current to the

cranking motor. If the coil tests are

satisfactory but the switch is still suspect,

it should be replaced with a new part.

Solenoid test

Although the reasons for low voltage or

normal voltage with slow cranking are

different, the procedures for locating the

problem area are the same. If the solenoid

clicks but the motor won’t turn, it means

current is flowing through the solenoid

coils but not through the main contacts.

Connect the voltmeter to the motor

terminal of the solenoid as per the figure

below .

If there's no voltage from the motor

terminal to ground (when the solenoid is

activated), that indicates the disc isn't

making contact with the terminals. The

solution is to repair or replace the

solenoid.

Starter motor test

If voltage is present at the solenoid motor

terminal, then the problem is the starter

motor or its cabling.

SOLENOID TEST

If your original test of the ignition (or run)

switch indicated normal voltage, but slow

or no cranking, your next step is to check

the motor system and its connections.

If the drive pinion keeps shifting out of

mesh with the flywheel, then check for a

broken or a loose external ground wire on

the solenoid. Replace a broken wire or

reattach a loose one.

Measure the amp draw with ammeter in

either the positive, see figure below , or

ground cable, see figure below , of the

starter motor while pressing the start

switch. If the amp draw is excessive,

according to the manufactures

specifications, then the starter motor is

faulty. Slow cranking or high current draw

can also indicate that bushings are worn

because of an off-center armature.

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BG825 A51

Worn bushings and / or and off-center

armature cause poling and throw off the

alignment of the magnetic fields. But,

before you replace the starter, check the

condition of the engine to make sure it

turns freely. An engine in poor condition

could cause the starter to work harder orlonger. In other words, the starter may not

be the problem. It may be damaged by the

engine’s poor condition.

STARTER MOTOR TEST, POSITIVECABLE

STARTER MOTOR TEST, NEGATIVE

CABLE

Voltage drop test

Sluggish cranking may be caused by a

very small amount of extra resistance in

the circuit. This may come from dirty

connections or bad or broken cables. With

the voltage drop test, you first must check

the starter’s positive terminals, then the

negative terminals.

Positive cable test

Connect voltmeter, ammeter, and carbon

pile tester as per figure below . Adjust a

carbon pile load tester until ammeterreads 500 amps through to the meter.

Note the voltage reading. On 12-volt

system, voltage drop should not exceed0

.4 volts. On a 24 volt system, voltage drop

should not exceed 1 volt. Turn off carbon

pile tester when test is complete.

POSITIVE CABLE TEST

Negative cable test

Connect voltmeter, ammeter, and carbon

pile load tester as per figure below. Adjust

carbon pile load tester until ammeter

reads 500 amps. Note the voltage

reading. On 12- volt system, voltage drop

should not exceed .4 volts. On a 24 volt

system, voltage drop should not exceed 1

volt. Turn off carbon pile tester when test

is complete.

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BG825 A52

NEGATIVE CABLE TEST

Solenoid voltage drop test

The final check takes place at the

solenoid terminal. And for this test, you

must crank the engine. Disconnect the

carbon pile load tester, voltmeter (if

applicable), and ammeter so that none of

the testing equipment will be damaged by

the test procedure. An auto ranging digital

voltmeter is useful in this case, as full

battery voltage appears across the

solenoid terminals before they close.

Connect voltmeter as per figure below.Crank the engine and note the voltage

reading. No more than two-tenths voltage

drop should exist between the solenoid

contacts.

SOLENOID VOLTAGE DROP TEST

The voltage readings from the three tests

(Positive and Negative cable tests and

Solenoid voltage drop test) must not add

up to more than one volt for a 12 volt

system or 2.5 volts for a 24 volt system.

If the voltage drop is more than allowable,

check the cables and connections. To be

sure the problem is actually a bad cable,

do the voltage drop test over again using

a jumper cable to parallel the original

cable. If the voltage drop is acceptable,

then you know the cable is the problem.

One final note: There are many variations

of grounding the starter circuit. Some

vehicles have a ground cable for the

battery and another ground cable for the

starter motor. Both attach to the frame.

When doing a voltage drop test, you mustcheck all cables regardless of the circuit.

Starter Replacement

In the event that all of the diagnostic /

troubleshooting procedures point to a

faulty starter, you'll need to replace your

unit with a new starter.

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BG825 A53

4. INSTRUMENTS ANDCONTROLS

CONTROL LEVERS ANDPEDALS

4.1 WORK EQUIPMENT CONTROL

LEVER

Control levers operate the workequipment.

Details are as shown in the Figure 4.1. asfollows:

FIGURE 4.1. CONTROL LEVERS

1. Left blade lift lever

2. Ripper lift lever

3. Blade side shift lever

4. Power tilt control lever

5. Blade rotation control lever

6. Drawbar side shift lever

7. Articulation control lever

8. Leaning lever

9. Scarified life lever

10. Right blade lift lever

4.2 STEERING WHEEL TILT LEVER

This lever is used to tilt the steering wheeland instrument panel forward orbackward.

Turn the lever to the left to release thelock, move the steering wheel to ehdesired position, then tighten the lever to

lock in position.

The steering wheel can be adjusted freelyto 20 degrees.

Always stop the machine beforeadjusting the angle of the steeringwheel.

4.3 STEERING POST TILT PEDAL

Depress the pedal and the steering postcan be tilted.

Adjust to give a suitable operating positionfor your physique.


FIGURE 4.3. STEERING POST TILT

PEDAL

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BG825 A54

4.4 WORK EQUIPMENT CONTROLLEVER SAFETY LOCK

This is locking mechanism for controllevers.

Mechanical lever lock is shown in the

Figure 4.4. as follows.

FIGURE 4.4. CONTROL LEVER SAFETY

LOCK

4.5 FUEL CONTROL LEVER

This adjusts the engine speed and output.

Engine stop:Lever at S position

Low idling:

Pull lever from S position to positionwhere operating force changes.

High idling:

Lever at F position

Fuel control lever (1) is shown in the

Figure 4.5. as follows.

FIGURE 4.5. FUEL CONTROL LEVER

4.6 GEAR SHIFT LEVER (&PARKING BRAKE)

This lever is used to change thetransmission gear.

There are eight gears forward and

reverse, so place the gear shift lever in

the desired position to shift gear.

When the lever is put in the 'P' position,

the parking brake applied.

The button on the lever need only be

pressed when shifting the following

positions:

(BOTH FORWARD AND REVERSE).

When starting the engine, the engine will

not start if the gear shift lever is not in theP position.

The parking brake does not work unless

the staring switch at ON.

Gear shift lever (1) is shown in the Figure

4.6. as follows

P N N P

5 7 6 6

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BG825 A56

Do not put your foot on this pedalunnecessarily.

4.9 ACCELERATOR PEDAL

This pedal is interconnected with the fuel

control lever. Therefore, the engine is

easily controlled from low idling to full

running by means of the accelerator

pedal, with the fuel control lever held at

low idling position. If the pedal is raised

from low idling position, the engine will

stop.


FIGURE 4.9. ACCELERATOR PEDAL

4.10 DUST INDICATOR

This device indicates clogging of the aircleaner element. When red piston (1)

appears in the transparent part of this

indicator, the element is clogged.

Immediately clean element.

After cleaning, push indicator button (2) to

return red piston to original position.

Details are as shown in the Figure 4.10.

as follows:

FIGURE 4.10. DUST INDICATOR

4.11 ARTICULATE LOCK PIN

This pin is used to lock the front frame

and rear frame to prevent the machine

from bending when servicing or

transporting the machine.


as follows:

FIGURE 4.11. ARTICULATE LOCK PIN

When servicing or transporting themachine always use this lock pin.

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BG825 A57

For normal t raveling, always removethe lock pin.

4.12 OPERATOR’S SEAT

Adjust the seat position at the beginning

of each shift or when operators change.

Adjust the seat so that the brake pedal

can be depressed all the way with the

operator's back against the back rest.

A: Seat height adjustment

To LOWER seat, turn lever (1) to RIGHT.

To RAISE seat, turn lever (1) to LEFT.

Range of adjustment: 75 mm

B: Forward-backward adjustment

Move lever (2) to the left set the seat in

the desired position, then release thelever.

Range of adjustment:

140 mm (7stages)

C: Seat cushion adjustment

Turn knob (3) to make the seat

comfortable and match your weight.

For LIGHT weight, turn to RIGHT.

For HEAVY weight, turn to LEFT.

D: Seat angle adjustment

Move lever (4) up and push back to adjust

seat angle (2 stages).

E: Backrest adjustment

Pull lever (5), set backrest to desired

position, then release lever.

Adjustment range: 4 stages

Details are as shown in the Figure 4.12.as follows:

FIGURE 4.12. OPERATOR'S SEAT

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BG825 A58

4.13 MCB

The MCB protect the electric devices and

wiring from burning out.


as follows:

FIGURE 4.13. MCB

Replace a fuse with another of the samecapacity.

Before replacing a fuse, be sure to turnoff the starting switch.

The Circuit breaker decal with rating isshown below Figure 4.13.a

FIGURE 4.13. CIRCUIT BRAKER

DECAL

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BG825 A59

5. CHECK BEFORE STARTING

The check before starting shall never

be neglected as troubles are prevented

before hand by the check.

Walk around the machine body andcheck whether there is any trace ofleakage of oil or water. In particular,the joint of high pressure hose andhydraulic cylinder should be paidspecial attention.

In case leakage is found, inspect theleaking location and stop the leakage.When leakage is not stopped, you arerequest to contact BEML servicepersonnel.

Inspect the tightening of bolts and nutson every section. When loosenedones are found, apply increasedtightening. In particular, attachmentpositions of air cleaner and mufflershould be paid special attention.

5.1 CHECK AND REFILLCOOLANT

Remove radiator cap (1) at the top rear of

the machine and check that the cooling

water reaches the area marked by shaded

lines. Add water if necessary.

If volume of coolant added is more than

usual, check for possible water leakage.

Details are as shown in the Figure 5.1. as

follows:

FIGURE 5.1. REFILL COOLANT

Do not remove the cap while coolingwater is hot, hot water may spout out.

When removing the radiator cap, liftthe lever to relieve inner pressure

5.2 CHECK AND REFILL FUELTANK

Use fuel gauge to check the fuellevel.

Top up the tank through the filler afterthe day’s work is over.

A clogged cap breather hole may stopthe fuel flow to the engine.

Check it from time to time and clean.

Fuel capacity : 500 lts


follows:

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FIGURE 5.2. REFILL FUEL TANK

When adding fuel, never let the fueloverflow. This may cause a fire.

5.3 DRAIN WATER AND SEDIMENTIN FUEL TANK

Loosen fuel tank drain valve and drain

sediment and water accumulated at the

bottom, together with fuel.

5.4 DRAIN WATER FROM AIR TANK

Open drain plugs to drain water afterstopping the engine.

For machines with auto drain valveDepress the brake pedal several timesand the water in the drain valve will bedrained.


follows:

FIGURE 5.4. DRAIN WATER FROM AIRTANK

5.5 CHECK OIL LEVEL IN ENGINEOIL PAN

Use dipstick to check the oil level.

The oil level should be between markL and H. If necessary, add oil at oilfiller (F) .


follows:

FIGURE 5.5. OIL LEVEL IN ENGINE OIL

PAN

F

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The type of lubricant used depends on

the ambient temperature. Select

according to table “FUEL, COOLANT

AND LUBRICANTS".

When checking the oil level, park the

machine on a level surface, stop theengine and waits for 15 minutes

before checking.

5.6 CHECK ELECTRICAL WIRING

Check for damage of the fuse and anysign of disconnection of short circuit in theelectric wiring. Check also for looseterminals and tighten any loose parts.

Check the following points carefully.

Battery Starting motor

Alternator

If the fuse is damaged or there is anysign of short circuiting in the electricwiring, always, investigate the causeand correct it.

Contact your BEML service personnel forinvestigation and correction of the cause.

5.7 CHECK DUST INDICATOR

When air cleaner element is clogged, the

red piston of dust indicator (1) reaches

service level and gets locked.


follows:

FIGURE 5.7. CHECK DUST INDICATOR

In that case, clean element referring to the

section “WHEN REQUIRED”.

After cleaning element, push button to

return red piston.

5.8 CHECK AND ADJUST TIRE

PRESSURE

Standard pressure

Front wheel : 40 PSI ( 2.81 kg/cm2 )Rear wheel : 40 PSI ( 2.81 kg/cm2 )

Make sure that tire and rim is free fromwear and damage, and that hub nuts arenot loose.

5.9 CHECK AND ADJUSTSTEERING WHEEL

When checking steering wheel play, start

engine and raise front wheels off ground.

The standard steering wheel play is 10 to

12 mm. If the play is beyond standard or

steering is abnormal, contact your BEML

service personnel.

FIGURE 5.9. CHECK AND ADJUST

STEERING WHEEL

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5.10 IS RISE IN AIR PRESSURENORMAL?

When the pressure inside the air tank is 0,

and air is charged, the time taken for the

air pressure indicator to reach the green

range should be as follows.

Engine low idling: Approx. 3 minutes

Engine full: Within 1.5 minutes

5.11 OTHER CHECK POINTS

CHECK LAMPS FOR SWITCHING,DIRT AND DAMAGE.

CHECK REAR VIEW MIRROR FORPOSITIONING, DIRT AND DAMAGE.

CHECK FOR DIRT AND DAMAGEON REFLECTOR

CHECK HORN

IS THE COLOR OF EXHAUSTGAS NORMAL

DO THE INSTRUMENTSFUNCTION NORMALLY?

HAVE ANY DEFECTS WHICH WEREFOUND DURING THE PREVIOUSDAY’S OPERATION BEENCORRECTED?

CHECK THE DOOR LOCK FORNORMAL FUNCTION.

5.12 CHECK THE WINDSHIELDWIPER, WINDOW WASHER ANDDEFROSTER FOR NORMALFUNCTION. CHECK FORSUFFICIENT WASHER FLUIDLEVEL.

If the windshield washer fluid level is

low, add fluid through cap (1).

FIGURE 5.12. WINDSHIELD WASHER

5.13 CHECK FOR SEDIMENT ANDWATER IN THE WATERSEPARATOR

The water separator separates water

mixed in the fuel. If float (2) is at or above

red line (1), drain the water.

FIGURE 5.12. WATER SEPARATOR

For the draining procedure, see section

“WHEN REQUIRED”

Check the fuel tank to remove water

and sediment in the fuel.

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6. OPERATING YOUR MACHINE

6.1 BEFORE STARTING THE

ENGINE

• Before starting the engine, check theposition of all levers.

• Carry out an initial inspection.(Fordetails of the inspection see CHECKBEFORE STARING.)

• Is gear shift lever (parking brake) (1)In the PARKING position and locked?

• Engine will not start unless gear shiftLever is in PARKING.

• Are work equipment control levers (2)at the neutral (HOLD) position and

locked with the safety lock?


FIGURE 6.1. CHECKS BEFORE

STARTING ENGINE

6.2 TO START THE ENGINE

• Set fuel control lever (1) at the HALFOPEN position.

• To start the engine, put the key (2) tothe START position and turn over thestarting motor.

• As soon as the engine starts. Releasethe starting switch key (2) to allow it toreturn automatically to ON position.


FIGURE 6.2. TO START ENGINE

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Do not leave key in START for morethan 20 seconds.

If engine will not start, repeat thestarting procedure after about 2minutes.

To start engine in cold weather refer toCOLD WEATHER OPERATION.

6.2.1 SPECIAL STARTING

When starting after running out of fuel, fill

with fuel, then bleed the air from the fuel

system before starting.

6.3 CHECK AFTER STARTING

After starting the engine, do not operatethe machine immediately. First carry out

the following operations and checks.

Pull the fuel control lever (1) and runthe engine at mid range speed forabout 5 minutes with no load.

Details shown in the Figure 6.3. below

FIGURE 6.3. CHECK AFTER STARTING

After warm-up run is completed, checkengine water temperature gauge,engine oil pressure gauge and airpressure gauge for proper operation.

Run engine with light load until enginewater temperature gauge indicatormoves into green range.

Check for normal coloration ofexhaust, any abnormal sound orvibration.

Avoid sudden acceleration of the

engine until the warming up operation

is completed.

Do not run the engine at low idling or

high idling for more than 20 minutes. If

it is necessary to run the engine atidling, apply a load from time to time or

raise the engine speed to a midrange

speed.

6.4 TO STOP THE ENGINE

Idle the engine at low speed for about

5 minutes to cool it.

Set fuel control lever (1) to the STOP

position to stop the engine.

It is also possible to release the

accelerator pedal to “STOP” position and

stop the engine.

Return the starting switch (2) to the

OFF position, and withdraw the key.


FIGURE 6.4. TO STOP THE ENGINE

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Do not attempt to stop a hot engineimmediately unless it is necessary.Such unreasonable operation willreduce the life span of the variousengine parts.

Specially when stopping anoverheated engine, be sure to cool theengine gradually by idling it at amiddle idling speed.

6.5 TO MOVE THE MACHINE OFF

Free safety lock of work equipment

levers and bring the work equipment in

the traveling posture.

Depress inching pedal (1) and set

gear shift lever (2) to 1st, 2nd and 3rd

speed.

Release inching pedal (1), depressaccelerator pedal (3), and the machinewill start.

When starting the machine, check thatthe air pressure monitor is OFF.


FIGURE 6.5. TO MOVE THE M/C OFF

6.6 CHANGING GEAR SPEED

Acceleration

Partially release the accelerator pedal

(1) and shift the gear shift lever (2) tothe next stepped-up position.

Deceleration

Release accelerator pedal (1) to

decrease traveling speed and shift

gear shift lever (2) to the next stepped-

down position. When shifting gear,

always shift one speed at a time.

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FIGURE 6.6. CHANGING GEAR SPEED

6.7 FORWARD-REVERSE SHIFTING

Always stop the machine when switchingbetween FORWARD and REVERSE.

Depress brake pedal (1) to reduce the

travel speed, then depress inching

pedal (2) to stop the machine.

Set gear shift lever (3) to the desired

position, then depress accelerator

pedal (4) while slowly releasing

inching pedal (2) to start the machine.


FIGURE 6.7. FORWARD REVERSE

SHIFTING

6.8 TURNING

The grader turns to the desired side byturning the steering wheel (1) to that side.


FIGURE 6.8. TURNING

Leaning to the turning side will minimizethe turning radius. In case the graderturns while reversing, leaning to theopposite of the turning side will minimizethe turning radius.

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6.9 TO STOP THE MACHINE ( INEQPT RUNNING CONDITION )

• Release the accelerator pedal (1)

• Depress the brake pedal (2). Beforethe machine come to a stop, depressthe inching pedal (3).


FIGURE 6.9. STOPPING THE M/C

• Place gear shift (parking brake) leverat the P position to apply the parkingbrake.

• Lock safety lock for work equipmentlevers.

• Stop the machine on hard and evenground to prevent it from falling downor slipping.

6.10 CAUTIONS FOR OPERATINGHILLS

When traveling downhill, use the samegear as when going up the hill, and usethe engine as a brake. If the travel speedis still too fast, use the foot brake as

necessary.

6.11 SLOPES, STEEP HILLS

When the engine comes to a stop duringuphill or downhill traveling.

Depress the brake pedal to stop themachine.

Return the gear shift lever (parking brake)to the parking P position and start theengine.

This machine has two brake controlsystems. If one breaks down the otheris still effective. However becausebraking capacity is reduced driveslowly when traveling.

Use the parking brake as necessary tocompensate insufficient effect of thewheel brake.

Do not shift gear or place thetransmission in neutral when goingdownhill. The braking effect of theengine cannot be used, so this isdangerous. Always keep the gear shiftlever in a travel position when goingdownhill. Failure to do this may resultin engine overrun and damage to theengine or transmission. To preventengine overrun, always shift down onegear at a time.

6.12 PRECAUTIONS WHENSTOPPING OR PARKINGMACHINE

When stopping or parking, pay attention tothe following points.

Stop the machine on firm level ground in asafe place where there is no danger fromfalling rocks, landslips or floods. Lower the

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work equipment to the ground, place allcontrol levers in NEUTRAL or HOLD andlock in place.

7. COLD WEATHEROPERATION

7.1 PREPARATION FOR LOWTEMPERATURE

If the temperature becomes low, itbecomes difficult to start the engine, andthe coolant may freeze, so do as follows.

7.2 FUEL AND LUBRICANTS

Change fuel and oil with low viscosity forall systems.

For details of the specified viscosity, see

the

TABLE OF FUEL, COOLANT ANDLUBRICANTS.

7.3 COOLANT

After cleaning inside of the coolingsystem, add antifreeze to the coolant toprevent the coolant from freezing whenthe machine is not being used.

For details of the antifreeze mixture

when changing the coolant, see whenREQUIRED.

Care in using Antif reeze

Use a permanent Anti freeze (ethyleneglycol mixed with corrosion inhibitor,antifoam agent, etc.) meeting the standardrequirements as shown below.

With permanent antifreeze, no change ofcoolant is required for a year. If it isdoubtful that available antifreeze meetsthe standard requirements, ask thesupplier of that antifreeze for information.Standard requirements for permanentantifreeze

SAE……………………………......….J1034

FEDERAL STANDARD……………………O-A-548D

Never use methanol, ethanol orpropanol based antifreeze.

Where no permanent antifreeze isavailable, an ethylene glycol antifreezewithout corrosion inhibitor may beused only for the cold season. In this

case, clean the cooling system twice ayear (in spring and autumn). Whenrefilling the cooling system, addantifreeze in autumn, but do not addany in spring.

Absolutely avoid using any water leakpreventing agent irrespective ofwhether it is used independently ormixed with antifreeze.

Do not mix one antifreeze with adifferent brand.

Anti freeze is flammable, so keep itaway from any flame.

7.4 BATTERY

As ambient temperature drops, batterycapacity will drop, and electrolyte maysometimes freeze if battery charge is low.

Maintain battery at a charge level ofapprox. 100% and insulate it against coldtemperature so that machine can bereadily started the next morning.

Measure specific gravity of fluid andobtain rate of charge from the followingconversion table:

Temp ofFluid /Rate ofCharge

200C 0

0C -10

0C - 20

0C

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

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.

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To avoid gas explosions, do not bringfire or sparks near the battery.

If the electrolyte gets on your skin orclothes, immediately wash with plentyof clean water.

7.5 STARTING IN COLD WEATHER

For attention of engine starting, refer tosection “OPERATING YOUR MACHINE”

7.5.1 TO START THE ENGINE

Set fuel control lever (1) at the HALFOPEN position.

Place starting key (2) in HEAT positionto flash preheating monitor (3).

Details shown in the Figure 7.5.1 below

FIGURE 7.5.1 STARTING THE M/C IN

COLD WEATHER

Necessary preheating time is as follows.

Ambient temperature Preheat time

Above 0 deg cent -

0 deg cent to -10 deg cent 20 seconds

-10 deg cent to -20 deg cent 30 seconds

If the preheating time is too short ortoo long, the engine will be difficult tostart, so always keep to the correctpreheating time.

When preheating monitor (3) goes off,

turn the key (2) to START position tostart engine.

When the engine starts, turn key (2) tothe ON position. (When releasing key,

the key will return automatically toON.)

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Put the fuel control lever (1) in LOWIDLING position.

If the engine does not start up despitecarrying out the above operations,leave it for about 2 minutes and thenrepeat the above procedure 2 and 3.

Once the engine starts up, thoroughlywarm up the engine before putting themachine into operation. Initially, put

the gear shift lever in the lowestposition, and then gradually apply theload.

Never use starting aid fluids as theymay cause explosions.

8. CAUTIONS AFTERCOMPLETION OF WORK

Mud and water attached on the

machine.

Mud can easily be removed soon after

it has adhered to the machine Dried or

frozen mud will not only become

difficult to remove, but also cause

various defects.

In particular, water drops collected on

the surface of the piston rod of the

hydraulic cylinder shall be fully wiped

out. When water drops is frozen on the

surface of the piston rod, the seal may

be broken.

When washing the machine, be

careful not to throw water on the

alternator and breathers.

Drain water collected in fuel system sothat such water may be frozen atnight.

As battery capacity drops at lowambient temperature, cover thebattery or remove it from the machine

to be kept warm at night.

(In a machine equipped with autodrain)

Depress the brake pedal to purge the

air out of the air system. The brake

pedal may be depressed and released

several times to completely purge the

air.

9. AFTER COLD WEATHER

When weather becomes warm, perform

the following without fail :

Replace lubricating oils for various units

with the ones specified for warm-weather

use.

If for any reason permanent antifreeze

can't be used, and an ethyl glycol base

antifreeze (winter, one season type) is

used instead, or if no antifreeze is used,

drain the cooling system completely, then

clean the inside of the cooling system

thoroughly, and fill with ACF.

10. WORKS TO BE CARRIEDOUT BY A MOTOR GRADER

Land Grading (Figure 10.1.)

To level-finish the scraped or turned

up ground, drive the machine in 1st to

2nd with the blade kept at a givenlevel approx. to the ground. The

scraping angle is set at the standard

angle of 36deg. Take care not to run

over the banking to avoid the machine

pitching, otherwise uneven scraping of

the road face occurs and traction

power will be decreased.

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FIGURE 10.1.

Repairing of Gravel Road (Figure10.2.)

When repairing a gravel road, lowerthe blade so that it can just touchesthe surface of the road and drives thegrader in 1st to 2nd speed range. Although it is desirable that the

repairing operation should be finishedby a minimum cycle times of travel,travelling too fast speed may causerough finishing of the road.

FIGURE 10.2.

Snow removing (Figure 10.3.)

In the case of fresh snow, set theblade at the appropriate propulsionangle and drive the machine withenough high speed (3rd or 4th gear) asa throw aside the snow.

In case of heavy or a thick layer ofsnow, drive the machine in 1st or 2nd

gear. The scarifier can also be usedfor turning up the snow. The snow inthrown to one side of the machine

In cases of extremely heavy snow, thesnow plow attachment (optional) ismore effective

Take enough caution to obstaclescovered under the snow.

FIGURE 10.3.

Scarifying (With Scarifier - Option- Attached) (Figure 10.4.)

The scarifier (OP) is attached to breakup ground surfaces too hard to bepenetrated with the blade. In thisoperation, the scarifier is usuallydriven in 1st and 2nd speed range. Itis necessary for the teeth of thescarifier to penetrate deep into theground. If the number of the scarifierteeth is not adequate to penetrate theteeth deep into the ground, reduce the

teeth in number so as to allow properscarifying. (The number of the scarifierteeth must be 5 or more).

FIGURE 10.4.

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Mixing (Figure 10.5.)

The blade of the grader is available formixing up road construction materialsby its rolling function. In this operation,the grader should be driven in the 2ndand 3rd speed range with the blade

forward tilted and slightly angled. Toogreat a volume of mixing materialsmay prevent sufficient rolling of them.

FIGURE 10.5.

Spreading (Figure 10.6.)

The traveling speed of the grader ismost suitable in the 2nd to 3rd speedrange, with the blade sliding, as in the

spreading operation. Avoid changingits traveling direction unnecessarilylest the newly flattened surface will bedisturbed by the rear wheels of thegrader. Be careful that the materialsare spread to an adequate thickness.

FIGURE 10.6.

Ditching (Figure 10.7.)

Ditching should be in the 1st to 2ndspeed operation. The blade mustpositioned in such a manner that dugsoil is inside the rear wheels. Inaddition, be sure to remove the earth

heaped up under the chassis before itreaches the bottom of the machine,Lean the front wheels, correspondinglyto the tilt of the machine.

FIGURE 10.7.

Bank Cutting (Figure 10.8.)

Adjust the blade to the bank cuttingposition at the first speed range.

To allow the grader to run straight,lean the front wheels adequately forthe tilt.

FIGURE 10.8.

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11. JOBS EFFECTUATED WITHTHE ARTICULATED FRONTFRAME

The motor grader can be effectivelyapplied to the following jobs with thearticulated front frame.

When performing land leveling,repairing of gravel road or snowremoving operation on a narrow andsharply curved road, the 7.9 mreduced turning radius of the machineequipped with the articulated frontframe allows the operator to travel themachine easily.(Figure 11.1.)

FIGURE 11.1.

During land leveling, allowing the frontwheels to run on the previouslyleveled track adjacent to the trankbeing leveled is effective in minimizingthe vertical. Vibration of the machine,thus increasing the smoothness of thefinished ground surface. (Figure 11.2.)

FIGURE 11.2.

By concurrent use of blade side shiftand front wheel offset, road cornersare made easy for operations(with

leaned front wheels and articulatedfront frame). (Figure 11.3.)

FIGURE 11.3.

12. OPERATING OF WORKEQUIPMENT

12.1 OPERATION METHOD OF THEWORK EQUIPMENT CONTROLLEVER

There are provided ten work equipmentcontrol levers, which are operated as areindicated in the following figures. (Figure12.1.a. & 12.1.b.)

FIGURE 12.1.a.

When operating the work equipmentcontrol lever, sufficient attention isrequired for the movement of the workequipment and its movement range mustbe limited, as the work equipment or the

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hydraulic cylinder possibly hit againstparts, damaging them.

FIGURE 12.2.b

12.2 CAUTIONS IN OPERATION OFWORK EQUIPMENT

When the work equipment is operated,special attention should be given tocontacts at the following parts.

Front wheel and blade (Figure 12.2.a.)

FIGURE 12.2.a.

Rear wheel and blade (Figure 12.2.b.)

FIGURE 12.2.b.

Blade and step (Figure 12.2.c)

FIGURE 12.2.c.

13. ADJUSTMENT IN SHIFTING

OF WORK ATTACHMENT

It is essential to shift the work attachmentto an optimum position for each work, toallow high job efficiency.

13.1 BLADE PROJECTION

The degree of projection is controllable bythe control lever during operation. Iffurther projection is needed, stop thegrader for a while and change theinstalling position of the blade horizontal

shifting cylinder piston rod, as follows.(Figure 13.1.)

Projection to right Position (1)

FIGURE 13.1.

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13.2 PROPULSION ANGLE OFBLADE

Angle of blade and body center line iscalled the blade propulsion angle.

In the normal scraping work, set the angle

at 600 more or less. Set at a lesser anglewhen the scraping resistance is great, orwhen the soil is hard, or when the soil infront of the blade is difficult to carry orthrow to the side.

13.3 ADJUSTMENT OF BLADECUTTING ANGLE

This machine is equipped with a power tiltblade, so the blade cutting angle can bevaried freely in the following range.

Installation of this power tilt blade givesthe following advantages.

Optimum blade cutting angle can beobtained by operating the control leverfor soil quality.

Since the cutting edge can be set tothe desirable angle, a powerful

breaking is available to cut the frozensurface during snow removal.

If the blade is operated with thehydraulic tip control, the distancebetween the cutting edge and theexcavation surface changes. Thismeans that fine adjustment of theexcavation surface is possible.

In the low-banking position whenraising the dirt and snow, the optimumblade cutting angle can be selected toincrease operating efficiency.

13.4 BANK-CUTTING POSTURE(RIGHT SIDE)

Fully protrude the blade drawbar to the

right.

Place lifter lock switch in RETRACTposition on the operator’scompartment to remove pin .

If the pin cannot be removedbecause of interference with lifter ,operate the blade lift cylinders asnecessary.

Extend the right hand blade cylinderand retract the left hand cylinder,

rotate lifter, and move the bracket holeand pin apart.

Place lifter lock switch at the INDEXposition, turn lifter further and insertpin into the bracket hole.

When the pin has entered the hole, setlifter lock switch to the LOCK position.

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Retract the right hand lift cylinder andextend the left hand cylinder. Repeatthis several times so that the circle isrotated with the blade raised on theright hand side, and desired bank-cutposture can be attained.

When bringing the blade into bankcut posture on the left-side of themachine, change every “left-hand”and “right-hand” in the abovementioned description with eachother.

When bringing the blade into bank-cut posture, be careful not to clashthe blade against various portionsof the machine.


FIGURE 13.4.

Always lower the blade to the groundbefore removing the bank control lockpin. If the blade is raised, it may rotateand fall.

Drawbar and lif ter (Figure 13.4.a.)

FIGURE 13.4.a.

Drawbar and frame (Figure 13.4.b.)

FIGURE 13.4.b.

13.5 SHOULDER REACH POSTURE(RIGHT SIDE)

Rotate the lifter in a similar manner tothe bank cutting posture, and lock itusing the bank control lock pin.

Rotate the circle to the desiredposition.

Put the machine in the left hand sideshoulder reach posture using thesame procedure as the above.

When increasing the size of theshoulder reach, change the mountingposition of the piston rod of bladehorizontal feed cylinder.

(Refer to the section on blade thrust.)

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The banking performance is improved,if the mounting position for the pistonrod of the blade horizontal feedcylinder is changed as follows:

When banking to right, to a position

where the blade is thrusted left.

When banking to left, to a positionwhere the blade is thrusted to right.

13.6 OPERATION OF THE BLADE ACCUMULATOR (OPTIONAL)

Lower the blade to the ground andstop the engine. Turn the startingswitch to the ON position to supplypower to the electric circuits, then turnon the accumulator switch. Next, move

the R.H. and L.H. blade lift leversforward and backward to release theresidual pressure in the accumulatorand the hydraulic circuits.

Turn off the accumulator switch, andthen start the engine.

Next, extend the R.H. and L.H. bladelift cylinders about 50 mm. (At thistime, holding pressure is produced atthe bottom of the blade lift cylinders.)

Turn on the accumulator switch tooperate the accumulator. The oil in thebottom of the R.H. and L.H. blade liftcylinders will flow into theaccumulator, both blade lift cylinderswill shorten, and the front wheels willlower to the ground.

At th is time, a pressure is maintained

at the bottom of the blade lift cyl inders,that is, a pressure acts on the blade.

When the machine is operated under

this condition, the blade can follow a

difference in ground level of about

50mm, which is the standard operation

when an accumulator is in use.

In actual operation, the blade liftcylinder levers will move properly sothat the blade can follow the requireddifference in ground level with the

proper pressing force.

Once the accumulator is set and themachine is started, the blade lift leversdo not need to be operated. Whenstopping the work for a time, theaccumulator can be reset to the sameCondition as before stopping the workby turning off the switch, lifting the

blade, lowering it to the ground again,and turning on the switch again.

13.7 FEATURES OF THE BLADE ACCUMULATOR (OPTIONAL)

Ease of work

The blade does not need to beoperated.

This work does not require a lot ofskill.

Safety and protection

Shocks are reduced. The machine is protected from buried

objects. (The machine runs overprojecting objects.)

Improved steering performance

Steering performance on curves isimproved.

Side slips on curves are reduced.

Steering performance with the leaningsystem is improved.

Side slips made while using theleaning system are reduced.

Trouble with front wheels (floating orunstable wheels) is eliminated.

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Improved workability

The pressing force of the blade isimproved.

The relief of the blade is improved.

14. REVERSING ANDREPLACEMENT OF CUTTINGEDGE AND END BIT

Replace cutting edges and end bitsbefore their blade’s end faces wear out .When wear is extended to themounting faces, their repair must bedone prior to replacing.

14.1 TURNING AND REPLACING

Lift the blade to a suitable height andput a block underneath the blade railto prevent its falling.

Do not raise the blade unnecessarilyhigh. Be sure not to put your body

underneath the blade when blocking it

Clean the mounting face afterdetaching the cutting edge and theend bit.

Mount the cutting edges after invertingit, or replacing it with a new one.

The tightening torque for the mountingnuts is 40 to 54 kgm.

Tighten the nuts again after severalhours’ operation.

If both ends of the cutting edge andside edges are worn out, replace them

with new ones.

14.2 REPLACING RIPPER POINT

Drive out the pin with a bar andhammer, and remove the point

Fit a new point to the shank and drivein the pin. The pin can be reused.

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15. CHANGING TIRES

15.1 HOW TO CHANGE TIRES

Front wheel

Lower the work equipment to the

ground set the gear shift parking brakelever to the P Position to apply theparking brake.

Then, attach the socket wrench(accessory machine tool) to the hubnuts and loosen all the hub nuts by 3/4to 1 turn.

Depress the lift cylinder. If the fronttires are lifted, lock the control lever,remove the hub nuts and change allthe tires.

Details shown in the Figure 15.1.

FIGURE 15.1.

In installing new tires, tighten lightlywith the tires lifted and tighten the tiresto the specified torque in the ordershown in the photos, after placing thetires on the ground.

Tightening torque : 225+25 kgm

Whenever the front tires are raised offthe ground, support the front axlecenter frame on the block to assuresafety.

Rear w heel

Repeat the front wheel changeprocedures 1) and 2).

Depress fully the right and left liftcylinders and the front tires are liftedabout 50 cm off ground. Retract the liftcylinder on the side where the tire isnot removed, to lift rear wheels.

Install new tires according to theprocedure 4) of the wheel tire change.

Tightening torque:225+ 25 kgm

Whenever the rear wheels are raisedoff the ground, stably support thetandem on the block to assure safety.

16. HOW TO USE LEANINGSTOPPER

When a front tire punctures, do not

attempt to travel the machine by

temporarily applying a pad to the swing

stopper. If it is necessary, travel the

machine slowly only within the minimum

necessary distance. In this case, be sure

to securely keep the punctured tire off the

ground with chains, etc.

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BG825 A80

When the leaning pipe is damaged,temporarily prevent the front wheels fromleaning so that the machine can besuccessfully self-propelled to the nearestrepair shop.

How to apply the leaning stopper

Fix the leaning rod (2) to the front axle

using the bolts (1) provided in the toolbox.

If the machine is traveled with theleaning cylinder piston rod fluctuatingor the front wheels leaning on oneside, because of damaged leaningpiping, dangerously unstable steeringand excessively worn tires will result.

Have the faulty leaning pipe repairedby mechanics quickly.

17. DRIVING ALONG ROAD

In addition to strict observance of trafficlaws and rules concerned, keep thefollowing in mind:

17.1 POSITION OF BLADE WHENTRAVELING

When travelling, raise the blade fully andset it so that it does not extend outside themachine. (Figure 17.1.)

FIGURE 17.1.

Be careful to keep a clearancebetween the blade and front tires.

If the machine is articulated with theblade at the minimum propulsionangle, the blade will damage step.

17.2 WAY TO INSERT SHACK WHENTRANSPORTING

The way to insert the shank whentransporting is as shown in the diagrambelow.

Install the shank that comes in the centerof the ripper body with the point facing tothe rear, or install it in a position otherthan the center.

Do not install the shank in the center ofthe ripper body with the point facingforward. The shank may damage theripper cylinder.

17.3 ARTICULATED OPERATIONS

When performing operations with themachine articulated, remove the lock linkon the left side of the machine.

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BG825 A81

The machine can be articulated 250 toboth right and left, giving a minimumturning radius of 7.9m.

Remove the snap pin (1), then pull outpin (2).

Put the removed lock pin (1) in the pincase under the operator’s cab and fix

the lock pin to the case with the

removed pin and snap pin (2).

(Figure 17.3.)

FIGURE 17.3.

17.4 PRECAUTIONS WHENTRAVELING ON ROADS

To relieve operator’s fatigue, take a rest

by 30 minutes – 1 hour – 30 minutes

mode, every 80 kilometers or every 2

hours of traveling (whichever term expires

earlier).

18. HANDLING OF BATTERY

18.1 PRECAUTIONS FOR CHARGINGBATTERY

Before charging, disconnect the cablefrom the negative (-) terminal of thebattery. Otherwise, an unusually highvoltage will damage the alternator.

While charging the battery, remove allbattery plugs for satisfactoryventilation.

To avoid gas explosions, do not bringfire or sparks near the battery asshown in the Figure 18.1.a.

FIGURE 18.1.a

If the electrolyte temperature exceeds45 degree Cent, stop charging for awhile.

Turn off the charger as soon as the

battery is charged.

Overcharging the battery may causefollowings:

a) Over heating the battery

b) Decreasing the quantity ofelectrolyte.

c) Damaging the electrode plate.

If the electrolyte gets on your skin or

clothes, immediately wash with plentyof clean water.

Do not mix up cables (positive (+) tonegative (-) or negative (-) to positive(+), as it will damage the alternator asshown in the Figure 18.1.b.

FIGURE 18.1.b

When inspecting or servicing abattery, be sure to stop the engine and

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BG825 A82

turn. The starting switch key to “OFF”position.

When performing any service tobattery besides checking theelectrolyte level or measuring thespecific gravity, disconnect cables

from the battery.

18.2 REMOVAL AND INSTALLATIONOF BATTERY

When removing battery, firstdisconnect the cable from the ground(normally, from the negative (-)terminal). If a tool touches a cableconnecting the positive terminal andthe chassis, there is danger of sparksbeing emitted. Details shown in theFigure 18.2.

When installing battery, the groundcable should be connected to theground terminal as the last step.

FIGURE 18.2.

18.3 STARTING ENGINE WITH ABOOSTER CABLE

When starting up the engine with abooster cable do as follows:

Before connecting the booster cable

a) Size of booster cable and clipshould be suitable for the batterysize.

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

c) Make sure cables and clips arefirmly secured.

d) Keep the starting switch key inOFF position.

e) The battery of the running engine

must be the same capacity as thatof engine to be started.

Connect the booster cables in thefollowing manner.

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

b) Connect the other clip to thepositive (+) terminal to the enginewhich is running.

c) Connect one clip of booster cableB to the negative (-) terminal of theengine which is running.

d) Connect the other clip to the bodyof the machine to be started.

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

Mark sure that the booster cableconnections are correct. Connect thebooster cable to the body as far aspossible from the battery.

Details are shown below in Figure 18.3.a.

FIGURE 18.3.a.

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BG825 A83

When connecting the cables, nevercontact the positive (+) and negative (-)terminals.

Starting the engine

Turn the starting switch key to STARTposition and start up the engine.

If the engine doesn’t start at first, tryagain after 2 minutes or so.

After the engine has started, the boostercables should be disconnected in thereverse order in which they wereconnected.

Disconnecting the booster cables

a) Disconnect the clip of booster cable Bfrom the body of the machine whichwas started.

b) Disconnect the other clip from thenegative (-) terminal of the runningengine.

c) Disconnect the clip of booster cable Afrom the positive (+) terminal of therunning engine.

d) Disconnect the other clip from thepositive (+) terminal of the enginewhich was started.

Details are shown below in Figure 18.3.b.

FIGURE 18.3.b.

19. TOWING

19.1 TOWING THE MACHINE

This machine must not be towed except inemergencies. When towing the machine,

take the following precautions.

If there is a failure in the air circui t, thebrakes cannot be used, so beextremely careful when towing.

When engine can be used.

Always keeps the engine runningwhen towing the machine, so that thesteering and braking can be used.

When engine cannot be used.

When transporting a disabled machineby towing, the transportation distanceshould be within 600 m at a speed of 8km/h or less. (When towing more than600 m, remove the drive shaft.)

If the distance is more than the abovementioned, or if more than one day

has elapsed since the engine trouble,be sure to use the trailer fortransportation.

If the machine is towed without theengine running, on lubrication oil willbe supplied to the transmission. Thegears and bearings are rotated, so thismay cause them to be damaged.

If leakage in the air circuit has causedthe pressure inside the air tank todrop, the parking brake will be applied.When towing the machine, release the

parking brake.

19.2 RELEASING PARKING BRAKE

If the pressure in the air tank drops below

2.4 kg/cm2, the parking brake is applied

automatically. Therefore, when towing the

machine, release the parking brake as

follows.

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BG825 A84

Turn bolt (1) and the parking brake will be

released.

Stop the machine on a flat surface when

releasing the parking brake, and check

that the surroundings are safe. In

emergencies or when the parking brake

must be released on a hill, block the tires

carefully before releasing the brake.

20. TRANSPORTATION

In addition to strict observance of traffic

laws and rules concerned, it is desirable

to provide a special platform for loading

and unloading of the motor grader. If it is

necessary to use a ramp when loading a

motor grader on a trailer or unloading it

from a trailer, observe the followinginstructions to assure safety:

Securely brake the trailer and chock

trailer tires. Securely fix the ramp

boards in place so that the center of

motor grader being loaded coincides

with the center line of the trailer.

Width, length and thickness of ramp

boards must large enough to assure

safe loading and unloading of themotor grader.

Remove all the mud from the

undercarriage to prevent the machine

from slipping to the side on hilly roads.

Slowly travel the motor grader on the

ramp straight.

Never attempt to change the directionof travel on the ramp. If it is necessaryto change the direction of travel, oncereturn the machine to the original

position.

Remove the mud form the under

carriage to prevent the machine from

slipp ing to the side on slopes.

Properly load the motor grader on the

trailer at the specified position. To

prevent the grader on the trailer from

moving back and forth during

transportation, apply a chock to front

and rear of each wheel and fix the

motor grader with chains and wire

ropes. Pay special care to prevent the

motor grader from slipping sideward.

Rest the work equipment on the trailer

deck and observe the following:

Place the gear shift lever in the parking

position.

Place work equipment control lever in hold

position.

Apply safety locks.

Pull the staring switch key out.

Determine the optimum transportation

route, taking width of road and

permissible overhead clearance and

weight limitation into consideration.

Lock the articulation lock pin in the

same way as for normal travel.

Lock the articulation lock pin in the

same way as for normal travel.

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BG825 A85

Do not leave the front wheels raised offthe trailer deck using the brad as a jack. The front wheels wi ll fal l g radual lyduring transportation.

When loading the machine, choose afirm level road surface. Be sure thatyou are well clear of the road shoulder.

When transporting this machine,check with your BEML servicepersonnel for advice.

21. EMERGENCY STEERINGSYSTEM

21.1 FUNCTION

This system acts to prevent steering

failure caused by a breakdown in the

engine or hydraulic pump when the

machine is being operated.

If the pressure in the steering hydraulic

circuit goes below 7 kg/cm2, the pressureswitch is turned ON, and the electric

motor is actuated to turn the hydraulic

pump and supply hydraulic pressure to

the steering circuit to make it possible to

operate the steering.

However, if the machine is traveling at

less than 1 km/h (0.62mph) (including

when the machine is stopped), the

steering is not automatically actuated.

The emergency steering motor must

not be operated continuously more

than 30 seconds.

21.2 CHECKS

WHEN REQUIRED

Check that AUTO/MANUAL selectorswitch is at the AUTO position.

Start the engine and raise the front

wheels of the ground with the blade.

Normally keep the AUTO / manual

selector switch at the AUTO position.

Stop the engine. Be sure to leave the

starting switch at the ON position.

Turn the AUTO/MANUAL selector

switch to the “MANU” position.

When the switch is operated, check

that the alarm buzzer sounds

continuously and that the electric

pump for the emergency steering is

operated.

Turn the steering wheel and check

that the steering can be operated

without problem.

When checking above points, do not

continue the check for more than 30

seconds.

Turn the AUTO/MANUAL selector

switch to the AUTO position and check

that the monitor and warning lamps go

out, and that the electric pump for the

emergency steering stops working.

If any abnormality occurs, turn the

starting switch to the OFF position to

stop the whole system.

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BG825 A86

EVERY 500 HOURS SERVICE

Start the engine, and drive themachine with the engine at full throttle.

Depress the inching pedal, and movethe fuel control lever to the ENGINE

STOP position to stop the engine.

Check that the alarm buzzer soundscontinuously, that monitor lamp (1)and central warning lamp flash, andthat the electric pump for theemergency steering is operated whenthe engine stops.

Depress the brake to stop themachine, and check that all the itemsactuated in Step 3 stop.

Do not continue the check in Step 3for more than 30seconds.

When checking the emergency

steering or when actuating the system

in emergencies, the level of the oil in

the auxiliary tank may go down. Check

the oil level in the auxiliary tank and

always keep the level in the auxiliary

tank above 2/3. When checking, fill the

tank.

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SECTION - B

MAINTENANCE

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BG825 B1

Section BMAINTENANCE

INDEX


1. 1. PERIODIC MAINTENANCE B3

2. 2. PRECAUTIONS FOR MAINTENANCE B3

2.1. General B3

3. 3. DURING MAINTENANCE B4

4.4. PERIODICAL REPLACEMENT OF SAFETY

PARTSB6

5. 5. OIL FILLER AND LEVEL GAUGE POSITIONS B7

6. 6. LUBRICATION CHART B8

7. 7. MAINTENANCE TABLE B9

7.1. Every 50 Hours Service B12





7.6. When Required B25

7.6.1 Clean inside of cooling system B25

7.6.2 Check, clean and replace Air cleanerelement

B26

7.6.3 Electrical intake air heater B28

7.6.4 Clean condenser of Air Conditioner B29

7.6.5 Water separator B29

8. 8. ADJUSTMENT B298.1. Adjustment of Inch Pedal B29

9. 9. TROUBLE SHOOTING GUIDE B30

9.1. Engine B30

9.2. Chassis B31

9.3. Electrical system B32

9.3.1 Trouble shooting for Murphy B33

9.3.1.1 Overview B33

9.3.1.2 Power View 750 Display B34

9.3.1.3 I/O Module B37

9.3.1.4 Troubleshooting B39

10. 10. STORAGE B4310.1. Before storage B43

10.2. During storage B43

10.3. After storage B43

11. 11. MACHINE AND ENGINE SERIAL NUMBERS B43

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BG825 B2

NOTES:

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BG825 B3

MAINTENANCE

1. PERIODIC MAINTENANCE

Proper lubrication and maintenanceassure trouble-free operation and long

machine life. Time and money spend forscheduled periodic maintenance will beamply compensated by prolongedmachine operation and reduced operatingcost.

All hourly figures given in the followingdescriptions are based on service meterreadings. In practice, however, it isrecommended to review and convertsome / all of them into units of days,weeks and months to make themaintenance schedule more convenient

for day to day monitoring under hostileoperating conditions, it may be necessaryto review and shorten the maintenanceintervals.

2. PRECAUTIONS FORMAINTENANCE

2.1 GENERAL

Wear well-fitting helmet, safety shoes andworking clothes. When drilling, grinding orhammering, always wear protectivegoggles.

Fuel or oil is dangerous substance. Neverhandle fuel, oil grease or oily clothes inplaces where there is any fire of flame. Asprecaution in case of fire, always know thelocation and directions for use of fireextinguishers and other fire-fightingequipment.

Always stop the engine before cleaningthe machine or adding fuel.

When working with other, choose a groupleader and work according to hisinstruction. Do not perform anymaintenance beyond the agreed work asshown in the Figure below 2-1.

FIGURE 2-1. WORK AS PERINSTRUCTION

Do not handle electrical equipment whilewearing wet gloves, or in wet places, asthis can cause electric shock as shown inthe Figure below 2-2.

FIGURE 2-2. HANDLE ELECTRICAL

EQUIPMENT CAREFULLY

During maintenance do not allow anyunauthorized person to stand near themachine.

Exhaust gas is dangerous. When workinginside, be particularly careful to have goodventilation as shown in the Figure below2-3.

FIGURE 2-3. PROPER VENTILATION

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BG825 B4

Unless you have special instructions tothe contrary do not do maintenance,maintenance should always be carried outwith the engine stopped. If maintenanceis carried out with the engine running,there must be two men present as shownin the Figure below 2-4.

FIGURE 2-4. PROPER PROCEDUREFOR MAINTENANCE

While one person sitting in the operator'sseat and the other one performing themaintenance never touch any movingpart.

Always remember that the hydraulic oilcircuit is under pressure. When feeding ordraining the oil or carrying out inspectionand maintenance release the pressurefirst. The procedure for releasing thehydraulic pressure is as follows: lower theblade and scarifier (option) to the ground,

and stop the engine; move the controllevers to each position two or three timesand then slowly loosen the oil filter cap asshown in the Figure below 2-5.

FIGURE 2-5. HYDRAULIC OIL UNDERPRESSURE

Always use BEML genuine parts forreplacement.

Always use the grades of grease and oilrecommended by BEML. Choose theviscosity specified for the ambienttemperature.

Always use pure oil or grease, and besure to use clean containers.

When checking or changing the oil, do it ina place free of dust, and prevent any dirtfrom getting into the oil.

3. DURING MAINTENANCE

Parking the machine on firm, flat ground.Lower the blade and scarifier (option) tothe ground stop the engine. Return the

gear shift lever to "NEUTRAL", apply thebrake lock and set each control lever to"LOCK" When maintenance has to becarried out with the blade and scarifier(option) raised, they must be securelysupported by blocks.

Thoroughly wash the machine. Inparticular be careful to clean the filler capsgrease fittings and the area around thedipsticks.

Be careful not to let any dirt or dust in to

the system.

Hang a caution sign in the operator'scompartment (for example "Do not start"or "Maintenance in progress) this willprevent anyone from starting or movingthe machine by mistake as shown in theFigure below 3-1.

FIGURE 3-1. HANG CAUTION WHILEDOING MAINTENANCE

Flame should never be used instead oflamps. Never use a naked flame to check

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BG825 B5

leaks or the level of oil, fuel, anti-freeze orelectrolyte as shown in the Figure below3-2.

FIGURE 3-2. AVOID FLAMES

Immediately remove any oil or grease onthe floor of the operator’s compartment, oron the handrail. It is very dangerous ifsomeone slips while on the machine.

When check an open gear case there is arisk of dropping things in. Before removingthe covers to inspect such cases, emptyeverything from your pockets. Beparticularly careful to remove wrenchesand nuts as shown in the Figure 3-3.

FIGURE 3-3. KEEP TOOLS PROPERLY

Before draining the oil, warm up it to atemperature 20 to 40 degree centigrade.

Be particularly careful when removing the

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

After replacing oil, filter, element orstrainer, bleed the air from the circuit.

When the strainer is located in the oil filter,the strainer must not be removed whileadding oil.

When adding oil or checking the oil level,check that the oil is at the correct level. After greasing up, always wipe off the old

grease that was forced out.

When changing the oil or filter, check thedrained oil and filter for any signs ofexcessive metal particles or other foreignmaterials.

When removing parts containing O-rings,gaskets or seals, clean the mountingsurface and replace with new sealingparts.

When the work equipment is raised for

inspection or repair, always place blocksunderneath to prevent falling as shown inthe Figure 3-4.

FIGURE 3-4. PLACE BLOCKSUNDERNEATH

When the machine is jacked up, alwaysput chocks against the wheels on theopposite side. After jacking up, placeblocks to prevent the machine from fallingas shown in the Figure 3-5.

FIGURE 3-5. WHILE MACHINE ISJACKED UP

Disassembly, repair and assembly of tiresrequire special equipment and high skill.

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BG825 B6

Always consult a specialized tire repairshop as shown in the Figure 2-11.

FIGURE 3-5. WHILE REPLACING TIRES

Always lock the front and rear framesbefore inspecting and servicing the

machine. (Inarticulate frame model).

When handling the cutting edges alwayswear gloves.

Special measuring apparatus is neededfor testing hydraulic pressure.

Remove the negative terminal from thebattery in maintaining the electricalsystem.

The users of our machine should carry out

periodical maintenance in order to ensurethe working and operation safety asshown in the Figure 3-6.

FIGURE 3-6. CARRY OUT PERIODICMAINTENANCE

When carrying out other difficultmaintenance works, carrying them outcarelessly can cause unexpectedaccidents. If you consider themaintenance is too difficult, alwaysrequest the BEML service personnel tocarry it out.

4. PERIODICAL REPLACEMENTOF SAFETY PARTS

Periodic replacement of safety partsshould be done to maintain the safetystandards.

Parts with passage of time have a greatertendency to deteriorate in quality.Furthermore their defective condition isdifficult to detect during periodicmaintenance. These parts must betherefore replaced with the new ones aftera predefined interval even though there isno abnormality. If any abnormality is foundparts must be replaced before thepredetermined period expires.

Periodical replacement is completelydifferent from the replacement due to the

claim against the guarantee by themanufacturer so they must be treatedseparately.

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BG825 B7

5. OIL FILLER AND LEVELGAUGE POSITIONS

1. Cooling water inlet

2. Transmission case drain plug

3. Engine oil pan oil filler and level gauge

4. Cooling water drain valve

5. Tandem drive case drain plug

6. Circle reverse gear case oil filler anddrain plug.

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BG825 B8

6. LUBRICATION CHART

Maintenance of the Vehicle to be taken up as per Lubrication Chart below -:

LUBE KEY TYPE OF LUBRICATION 0°C TO +32°C ABOVE 32°C

CENGINE OIL SAE 15W40 SAE 15W40

ATRANSMISSION OIL CD SAE 30W CD SAE 30W

BHYDRAULIC OIL CD SAE 10W CD SAE 10W

LLITHIUM BASE GREASE NLGI,GRADE#2 NLGI,GRADE#2

FMULTI PURPOSE GEAR OIL GO SAE 90 GO SAE 140

A HIGH TEMPERATURE AXLE OIL CD SAE 30W CD SAE 30W

SL. NO. DESCRIPTION LUBEK EYNO. OF

SERVICEPOINTS

50250 500 1000 2000

1 CIRCLE GUIDE L 6 GREASE

2 BLADE GUIDE RAIL (SMEAR) L 2 GREASE

3 DRAW BAR BALL JOINT L 1 GREASE

4 BANK-CUT CONTROL BRACKET L 2 GREASE

5 BLADE LIFT CYLINDER BALL YOKE L 6 GREASE

6 BLADE LIFT CYLINDER BALL JOINT L 2 GREASE

7 DRAW BAR SIDESHIFT CYLINDER JOINT L 2 GREASE

8 POWER TILT CYLINDER PIN L 1 GREASE

9 RIPPER LINKAGE PIN (OP) L 8 GREASE

10 RIPPER CYLINDER PIN(OP) L 3 GREASE

11 LEANING CYLINDER PIN L 1 GREASE

12 TIE ROD L 2 GREASE

13 STEERING CYLINDER L 4 GREASE

14 LEANING PIN L 2 GREASE

15 LEANING ROD PIN L 2 GREASE

16 CENTER PIN L 1 GREASE

17 KING PIN L 6 GREASE

18 ARTICULATION CYLINDER PIN L 4 GREASE

19 PROPELLER SHAFT L 2 GREASE

19A HITCH PIN L 2 GREASE

19B CONSOLE TILT BRACKET L 2 GREASE

19C POWER TILT CYLINDER MTG. BRACK ET L 2 GREASE

20 ENGINE OIL PAN C 1 CHECK CHANGE

21 OIL CASE TRANSMSSION A 1 CHECK CHANGE

22 OIL CASE FINAL DRIVE A 1 CHECK CHANGE

23 TANDEM DRIVE CASE A 2 CHECK CHANGE

24 HYDRAULIC OIL B 1 CHECK CHANGE

25 OIL CASE WORM GEAR F 1 CHECK CHANGE

26 FRONT WHEEL SPINDLE BEARING OIL A 2 CHECK CHANGE

27 ENGINE OIL FILTER CARTRIDGE 1 CHANGE

28 CENTRIFIGAL OIL FILTER 1 $

29 MAIN FUEL FILTER CARTRIDGE 1 CHANGE

30 PRE FUEL FILTER CARTRIDGE 1 CHANGE

31 TRANSMISSION FILTER ELEMENT 1 CHANGE

32 HYDRAULIC OIL FILTER ELEMENT 1 CHANGE

33 CRANK CASE BREATHER **

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BG825 B9

7. MAINTENANCE TABLE

No. Item Service

CHECK BEFORE STARTING

a. Oil and water leak Check

b. Nuts and bolts Check and retighten

c. Electric wiring Check and retighten

d. Coolant Check and Supply

e. Fuel Check and Supply

f. Fuel tank Drain water and sediment

g. Air tank Drain water

h. Engine oil pan Check and Supply

I Dust indicator Check

j. Tire pressure Check and adjust

k. Steering wheel play Check

l. Air pressure Check

m. Lamps Check

n. Rear view mirror Check

o. Reflector Check

p. Horn Check

q. Exhaust gas cooler Check

r. Instruments Check

s. Previous day’s defects Check

t. Door lock Check

u. Wiper, window washer and defroster Check

v. Water separator Inspect float position


a. Greasing 1. Circle Guide Greasing 6 points

2. Blade Guide Rail (Smear) Greasing 2 points

3. Draw Bar Ball Joint Greasing 1 point

4. Bank - Cut Control Bracket Greasing 2 points

5. Blade lift cylinder yoke Greasing 6 points

6. Blade lift cylinder ball joint Greasing 2 point

7. Draw bar side shift cylinder joint Greasing 2 points

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BG825 B10

No. Item Service

8. Power tilt cylinder pin Greasing 01 point

9. Ripper linkage pin (op) Greasing 8 points

10. Ripper cylinder pin (op) Greasing 3 points

11. Leaning cylinder pin Greasing 1 point

12. Tie rod Greasing 2 points

13. Steering cylinder Greasing 4 points

14. Leaning pin Greasing 2 points

15. Leaning rod pin Greasing 2 points

16. Centre pin Greasing 1 point

17. King pin Greasing 6 point

18. Articulation cylinder pin Greasing 4 points

19. Propeller shaft Greasing 2 points

19a. Hitch pin Greasing 2 points

19b. Console tilt bracket Greasing 2 points

19c. Power tilt cylinder mtg. Bracket (op) Greasing 2 point

20. Engine Oil Pan Check Engine Oil

21. Oil Case Transmission Check Transmission Oil

22. Oil Case Final drive Check Oil

23. Tandem Drive Case Check Oil

24. Hydraulic Oil Check Hydraulic Oil

25. Oil Case Worm Gear Check Multi Purpose gear oil

26. Front Wheel Spindle Bearing Oil Check Oil

INITIAL 250 HOURS SERVICE

a. Engine oil pan Change Oil

b. Engine oil filter Cartridge Change Oil

c. Centrifugal Oil Filter Clean and Replace paper insert

d. Main Fuel Filter Cartridge Change Oil

e. Pre Fuel Filter Cartridge Change Oil

f. Crank Case Breather Check and Clean

g. Oil Case Transmission Change

h. Oil Case Final drive Change

i. Tandem Drive Case Change

j. Hydraulic Oil Change

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BG825 B11

No. Item Service

k. Oil Case Worm Gear Change

l. Hydraulic Oil Filter Element Change


a. Engine oil pan Change Oil

b. Engine oil filter Cartridge Change Oil

c. Centrifugal Oil FilterFilters to be cleaned by removing sediments &

Replace paper insert

d. Main Fuel Filter Cartridge Change Oil

e. Pre Fuel Filter Cartridge Change Oil

f. Crank Case Breather Check and Clean


a. Transmission Filter Element Change


a. Oil Case Transmission Change

b. Oil Case Final drive Change

c. Tandem Drive Case Change

d. Hydraulic Oil Change

e. Oil Case Worm Gear Change

f. Hydraulic Oil Filter Element Change


a. Front Wheel Spindle Bearing Oil Change Oil

WHEN REQUIRED

a. Cooling system Clean

b. Air cleaner

Check, clean or replace when required

Note: To be replaced along with the innerelement after 6 times of cleaning

c. Electrical intake air heater Check

d. Air condenser Clean

e. Water separator Drain water

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BG825 B12

7.1. EVERY 50 HOURS SERVICE

Greasing -:

In every 50 hours the below points shouldbe greased properly.

Circle Guide (6 points)

Grease all around the circle part.

Details shown in the Figure 7.1.1.

FIGURE 7.1.1.

Blade guide rail (2 points)

Apply grease all over the guide rail


FIGURE 7.1.2.

Draw Bar Ball Joint (1 point)

Grease all over the part

Check ball joint connecting nuts at thefront of the drawbar for loosening. If theconnecting portions are loose, retightenthem.


FIGURE 7.1.3.

Bank - Cut Control Bracket (2 points)



FIGURE 7.1.4.

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BG825 B13

Blade lift cylinder yoke (6 points)

Grease all over the part.


FIGURE 7.1.5.

Blade lift cylinder ball joint (2 points)

Grease all over the part.


FIGURE 7.1.6.

Draw bar side shift cylinder joint(2 points)



FIGURE 7.1.7.

Power tilt cylinder pin (1 point)



FIGURE 7.1.8.

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BG825 B14

Ripper linkage pin (op) (8 points)



FIGURE 7.1.9.

Ripper cylinder pin (op) (3 points)



FIGURE 7.1.10.

Leaning cylinder pin (1 point)



FIGURE 7.1.11.

Tie rod (2 points)



FIGURE 7.1.12.

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BG825 B15

Steering cylinder (4 points)



FIGURE 7.1.13.

Leaning pin (2 points)



FIGURE 7.1.14.

Leaning rod pin (2 points)



FIGURE 7.1.15.

Centre pin (1 point)



FIGURE 7.1.16.

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BG825 B17

Checking -:

In every 50 hours the below points shouldbe checked properly.

Engine Oil Pan

Check the Engine Oil Pan


FIGURE 7.1.20.

Oil Case Transmission

Check the oil level with oil level gauge fiveminutes after stopping the engine.

If necessary, add oil through filler .

The type of lubricant used depends on theambient temperature.

Select according to the table “FUEL,COOLANT AND LUBRICANTS”.


FIGURE 7.1.21.

Oil Case Final drive

Check the oil level with oil level gauge. Ifnecessary, and oil through filler .

The type of lubricant used depends on the

ambient temperature. Select according to

the table “FUEL, COOLANT AND

LUBRICANTS".


FIGURE 7.1.22.

Tandem Drive Case

Check the oil level with oil level gauge. Ifnecessary, add oil through filler .

The type of lubricant used depends on theambient temperature.

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BG825 B18

Select according to the table “FUEL,COOLANT AND LUBRICANTS.”


FIGURE 7.1.23.

Hydraulic Oil

1. Set the machine in position as followsto check the oil level.

Return the leaning of the front tiresto the upright position and face thewheels straight to the front.

Set the front frame and rear framefacing straight (articulated angle).

Return the drawbar side shift andblade side shift to the center of themachine, set the blade at rightangles to the chassis and lower itlightly to the ground.

Raise the scarifier fully.

2. Close valve (1).

3. Loosen oil filler port slowly and release

the air inside the hydraulic tank

completely.

4. Check the oil level with oil level gauge.

Add engine oil through filler , if

necessary.



the table “FUEL, COOLANT AND

LUBRICANTS”,

5. Tighten oil filler port (F), and open

valve (1).

Details shown in the Figure 7.1.24

FIGURE 7.1.24.

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BG825 B19

Oil Case Worm Gear

Check the Oil Case Worm Gear


FIGURE 7.1.25.

Front Wheel Spindle Bearing Oil

Check the Front Wheel Spindle BearingOil.


FIGURE 7.1.26.


Changing -:

In every 250 hours the below items shouldbe changed .

Engine oil pan

Change the Engine Oil

Before draining the oil, warm up to atemperature 20 to 40 degree centigrade.

Loosen drain plug to drain oil afterdraining, tighten it.

The type of lubricant used depends on theambient temperature. Select according tothe table “FUEL, COOLANT AND

LUBRICANTS”.

Refill capacity: 34 lts.


FIGURE 7.2.1.

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BG825 B20

Use API category CD class oil. If CC classoil must be used, change the oil andreplace the oil filter at half the usualinterval.

Engine oil filter Cartridge

If filter cartridge is removed immediatelyafter stopping the engine, oil will spill. Waitat least 10 minutes after stopping theengine before replacing the filter cartridge.

Change the Engine Oil filter cartridgeusing the tool provided, rotate cartridgeelement counterclockwise. Fill the newcartridge with clean oil and refit it afterapplying a dab of oil to the gasket face.

Be careful not to tighten cartridge upexcessively.

After replacing the cartridge fill engine oilthrough oil filler.

Then idle the engine for a while, and usedipstick to check oil level.

Be sure to use a genuine cartridge.


FIGURE 7.2.2.

Main Fuel Filter Cartridge

Using the tool provided, rotate cartridgeelement counterclockwise.

Fill the new cartridge. With clean fuel andrefit it after applying a dab of oil to the

gasket face.

To refit the cartridge, place the gasketface in contact with the seal face of thefilter stand, then screw up the cartridge1/2 to 3/4 of a turn (be careful not totighten it up excessively.)

After replacing the cartridge, slacken offair vent plug .

Loosen feed pump knob and move thepump up and down to draw off fuel until air

ceases to come out of vent plug.

Tighten air vent plug, push feed pumpknob into place, and tighten it.

After replacing the cartridge, start upthe engine and check the filter sealface for possible fuel leakage.

Be sure to use a genuine BEMLcartridge.


FIGURE 7.2.3.

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BG825 B21

Pre Fuel Filter Cartridge

Change the Pre fuel filter cartridge


FIGURE 7.2.3.

Centrifugal Oil Filter

Clean and Replace Paper Insert -

In every 250 hours Clean Centrifugal Oil

filter by removing sediments and replace

paper insert.


FIGURE 7.2.4.

Crank Case Breather

Check and clean -

In every 250 hours Crank Case breather

should be checked and cleaned.

If required replace 'O'- Ring


FIGURE 7.2.5.


Changing -:

In every 500 hours following element to bechanged.

Transmission Filter Element

Change the transmission filter element.

Remove bolts fastening the filter case,remove case.

Remove the element and discard.

Thoroughly clean the case interior andremoved parts.

Install a new element.

Use a genuine element.

If required replace 'O'- Ring

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BG825 B22


FIGURE 7.3.1.


Changing -:

In every 1000 hours below to be changed.

Oil Case Transmission

Change the transmission oil by removingdrain plug. After draining oil, tighten drainplug.

Take out strainer and wash out dust withdiesel fuel.

After cleaning it, install strainer.

Refill transmission oil in specified amountthrough filler (F).

For the refilling procedure, see the item“ Initial 250 hour’s service.”

The type of lubricant used depends on theambient temperature. Select according to

the table “FUEL, COOLANT ANDLUBRICANTS”.

Refill capacity : 35 lts.


FIGURE 7.4.1

Oil Case Final drive

After draining oil through drain plug hole,

refill the gear oil through filler up to the

prescribed level.

For the refilling procedure, see the item

“ Initial 250 hour’s service.”



the table “FUEL, COOLANTAND

LUBRICANTS”.

Refill capacity : 57 lts.

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BG825 B23


FIGURE 7.4.2.

Tandem Drive Case

Change the Tandem oil Drive Case asbelow.

After draining oil through drain plug hole.

Refill the oil (SAE 30W) up to theprescribed level through the gauge hole .



ambient temperature. Select according tothe table “FUEL, COOLANT ANDLUBRICANTS”

Refill capacity: 95 lts. (each side)


FIGURE 7.4.3.

Hydraulic Oil

Change the Hydraulic oil as below.

Loosen oil filler port slowly to completelyrelease the air inside the hydraulic tank.

Set the container under drain plug to catchthe oil.

To prevent getting oil on yourself, loosendrain plug and drain the oil. To prevent theoil from spurting out, loosen drain plug,then gradually remove it.

After draining the oil, tighten drain plug.


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BG825 B24

The type of lubricant used depends on theambient temperature. Select according tothe table “FUEL, COOLANT ANDLUBRICANTS”

Refill capacity: 80 lts.


FIGURE 7.4.4.

Oil Case Worm Gear

Change Oil in the Oil case worm gear.

Details shown below in Figure 7.4.5.

FIGURE 7.4.5.

Hydraulic Oil Filter Element

Change Hydraulic oil filter element.

Details shown below in Figure 7.4.6.

FIGURE 7.4.6.


Front Wheel Spindle Bearing Oil

Change the Front Wheel Spindle bearingoil.

Details shown below in Figure 7.5.

FIGURE 7.5.

Maintenance for every 50, 250, 500,1000 and 2000 hours should be carriedout at the same time.

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BG825 B25

7.6. WHEN REQUIRED

7.6.1 CLEAN INSIDE OF COOLINGSYSTEM

Maintenance :

Follow the below instructions formaintaining (particularly during cold

season) the cooling system.

Radiator cap is always to be fitted. This

will avoid dust collection, coolant loss and

system pressure loss.

Clean / wash radiator fins periodically.

Periodicity to be determined based on the

usage and site condition.

Sharp tools should not be used for

cleaning tubes / fins as it may puncture

them.

If anticorrosive solution or antifreeze

solution is used, always keep extra

solution ( water + antifreeze or

anticorrosive ) in a container so that any

loss of coolant during day to day operation

could be replenished easily.

Check leakage of coolant during engine

‘ON’ and ‘OFF’ condition.

Avoid switching off the engine unless

there is leakage of coolant or any

abnormality.

Change the coolant at least once in a

year.

Observe the coolant temperature rising

rate. This will give an indication about the

cooling system problem.

Radiator (top tank) should not be filled up

to the mouth. It should be filled only up to

the filler neck. The empty space is meant

for coolant expansion and de-aeration.

Check the coolant for any traces of oilduring daily maintenance.

Do not remove strainer from radiator filler

tube.

Anti freeze is flammable, so keep itaway from any flame.

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BG825 B26

ANTI CORROSION FLUID

BEML Anti corrosion fluid is beingrecommended for all equipment fitted withBEML engines.

The details of the concentrate along with

other recommendations are appendedbelow:

ACF-ALP: Anti corrosion fluid aluminumprotection.

ACF-ALP (EGB): Anti corrosion fluid withaluminum protection. (Ethylene glycolbased)

The details of the concentrate along withrecommendations are appended below.

ACF-ALP: Colour of diluted solution:Fluorescent Blue

ACF-ALP (EGB): Colour of concentrate:Fluorescent Green

The PH value of the mixture (water +concentrate) has to be maintainedbetween 7.5~9.5 (Check through pHpaper).

Depending on the quality of raw waterused, an additional concentration of

concentrate beyond 1:10 may be required.

Before filling the radiator with the anti-corrosion fluid the radiator has to beflushed completely with clean water.

WATER FILLER

Radiator water filling is done from the capshown below.

RADIATOR WATER FILLING CAP

DRAIN VALVE ( BOTTOM OFRADIATOR)

Open drain valve at the bottom of theradiator and plug on the side of cylinderblock to drain off the cooling water.

DRAIN VALVE

Do not remove the cap while coolingwater is hot. Hot water may spout out.

When removing radiator cap, lift thelever to relieve inner pressure.

7.6.2 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

Checking

When the dust indicator (1) shows red the

air cleaner element needs cleaning.


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BG825 B27

FIGURE 7.6.2.

Cleaning and replacing the outerelement

1. Loosen clamp (1) and remove theCover (2) and outer element.

2. Clean the inner body and the cover.

3. Clean and check the outer element(Following pages) and reattach.

4. Press the dust indicator button andreturn the red piston to its place.

Replace the outer element which

has been cleaned 6 times repeatedlyor used throughout the year.

Replace the inner element at thesame item.

Replace seal washer (4) or wing nut(3) if they are broken.

Details shown in the Figure below.

AIR CLEANER ELEMENT

Replacing inner element

1. First remove the cover and the outer

element, and then remove the innerelement.

2. Cover the air inlet port.

3. Clean the air cleaner body interior.Remove the cover from the air inletport.

4. Install a new inner element andtighten it with nuts.

5. Install the outer element and the

cover. Push the dust indicator resetbutton.

Replace both inner and outerelements when the dust indicator redpiston appears soon after installingthe cleaned outer element eventhough it has not been cleaned 6times.

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BG825 B28

Check inner element mounting nutsfor looseness and, if necessary,retighten.

NOTE: Do not attempt to reinstall acleaned inner element.

Do not clean or replace the air cleanerelement with the engine running.

Cleaning outer element

With compressed air

Use correct air jet and avoid excess airpressure ( less than 7 kg/cm.²)

When using compressed air, wearsafety glasses and other thingsrequired to maintain safety.

The following methods require spareparts.

With water

Splash city water ( less than 3 kg/cm2 ) onelement from inside along folds, then fromoutside and again from inside, Dry andcheck it.

With cleaning agent

For removing oils and fats as well ascarbon etc. attached on the element, theelement may be cleaned in lukewarmsolution of mild detergent, then rinsed inclean water and left to drip dry.

Drying can be speeded up byblowing dried compressed air ( lessthan 7 kg/cm2 ) from the inside tothe outside of the element.

Never attempt to heat the element.

Using warm water (about 40 degcentigrade) instead of soapy water

may also be effective.

If small holes or thinner parts arefound on element when it is checkedwith an electric bulb after cleaningand drying, replace the element.

If element is usable, wrap it andstore it in dry place.

Do not use element whose folds or

gasket or seal are damaged.

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

7.6.3 ELECTRICAL INTAKE AIRHEATER

Check electrical intake air heater (1) oncea year before commencing work in thecold season.

Remove electrical intake air heater (1)from the engine intake connection, andcheck it for possible open-circuits and dirt.

When inspecting and replacing electricalintake air heater (1), replace the gasketwith new one.

Details in the Figure 7.6.3.

FIGURE 7.6.3.

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BG825 B29

7.6.4 CLEAN CONDENSER OF AIRCONDITIONER

Pull knob (1), remove filter (2), and cleanit. Details in the Figure 7.6.4..

FIGURE 7.6.4.

7.6.5 WATER SEPARATOR

The water separator separates watermixed in the fuel. If the float is at or abovethe red line, drain the water.

Even though water separator isinstalled, be sure to check the fueltank to remove water and sediment inthe fuel.

Water separator is shown in Figure 7.6.5

FIGURE 7.6.5.

When float (2) is at or above red line (1),drain the water according to the followingprocedure:

Loosen drain plug (3) and drain theaccumulated water until the floatreaches the bottom.

Tighten drain plug (3).

If the air is sucked into fuel line whendrain the water, be sure to bleed air inthe same manner as for the fuel filter.

(See Fuel Filter Cartridge in EVERY 250HOURS SERVICE section.)

8. ADJUSTMENT

8.1 ADJUSTMENT OF INCHING

PEDAL

When any abnormal pedal condition suchas mentioned below is noticed, consultyour BEML service personnel forchecking, readjustment or repair of theinching pedal system.

At full engine speed, the machine moveswhen the inching pedal (1) is depressedand the gear shift lever (2) is placed in theforward 1st speed position (The parkingbrake is left released.) Details shown in

the Figure 8.1.

FIGURE 8.1.

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BG825 B30

These abnormal conditions concerninginching pedal operation are sometimescaused by transmission troubles.Therefore, careful inspection of faultyconditions must be made by your BEMLservice personnel not only about theinching pedal control system, but also

about the transmission.

9. TROUBLE SHOOTING GUIDE

This guide is not intended to cover tocover every conditions, however manyof the more common possibilities arelisted.

9.1 ENGINE

Oil pressure gauge pointer will notreturn to its or iginal position, when the

engine is shut down and Oil pressuregauge pointer fluctuates abnormally.

Defective oil pressure gauge.

Insufficient oil in oil pan.

Oil pressure gauge pointer stays within

the red range on d ial.

Insufficient oil in oil pan.

Oil leakage due to damaged piping,

Loose piping joints or connections. Defective oil pressure gauge.

Oil leakage from full-flow filter.

Steam spurts out through the pressure

relief valve on the radiator.

Insufficient coolant or coolant leakage.

Loose fan belt.

Clogged radiator fins or damaged fins

Defective coolant temperature gauge.

Defective thermostat or its seal. Leaky thermostat seal.

Coolant temperature gauge pointer

stays in the red range on dial during

engine running.

Defective thermostat.

Defective coolant temperature gauge.

Clogged radiator fins or damaged fins.

Defective fan belt/tension

Rise in oil temp. of power train.

Lack of coolant.

Engine fails to start.

Insufficient fuel in fuel tank.

Air in fuel line.

Insufficient torque of starting motor to

crank up engine.

No fuel in fuel filter.

Poor battery condition

Engine does not start when the starting

motor is operated.

Check for sufficient fuel. Check for air leaks in the fuel system.

Check whether fuel filters have

choked.

Replace the injection pump or the

nozzle.

Check the valve clearance.

Check engine compression pressure.

Use cold starting aid where required.

Engine emits white or blue-white

exhaust gas.

Excessive oil in oil pan.

Improper fuel use.

Oil leaks in turbocharger.

Exhaust gas occasionally turns black.

Clean or replace the air cleaner

element.

Check & replace the FIP nozzle.

Check engine compression pressure.

Engine emits black exhaust smoke.

Clogged air cleaner elements.

Worn cylinder components.

Failure of turbo charger.

Excessive injection of fuel.

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BG825 B31

Engine runs but operates erratically

(Hunting)

Air in fuel supply lines.

Defective governor mechanism.

Engine knocks.

Use of improper fuel.

Overheat.

Excessive usage of air heater.

Improper FIP timing.

Fuel sometimes stops flowing.

Strainer in fuel feed pump clogged.

Breather in fuel tank clogged.

Leak of fuel Air entry in the fuel system

Engine stops during operation or does

not take load.

Insufficient supply of fuel.

Clogged fuel filter.

Clogged feed pump strainer.

Leakage from fuel piping.

Breather in fuel tank clogged

Engine does not pickup smoothl y.

Insufficient intake of Air

Insufficient supply of fuel.

Improper condition of fuel injection

system.

Improper fuel used.

Abnormal wear of fuel system

components (sub-zero operating

condition).

Improper fuel (poor lubricity of fuel).

Premature clogging of fuel filters due

to fuel gel formation.

Excessive water in the fuel.

9.2 CHASSIS

Tractive force is lacking. ( Insufficient

travel speed )

Refer to the section of engine.

Check transmission.

Release parking brake lever.

If machine falls to start at any gear shift

lever position.

Add oil to transmission case.

Check and adjust transmission.

Loud noise in the power transmitting

system

Add oil to transmission case and tandem

case.

Excessive wear of front wheels

Adjust toe-in.

Heat generation at front wheel hub

Adjust wheel bearing installation nut.

Apply grease.

Front wheel sway while traveling

Adjust toe-in and tie rod.

Replace steering linkage.

Equalize tire pressure on each side

Check wheel installation.

Retighten front wheel bearing

installation nut.

Steering wheel feels heavy

Check front tire pressure.

Apply grease on each bearing.

Adjust ball joint of pitman arm.

Repair piping.

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BG825 B32

Parking brake does not operate

satisfactorily

Adjust brake pad.

Polish lining surface with sandpaper.

Disassemble and clean brake drum.

Excessive blade swing during work

Adjust shims of ball joint and circle

guide.

Replace side bushing.

Correct blade rail.

Excessive vibration of the blade when

rotating during work

Adjust radial clearance of the circle.

Work equipment is slow to move by

operating the control lever

Add the oil to the specified level.

Wear of parking brake lining

Adjust clearance of lining.

9.3 ELECTRICAL SYSTEM

Lamp does not glow brightly even

when engine runs at high speed.

Lamp flickers while engine runs.

Check for loose terminals and open-

circuit wiring.

Adjust belt tension.

Charge monitor does not go out even

when engine runs at high speed.

Replace the charge lamp.

Replace the alternator.

Inspect and repair wiring.

Unusual noise is emitted from

alternator

Replace the alternator.

Starting motor does not turn when

starting switch is turned on.

Inspect and repair the wiring.

Charge the battery.

The pinion o f the starting motor keeps

going in and out.

Charge the battery.

Starting motor turns the engine sluggishly.

Charge the battery.

Replace the starting motor.

The starting motor disengages before the

engine start up.

Check and repair the wiring.

Charge the battery.

The engine pre-heating monitor does not

flash.

Check and repair wiring.

Replace the heater relay. Replace the monitor.

Charge monitor does not light up w hen

the engine is stationary.

(When the starting switch is in ON

position.)

Replace the monitor.

Inspect and repair the wiring.

Outside the electrical intake air heater is

not warm when torched with the hand.

Check and repair wiring.

Replace the electrical intake air

heater.

Check and repair the heater switch.

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BG825 B33

9.3.1 TROUBLE SHOOTING FOR MURPHY

9.3.1.1 Overview

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BG825 B34

9.3.1.2 Power View 750 Display

a. Connections

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BG825 B35

Only connection A is used with the following connections

1 VBATT + Red

2 CAN High Yellow

3 CAN low Green

4 - -

5 Ignition White/Purple6 VBATT - Black

b. Display

Active gauges Screen – I

Screen – II

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BG825 B36

Inactive Gauges

IN ACTIVE STATE

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BG825 B37

9.3.1.3 I/O Module

Connections – Manual Engine and Gearbox

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BG825 B38

Power and CAN

The 12 way connector has the following connections

Pin 1 Battery Positive Red

Pin 2 Battery negative Black

Pin 3

Pin 4

Pin 5 Mute (if fitted) White/black

Pin 6 Buzzer (if fitted) Grey

Pin 7 CAN high Yellow

Pin 8 CAN low Green

Pin 9 Clock supply White/Purple

Pin 10

Pin 11

Pin 12

Analogues

The analogue inputs are connected to 24 way part of the 64 way connector

Please refer to the individual vehicle connection diagram for senders that are

fitted.

Digitals

The digital inputs are connected to 40 way part of the 64 way connector

Please refer to the individual vehicle connection diagram for senders that are

fitted.

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BG825 B39

9.3.1.4 Troubleshoot ing

a. Display

Power up display

Ignition on

Buttons lit

and display

on?

Check Supply to PV750 display pins 1

(+ve), 6 (‐ve) and 5 (+ve with IGN on) No

All gauges

inactive?

Yes

Check CAN connections to PV750 display

pin 2 – CAN high

pin 3 – CAN low Yes

All Engine

gauges

inactive

No

Check CAN connection to

engine ECU

Check engine ECU

YesElectronic

Engine

Check Battery negative

connection to engine

Go to 4.2.1No

Yes

All Gearbox

gauges

inactive

No

Check CAN connection to

engine ECU

Check engine ECU

YesElectronic

Gearbox

Check battery negative

connection to gearbox

Go to

4.2.1

No

Yes

One gauge

or symbol

inactive

No

Go to 4.2.1Yes

End

No

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BG825 B40

b. I/O module

c.

Check individual

gauges/symbols

I/O unit

connectors

tight Tighten connectors

No

Yes

Yes Remove connection

to

sender and connect to

battery negative (ground)

YesResistive

Sender?

No

Analogue

input?

Is DM1 for

input FMI 4?

Remove connection to

sender and leave

disconnected

Yes

Is DM1 for

input FMI 3?

No

Check wiring

Check input is active in

profile

Frequency

sender?

Go to 4.2.4

Go to 4.2.2

Go to 4.2.3

No

4‐20mA

sender?

Yes

Yes

No

Fit known suitable resistance to input

Reading

correct No

Replace sender

Yes

Yes

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BG825 B41

Frequency

Inject frequency signal

No

Frequency

sender?

Gauge

operational

Yes

Yes

Replace MPU

Check wiring

Check input is active in profile

Replace I/O module

Disconnect sender and

connect wire to ground

No

4‐20mA

sender

DM1

SPN/FMI?

Yes

Replace Sender

Check wiring

Check if input is active in profile

Replace I/O module

Yes

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BG825 B42

d. Digital inputs

No

D1‐D7?

D8‐D32

Yes With input active check battery

positive is present at switch

Battery

positive?

Check wiring

Replace switch

Check wiring


Replace I/O module

Yes

Yes

No

Close to

negative

Disconnect sender and connect

to battery negative

Yes

Correct

operation

No Check wiring


Replace I/O module

Change switch

Sender is open from negative

Disconnect sender

Correct

operation

No Disconnect 40 way connector

on I/O module

Change switch

No

Yes

Yes

Correct

operation

No Check if input is active

Replace I/O module

Check wiring

Yes

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BG825 B43

10. STORAGE

10.1 BEFORE STORAGE

To place the machine in storage for anextended period of time, the followingmeasures must be taken to insure that it

can be returned to operation withminimum of service.

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

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

Completely fill fuel tank. Lubricate and

change oil before storage.

Lower the air pressure in the tires to about80% of the standard operating pressure.

Give a thin coat of grease to metal surface(hydraulic piston rods and oil seal).

As to batteries, remove the terminals andplace cover on them, or remove them fromthe machine and store separately.

In case the atmospheric temperature may

drop below 00C, add antifreeze in thecooling water.

Set the gear shift lever to neutral position,set the fuel control lever to engine stopposition, and leave the steering pedal notlocked.

10.2 DURING STORAGE

Operate the engine and move themachine for a short distance once amonth so that new oil film will be

generated and exhaustion of oil film in along period will be prevented.

Before using work equipment, wipe off thegrease from the pressure cylinder rod.

When it is unavoidably necessary tocarry out rust preventive operationindoors , open all windows and doors tocirculate the air and prevent the

accumulation of poisonous gases.

10.3 AFTER STORAGE

Carry out the following procedure whentaking the machine out of long termstorage.

Wipe off grease on the hydraulic pistonrod.

Completely fill fuel tank, lubricate and addoil.

If the machine is stored without carrying

out the monthly rust prevention operation,

request your BEML service personnel.

11. MACHINE AND ENGINESERIAL NUMBERS

When calling for service of mechanic or

when making replacement parts order, be

sure to give your BEML service

personnel the machine and engine serial

numbers as well as the service meter

reading before mentioned.

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SECTION - C

SPECIFICATION

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BG825 C2

NOTES:

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BG825 C3

SPECIFICATIONS

1. BG825 DETAILS

1.1. PERFORMANCE

Travel speed (In Km/hr)

Forward

1ST 2ND 3RD 4TH 5TH 6TH 7TH 8TH

4.0 5.4 8.0 11.5 15.8 21.4 31.3 44.9

Reverse

1ST 2ND 3RD 4TH 5TH 6TH 7TH 8TH

4.3 5.8 8.5 12.2 16.9 22.8 33.4 47.9

Maximum Drawbar Pull : 14,420kg

1.2. WEIGHT

Operating weight 25,750 kg

1.3. ENGINE

Model: BS6D140-1

Rated rpm 2100 rpm

Horse power 280 hp

Staring motor 24V,7.5 KW

1.4. AXLES

Oscillation angle: 32deg

Front Wheel Leaning : 18deg (each side)

1.5. STEERING

Minimum turning radius 7.9 m

Maximum steering angle 50 deg left and right of front wheels

1.6. BLADE RANGE

Maximum Bank cutting angle 90deg

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BG825 C4

2. BG825 LAYOUT(UNIT: mm)

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SECTION - D

FUEL AND LUBRICANTS

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BG825 D1

Section D

FUEL AND LUBRICANTS

INDEX


1.1. PROPER SELECTION OF FUEL AND

LUBRICANTSD3

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BG825 D2

NOTES:

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BG825 D3

FUEL AND LUBRICANTS

1. PROPER SELECTION OF FUEL AND LUBRICANTS

* ASTM D 975 No. 1

Note:

When fuel sulphur content is lessthan 0.5 % change oil in the oil panevery periodic maintenance hoursdescribed in this manual.

Change oil according to the followingtable if fuel sulphur content is above0.5 %

* ASTM : American Society ofTesting and Material

* SAE : Society of AutomotiveEngineers

* API : American PetroleumInstitute

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BG825 D4

Fuel sulphurcontent

Change interval of oilin engine oil pan

0.5 to 10% ½ of regular interval

Above 1.0 % ¼ of regular interval

When starting the engine in anatmospheric temperature of lowerthan zero degree centigrade, be sureto use engine oil of SAE 10W, eventhough an atmospheric temperaturegoes up 10 degree centigrade more orless in the day time.

Suitable multi grade oil can be usedfor varying ambient temperature(day/night)

Avoid mixing of different brands of oilseven if the grade of oil is same.

Use API classification CD as engineoil and if API classification CC, reducethe engine oil change interval to half.

We recommend BEML genuine oilwhich has been specificallyformulated and proved for use inengine and hydraulic work equipmentapplications.

Specified capacity : Total amount of oil including oil for components and oil in piping.

Refill capacity : Amount of oil needed to refill system during normal inspection andmaintenance.

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HYDRAULIC OIL

SL. NO. DESCRIPTION SUPPLIER (M/S) BRAND NAME

1

SAE 10W

I.O.C SERVO ULTRA KB 10W

2 CHEMOLEUMS BEML SUPER CLEAN EH 10W

3 I.B.P IBP ULTRA 10W4 B.L PROTOMAC ULT 10W

5 B.P.C.L MAK CD 10W

6 T.W.O VEEDOL 901-S3-10W

TRANSMISSION OIL

SL. NO. DESCRIPTION SUPPLIER (M/S) BRAND NAME

1

SAE 30W

I.O.C SERVO ULTRA KB 30

2 CHEMOLEUMS BEML SUPER CLEAN ET 30

3 I.B.P IBP ULTRA 304 B.L PROTOMAC ULT 30

5 B.P.C.L MAK CD 30

6 T.W.O VEEDOL 903-S3-30

GEAR OIL

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