BEML BH85

April 26, 2018 | Author: Okto Pus | Category: Transmission (Mechanics), Brake, Switch, Truck, Automatic Transmission
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BH85-1...

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RE N 785O& 785 O& M1120 M112009 09-- 02 02

RE N 785O& 785 O& M1120 M112009 09-- 02 02

OPERATION & MAINT AINTENANCE ANCE MANUAL

BH85 - 1 REAR DUMPER  APPLICA  A PPLICAB B LE SERIAL NO. 8454 & UP

BHARAT EARTH MOVERS LIMITED INDIA

CONTENTS OPERATION SAFE SA FETY TY HINT HINTS S .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

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GENE GE NERA RAL L LOCA LOCATI TION ONS S AND AND SPE SPECI CIFI FICA CATI TION ONS S .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

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INST INSTRU RUME MENT NT AND AND CONT CONTRO ROLS LS .... ....... ..... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... ....

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CHEC CHECK K BEF BEFOR ORE E ST STARTIN ARTING G .... ...... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ...

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OPER OP ERA ATION TION YOU YOUR R MACHI MACHINE NE ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... ..

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HAND HANDLI LING NG THE THE TIRES TIRES ... ..... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

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TOWI TOWING NG .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

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EMER EMERGE GENC NCY Y STEE STEERI RING NG .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

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RELE RELEAR ARSE SE OF PA PARK RKIN ING G BRAK BRAKE E .... ...... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

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EMER EMERGE GENC NCY Y BRA BRAKE KE .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

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DUMP DUMP BO BODY DY OP OPER ERA ATION TION ..... ....... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... ..

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HAND HANDLI LING NG OF BA BATT TTER ERY Y .... ...... .... .... .... .... ..... ..... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... ..... ..... .... .... ..

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MAINTENANCE PERI PE RIOD ODIC IC MAIN MAINTE TENA NANC NCE E .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

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PREC PRECAU AUTI TION ONS S FOR FOR MAIN MAINTE TENA NANC NCE E .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

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PAR PA RTS OF THE THE SAF SAFET ETY Y DEV DEVIC ICES ES .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

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MAIN MAINTE TENA NANC NCE E TABL TABLE E .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

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EVER EV ERY Y 50 HOUR HOURS S SE SERV RVIC ICE E .... ...... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... ..

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EVER EV ERY Y 250 250 HOUR HOURS S SE SERV RVIC ICE E ..... ....... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... ....

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EVER EV ERY Y 300 300 HOUR HOURS S SE SERV RVIC ICE E ..... ....... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... ....

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EVER EV ERY Y 500 500 HOUR HOURS S SE SERV RVIC ICE E ..... ....... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... ....

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EVER EV ERY Y 1000 1000 HOUR HOURS S SE SERV RVIC ICE. E... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

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EVER EV ERY Y 4000 4000 HOUR HOURS S SE SERV RVIC ICE E .... ...... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... ..

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WHEN WHEN REQUI REQUIRE RED D .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

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 ADJUSTMENT ................................................................ ................................................................................................................ ................................................

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TROU TROUBL BLE E SHOO SHOOTIN TING G GUID GUIDE E .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... ..

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STOR STORAG AGE E .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

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MACH MACHIN INE E AND AND ENGI ENGINE NE SER SERIA IAL L NUMB NUMBER ERS S .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

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FUEL FUEL,, COOL COOLAN ANT T AND AND LUBR LUBRIC ICAN ANTS TS .... ...... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..

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com/3.D/Beml 85

SAFET SAFETY Y HIN HINTS TS… …... GENERAL •

Wear well – fitting hard hat, safety shoes and working clothes. Never wear loose or unbuttoned d clothes as they may catch on protruding parts of machine. Never wear clothes covered in oil. If  the nature of the work so requires, wear protective goggles or mark, earplugs or other protection.



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



Do not overwork or drive after drinking. T Take ake care of your health. Driving while unfit can lead to mistakes in judgment in emergencies



Never allow more than the permitted number of  Person to ride on the machine.



Learn the prohibitions and rules about work procedures in the job site. Make every effort to prevent accidents by always following these and always bearing safety in mind.











BEFORE STARTING OPERATION

If there should an accident or any other  suchunexpected mishap, deal with it quickly, usingthe nearest apparatus. In addition, it is necessary to prevent any secondary mishaps. It is also important to know the emergency contact system. Learn before hand the locations and method of  use of emergency equipment such as first aid boxes, fire extinguishers or other firefighting equipment. Learn how to use to control devices, gauges and warning devices. Be sure you understand the Remember the check points and checking method for engine oil levels. Always know the dimensions and capacity of your machine. Fuel, oil and antifreeze are dangerous. Never  smoke or light matches when handling fuel, oil grease or antifreezes. Do not handle these substance near any fire or flame.



Examine the lay of the land and the kind o f soil at the site to determine the dangerous points and the best method of operation. Proceed with the work only after making safety arrangements about the dangerous points. Avoid operating near cliffs or deep gullies. Be particularly careful of the edge of cliffs, falling rocks or landslides.



 Always carry out inspection and mainte nance correctly. Check for leakage of fuel, lubricant or  hydraulic oil, and for loose, broken or missing part.



If there are any such problems always correct them. Never use the machine without correcting all problems.



Use repaired machines only after receiving permission from the serviceman in charge of the repair.



 Adjust the operator opera tor’s ’s seat until it is the most comfortable position for operating. Use seat belts if it is equipped to the seat, before you start to drive.



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



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



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



To ensure the safety of workers wo rkers near the machine, always signal or sound the hour to warn them before stating or sound the horn to warn them before starting the engine, moving the machine or turning. Be particularly careful to check that the rear is clear before backing the machine.



Do not leave parts or tools lying around in the vicinity of or on the floor or operator’s compartment. Keep everything in its proper place, to avoid any hindrance while driving.

When selecting a place for storing them, them , take care to choose a place away from wher e fire is used. •

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

Exhaust gas is dangerous. When running the engine for long periods in a poorly ventilated are a, there is a danger of gas poisonings, so open the windows or doors to ensure a good supply of fresh air. 1



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



Check the level of the fuel, lubricants and cooling Dust can reduce visibility, so it is important to use • water. Do not smoke or use naked flames when a sprinkler periodically to keep the dust down. checking. Extinguish cirettes before checking or  STRAIGHT refilling.Check that the radiator cap and all oil MAKE THE HAUL ROAD A S STRAIGHT  AS POSSIBLE fillercaps or plugs are firmly tightened.



When there is a leader, fix standard signals always follow these signals when operating. Learn the signs and rules used in the job site and always follow them.



For both safety and efficiency it is important to make as many straight stretches as possible Especially in the central area where the truck is traveling at high speed, the radius of curves should be made as large as possible. Avoid tight S-bends as they are parti cularly dangerous. The radius of curve should be at least 12 to 15 meters. When maintaining a winding haul road, pay attention to the following points,

 ARRANGEM  ARRANGEMENT ENT BEFORE BEFORE STARTI STARTING NG OPERA OPERATIO TIONS NS PLA NNING AND CONSTRUCTION OF HAUL ROADS. Maintenance of haul roads in the job site is of  utmost importance, not only for safety but also for reduction of cycle time. •





 As far as possible, roads should be for one-way traffic. Where it is impossible to make one-way roads, the road should have amplen width widt h to allow trucks to pass each other easily.

Roads must always be constructed to allow loaded trucks to ass on the inside (away from the edg e).



Place convex mirrors at blind curves or places with poor visibility. visibility.



Place warning signs at least 1.5 meters in from soft road shoulders or form places where there is danger of subsidence.



To allow night driving, it is important to install lighting or reflectors.



Gradients should be kept to within about 10%. In case of brake failure, downhill slopes should be provided with lay-bys.



Turning radius - lsrge enough to have room to spare.



Road width-larger than for straight roads



Outer edge- slightly higher than inside



Outer shoulder – much stronger than for other  roads.

C RO R O SS S S RO R O A DS D S O R S L O P IN I N G R OA OA D S A R E DANGEROUS

Where it is impossible to make the road wide enough, lay-bys should be constructed at frequent intervals.



 As far as possible, avoid having the haul road intersect another road. Particularly on sloped, if the roads intersect an angle, a ramp is formed, and at high speed, this causes heavy rolling which is dangero us.  Also, when a truck is driven across an unleveled slope, there is danger of the truck tilting and overturning. Therefore out level haul road across the slope. OPERATION DURING OPERATION •

Proceed with the operation steadily step by step.  Always aim at unhurried and harmonious safe operation. Dazzling high-speed operation may look efficient, but it does not continue for long. It causes breakdowns, in addition to being dangerous, and in the long run is not effective.



When stopping at crossing, to avoid collisions with order vehicles, keep your distance and confirm who has priority pr iority..



If there is no one giving instructions during operations, there is danger of being hit by dump trucks. In such places, all persons not concerned with the operation should be kept out of the operating area.

MAKE THE HAUL ROAD L EVEL When hauling, always drive at a speed suited to the road conditions. For this reason, maintenance of the haul road is essential for both safely and improve ment of efficiency. efficien cy. Especially after heavy rain, remember that conditions may have changed from those before the rain. •

The best method is to use bulldozes or motor  graders occasionally to maintain the haul road surface.

Fill Fill in hole holes, s, remo remove ve hump humps, s, and and correct correct any tilting of the road to side. Strengthen the road road and correct sagging sagging shoulders. shoulders. Remove rocks, trees or other obstacles. obstacles.

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When driving, sit in the operator’s seat correctly so that the truck can be operated proper ly. ly.



During while standing in the operator’s seat, or  driving while standing are dangerous.



maintenance Manual for instructions on how to use the retarder. Then, descend the hill using the engine and retarder to brake the machine.

 Always concentrate. It is extremely dangerous to allow yourself to be distracted or to think of other  things when operating a machine. Always pay attention to your driving, and to your surroundings. In dangerous places, or where there is restricted visibility, it is important to get down from the machine and confirm whether it is safe before continuing work.



Never drive off the road or in place, which you consider dangerous or outside the range of your  skill.



The machine should always be operated at speed where it can be correctly controlled. The following are dangerous. * Speeding



Take care not to overload the dump body. Overloading not only shortens the service life of  the truck, but also overheats the tires, causing them to burst.



When the dump truck is loaded with soil, its center  of gravity is higher than when unloaded. It therefore is easily affected by the road surface. Failure to remember this can be the cause of  overturning or other accidents.



When driving through puddles, water may get into the wheel brakes. Pay careful attention to this point as it drastically lower the efficiency of the brakes. In such a case, before driving driving on apply the brakes to heat up the brake lining to some extent and this will dry them out



Before crossing bridges, confirm that the bridge is strong enough to take the weight of the dump truck.

* Snaking * Coasting •





LOADING

 As far as possible sudden stopping or sudden starting should be avoided except in emergencies. Be ca careful to to av avoid re repeated st stamping o n the brakes. Before entering curves, slow down. Increase speed when coming out to the curve. If you enter  the curve without slowing down, or while braking, the rear wheels may go over the shoulder or the truck may go over the shoulder or the truck may skid. This is very dangerous. When there is a danger of going over the edge on road shoulders, of slopes or when passing other vehicles, use a leader and follow his signals.



If you attempt to control the speed of your truck by pressing lightly on the brake pedal, this may cause breakdown coming from over heating if the brakes (fading or separation tion of the lining). lining). This can be the cause of unexpected accidents, so do not use the brakes in t his way. way.



Where visibility is bad, such as at corners, or when entering or leaving a narrow road, slow down and sound the horn.



Be sure to load the dump truck evenly. evenly. If the weight is greater on one side, there is danger of losing control of the steering wheel or overturning.



If the load is too far forward, the steering beco mes heavy. It is too far back, the front wheels tend to leave the ground when going uphill.



When backing to dump a load, be careful not to back too far. Place blocks or build a small ridges to stop the wheels at the dumping point.



Never drive with the dump body raised. Always lowers the body before moving.



When continuing operations after rain, remember  that conditions may have changed from those before the rain, so proceed with caution. Be particularly careful when approaching the shoulder  of the road or cliffs, as the rain may have loose ned them.



 Always consider the weight of the machine when driving on roads in snow or rain, or on muddy or  soft terrain. Be careful to avoid the tires slipping or sinking in to the ground.



When towing a breakdown machine, first check the brakes are working properly, and then connect the machine machine the machine machine with with a suitable suitable towrope towrope or cable. When towing on roads, always follow

TRAVELLING DOWNHILL •

Never overrun the engine. Before starting to descend downhill slopes, stop and check that the brakes are working. It is dangerous to use only the brake pedal to control speed on a long downhill slope. In such a case see the operation &

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traffic regulations and attach a correct warring sing. •



 After earthquakes, confirm that the ground is still firm; after blasting, confirm that there are no unexplored charge remaining. Follow signals or  the leader’s instructions.

Traveling speed (max)

20m.

15 km/h

40m.

30 km/h

60m.

40 km/h

Safe speed (km/h)=

Return the gearshift lever to NEUTRAL.



Never fail to lower the dump body.



Run the engine at low idling to cool the engine slowly. slowly. Then stop the engine.



Remove the key from the starting switch.



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

Use, a sprinkler when necessary to keep the dust down and maintain good visibility.



 Always use lights light s when driving drivi ng at night or in tunnels, etc. always dip your light when meeting an oncoming vehicle.



 At night nig ht it is very easy eas y to make mist akes in estimating the distance and height of objects and land.





Stopping the Engine

Forward visibility (m)x 0.7 •

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

When visibility is poor, keep a greater distance from the machine in front and drive at a lower  speed. When visibility drops be low safety level,  AFTER OPERATION OPERATION stop work work and and wait wait for for the the visibi visibilit lity y to improve improve.. This table shows the relation between visibility Stopping the machine speed.  Apply the brake lock. • Forward visibility





The following factors should be considered when choosing a parking place: it should be on flat, firm ground where there is no danger of has to be parked on the road, always follow traffic regula tions. •

When driving in fog, mist or smoke, where visibility is poor, drive safely, following the precautions an d instructions given in traffic regulations.

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When the machine has to be parked on a slope, chokes must always be placed under the wheels.

GENERAL L OCATIONS A ND SPECIFICATIONS SPECIFICATIONS 1.

Under mirror

5.

Hydraulic tank

2.

Operator ’s cab

6.

Front Wheel

3.

Dump body

7.

Head lamp

4.

Rear wheel

WEIGHT •



1

2

3

Gross weight (empty – truck weight + maximum pay-load)

1,41,000 kg

Empty – truck weight:

56.000 kg

PERFORMANCE •

Traveling Speed Forward :

65km/h

Reverse :

12km/h



Maximum payload :

85,000kg



Dump body capacity:

58m3



Dumping speed (at 2100rpm) : 13.5 seconds

ENGINE •

Model:

QST30C



Fly wheel horsepower (at 2100 rpm): 950 hp

NOTE: Specifications to change without notice.

7

6

5

4

INSTRUMENT INSTRUMENT AND CONTROLS CONTROL S 3

4

6

5

1. Acce Accele lera rato torr peda pedall 2. Brak rake pedal edal 3. Turn Turn sig signa nall / dim dimme merr swit switch ch 4. Steer teerin ing g whee wheell 5. Horn button 6. Reta Retard rder er cont contro roll lev lever  er  7. Gear shift lever  7

2

1

5

1. AIR PRESSURE GAUGE

26. DUMP BRAK E LEVER

2. AMMETER

30. CUMMINS CLUSTER GAUGE

3. SPEEDOMETR

30a. TAC TACHO HO METER

4. T/C OIL OIL TEMP GAUGE

30b. CAN CONVER CONVERTOR TOR

5. BRAKE BRA KE OIL TEMP TEMP GAUGE

30c. 30c . GAUGE TEMP. TEMP.

6. VOLTMETER

30d. LIGHT LI GHT INDICATOR INDICATOR

7. KEY SWITCH

30e. SWITCH TOGGLE

8. HEAD LIGHT SWITCH

30f. GAUGE OIL PR.

9. GAUGE LIGHT SWITCH

30. TRANS FILLTER CLOGG

10. FOG LIGHT SWITCH 11. WIPER MOTOR SWITCH 12. W.S. WASHER SWITCH 13. HAZARD LIGHT SWITCH SWITCH 14. DIAGNOSTIC DATA LINK CONNECTOR(ENGINE) 15. RS 232 DATA LINK CONNECTOR FOR UEC/PAYLOAD UEC/PAYLOAD UNIT 16. SWITCH MOUNT PLATE 17. WARNING CLUSTER-1 18. GAUGE PANEL PANEL L H 19. GAUGE PANEL 20. SPEEDOMETER SPEEDOMETER CABLE CABL E 21. UEC DISPLAY SYSTEM 22. FIRE SUPPRESSION CONTROLL 23. FRONT BRAK E CUT OFF 24. EMERG EME RG.. STG. SWITCH 25. CAP 6

sound. When this happens, stop the machine and keep the engine speed raised until the pointer  enters the green range.

ENGINE OIL PRESSURE GAUGE •



Oil pressure is normal if the gauge pointer stays in the green range during engine running. Immediately after the engine starts, the pointer may deflect beyond the green range. In this case, extend the warm-up running of the engine until the pointer comes into the green range.

TORQUE CONVERTER OIL TEMPERATURE GAUGE •

When the pointer of the temperature gauge shows the green range, the oil temperature is normal.



When the pointer enters the red range, stop the machine 2000 rpm with the gear shift lever in neutral until the temperature drops to the normal value.



When the air pressure gets lower (less than 5.2 kg/cm2), the parking brake automatically works. Raise the air pressure so that the parking brake is released.



Don’t travel before the parking brake valve lever  is released.

TACHOMETER •

The tachometer indicates the engine speed in revolutions per minute. When the pointer enters the red range, it indicates that the engine is over  running. Either shift shift the lever to the proper speed stage or decelerate so that the pointer leaves the red range.



When the engine speed reaches 2500 rpm, the retarder brake works automatically to reduce engine speed and slow down to reduce engine speed and slow down the machine. Do not use this function unless absolutely necessary.

RETARDER RETARDER OIL TEMPERATURE GAUGE •

The Pointer staying in the green range indicates normality of the oil temperature.

When the pointer goes beyond the green range  AMMETER into the red range during operation of the engine, • Deflection of the pointer in green range indicates the machine (with the engine held running) hold battery charging. the engine to revolve at 2000 rpm with the gear  • Deflection of the pointer in red range indicates shift lever in neutral until the pointer goes back to battery discharging. the green range and the retarder oil temperature indicator lamp goes out. • The battery charging circuit is normal, if the pointer  shows the green range during engine operation. ENGINE WATER TEMPERATURE GAUGE SERVICE METER Water temperature is normal if pointer stays in • Indicates the total machine operation hours. When the green range during running of the engine. the engine is running, a current flows to advance the meter reading even if the machine is not •  After starting the engine, warm up the engine moving. sufficiently until the pointer comes into green •

range. •

If the pointer deflects beyond the green range to red range during traveling of the machine, reduced the engine speed to low idling speed and maintain this until pointer returns to green range.

 AIR PRESSURE GAUGE •



During operation this should normally register in the green range.



So, use it according to the following instructions.



Record the readings at the start and the end of a work, which will be a work record of the machine.



The time for periodical maintenance is informed.



It indicates the integrated working hours which must be informed at trouble information.



If the green range is not reached, the central warning lamp will light red and a buzzer will

When the engine is running, the meter indicator  turns to show that the meter is operating.

SPEEDOMETER

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downhill…

The The speed speedometer ometer indicate s the machine running speed in kilometer per hour. An odometer is built in the speedometer.

  (The retarder should not be used as a parking brake. (When leaving machine, apply parking brake lever and don’t use the retander control lever).

MACHINE WARNING DEVICE Central warning lamp (Red)

5.

Hydra ydrau ulic oil oil le level vel

In case, the following abnormality occurs, this warning lamp and pilot light, also warning buzzer  sounds.

6.

Body up

7.

Right tu turn

Then, immediately stop the machine and check causes.

8.

Park Parkin ing g Brak Brake: e: Lamp Lamp lig lights hts up whe when n the par parki king ng brake is applied by operation of the parking brake valve lever.

1.

Oil filter filter elemen elementt for for steeri steering ng or or hoist hoist is clog clogged ged..

2.

Rear Rear brake brake oil oil temp tempera eratu ture re exce exceeds eds the the allo allowab wable le limit.

3.

Torqu orque e con conve vert rter er is overh overhea eati ting ng..

4.

Engine Engine oil pressu pressure re is is less less than than speci specifie fied d value value 2 (1.0 ± 0.2 kg/cm ).

5.

Engi Engine ne is over overhe heat atiing. ng.

6.

Cooling Cooling water water capac capacity ity is less less than than specifi specified ed level. level.

7.

Air pressu pressure re is less less than than the specif specified ied value value 2 (5.2 ± 0.5 kg/cm ).

8.

Gear Gear shif shiftt lever lever is is plac placed ed in any any spe speed ed range range othe other  r  than the NEUTRAL position, during parking brake valve is applied.

9.

Attempt Attempting ing to star startt off off a machine machine with with the the parki parking ng brake left on.

Warning Cluster 

1.

Left Left Turn Turn:: Lamp Lamp fla flashe shes s when when the the turn turn sig signal nal is operated.

2.

High High bea beam: m: Lam Lamp p come comes s on when when the the head headla lamp mp is on high beam.

3.

Float Float:: Lamp Lamp com comes es on on when when the the dum dump p cont contro roll LOWER button is pressed, and the dump body will automatically float.

4.

Retard Retarder er brak brake: e: Lamp Lamp ligh lights ts up up when when the retard retarder  er  brake is on. For the details, refer to section “Driving on a

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For the releasing method of the emergency braking force, refer to section RELEASE OF PARKING BRAKE.

STARTING STARTING SWITCH

OFF OFF Key can be inserted and polled out this position and the switches of all the electric systems are set to off and the engine is stopped. ON When this position (ON) is reached by rotating clockwise for one step, the charging circuit and the lamp circuit are electrified. This position (ON) shall held after the engine is started. START Starting motor starts revolution by rotating the switch clockwise further for one step. And the engine is started. The key will be automatically restored the position ON by releasing your hand. PARKING BRAKE LEVER

When the levers is put in the “BRAKE” position, parking brake will be applied to the wheels. Simultaneously, Simultaneously, the parking lamp is lighted in red. ∗ In case of gear shift lever is placed in anyposition other than NEUTRAL while parking brake is applied central warning lamp lights and buzzer sounds.

So, immediately release parking brake. ∗

Except for emergency use, apply the parking

after the machine has been stopped completely. completely. If the brake air pressure drops to 5.2 kg/cm 2 or  less, the parking brake is automatically applied as an emergency brake. ∗

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HAND RETARDER LEVER

EMERGENCY BRAKE LEVER FRONT-BRAKE CUT-OFF LEVER

DUMP-BRAKE LEVER

FRONT BRAK E CUT-OFF CUT-OFF VALVE LEVER When the lever is put in the ‘OFF’ position, on application of Dual brake valve, the Front brake will not be actuated. When the lever is put in the ‘ON’ position, on application of Dual brake valve, the front brake will be actuated. During normal operation, the Front brake cut-off valve lever should be in the ‘OFF’ position. However, the position of Front brake cut-off valve position i.e. ‘ON’ of ‘OFF’ can be chosen depending on the haul road condition.

DUMP BRAKE VALVE LEVER When the lever is put in the ‘ON’ position, both Rear  and Parking brake will be actuated. When the lever is put in the ‘OFF’ position, both Rear  and Parking brake will be released. Dump brake valve should be used only during loading & dumping operation.

9A

EMERGENCY EMERGENCY BRAKE BRAK E LEVER When the lever is put in the “BRAKE” position, all the brakes (Front, Rear & Parking) will be applied. When it is placed in the “RELEASE” position, the emergency brake is released to allow the machine to travel. If the pressure in the main air reservoir drops below 2.2 kg/cm2 because of air leakage or other compressor  or air circuit trouble, the emergency relay valve operates the emergency relay valve operates the emergency brake to automatically stop the machine. Emergency brake should be used in case of emergency emergency o nly . Cautions For Handli Handli ng Do not run the machine if the pressure pre ssure of the main air reservoir drops below 2.2kg/cm2.. Traveling with a locked brake will burn up the lining. If some trouble in to air system, it causes the ∗ emergency brake to be applied. Simultaneously, central warning lamp will light up and warning buzzer will sound. For the releasing method of the emergency braking force, refer to section “EMERGENCY BRAKE” BRAKE”

10

switch lever is lifted upward, the head lights are changed to upper beams. When the lever is pushed downwards, the head lights are changed to lower beams. HORN BUTTON

Depress the center of the steering wheel to actuate the horn. RETARDER RETARDER CONTROL LEVER

TURN SIGNAL SWITCH When the retarder control lever is pulled towards the operator, an oil cooled multi-disc type brake, also used as a rear brake, is applied and retarder indicator  lamp turns on. The amount of lever movement towards the operator, the braking force will be released and retaeder indicator lamp turns off when the lever is pushed push ed forward.

The turn signal switch lever which is also used as the dimmer switch liver, is used when the machine changes its traveling direction. When turning to left, the switch lever is moved towards the operator. When turning to the right, the handle is moved forward. With the aforementioned operation, the respective turn signal lamp starts to blink. Simultaneously, Simultaneously, the signal pilot lamp on the instrument panel starts to blink.

When the retarder oil temperature rise one its gauge indicator enters red range so that pilot lamp and central warning lamp lights (an alarm buzzer also sounds), slow down or stop the machine. The keep the gear shift lever at neutral position and run the engine at 2000 rpm r pm until the gauge indicator  returns to the green renge. GEAR SHIFT LEVER

DIMMER SWITCH

The dimmer switch lever is also used as the turn signal switch level. The purpose of this switch is to change the head lamp beams to upper and lower. When the

11

This lever shifts the transmission according to traveling conditions.

POSITIONED: For ordinary traveling, the torque converter will automatically adjust the traveling speed, shifting gears from second to seventh as necessary. The maximum traveling speed is 65 kg/ h (62km/h) at this setting.



(



If the gear shift lever is placed at a position other  than N with the parking brake or emergency brake locked, the central warning lamp lights up and the alarm buzzer sounds.



Placing the gear shift lever at a position oth er than N with the dump lever at a position other than floa t lights up the central warning lamp and sounds the alarm buzzer.



Never move back the gear shift lever to N while traveling.

) : with with larg large e siz size e tir tire. e.

Position s 5-2 5-2 These positions are used when road conditions are not suitable for high-speed traveling, when traveling, on the shift ground or starting up a slope with load these positions are also on downhill slopes when it is necessary to use the engine as a brake.

DUMP BUTTON

In these positions, the transmission is automatically shifted to given a speed range which matches the travel speed of the machine. The range of  shifting for each posit position ion is as shown in the table below. Posi tion

( *

Transmission range

Max. Speed (Km/h)

5

1st torque converter  -5th direct

 35(33)

4

1st torque converter  -4th direct

 26 (25)

st

The dump button is provided to shift the dump body position. Button:

3

1  to  torque converter -3rd direct

19 (18)

1.

RAIS AISE (RED)

2

1st torque converter  -2nd direct

 15 (14)

2.

HOLD (BLU BLUE)

The dump body is kept held where it is.

) : w i t h l ar g e s i ze t i r e When When usi using ng the the ski skip p shif shiftt (for (for det detai ails ls,, refe referr to section OPERATING YOUR MACHINE),

These positions are used to select a speed range to match the slope.

3.

LOW LOWER (G (GREEN)



Before traveling, always make sure that the dump body operation indication lamp FLOAT FLOAT is on.



If the RAISE button is pressed once, the dump will keep on rising.

Position R:

To stop, press the HOLD button.

Set the lever at this position to back the machine. ∗

Push in the gear shift lever button. The torque converter intervenes to adjust the power flow:

For more details, refer to section DUMP BODY OPERATION.

Position N: This is neutral. When starting the engine, be sure to shift the lever to this position. ∗

Stop the machine completely before reversing the direction of travel.



If the engine is started with this lever at a position

If the LOWER button is released, the dump body will automatically float.

When checking the machine with dump body kept raised, always lock the dump lever lever at “HOLD” posi tion wit h safety safety lock and lay the safety wire between dump body and rear axle housing.

12

GEAR SHIFT CONTROLLER PEDALS

There are two Pedals right one is for accelarator  and left one is for Brake application. STEERING COLUMN TILT LEVER

This inform the location of any abnorma lity in the electronic control equipment for automatic shift. Inside the inspection window in the cover of the control box, there are one green and one red Led (light emitting diode). The combination of Off, flashing, On shows the location of the abnormality. abnormality. When the electronic control equipment is normal, the Led display is as shown in the table on the right. For details of Led display when the condition is abnormal, refer to section “Trouble Shooting Guide”.



The steering wheel is adjustable with an angle of back and forth and 30 mm up and 20 m m down to allow operator to select the best posture for  operation. Loosen lever and determine the best position by moving the wheel then t ighten lever.

When normal LED display

DUST LEVEL L EVEL INDICATORS (RESTRICTION INDICATOR)

RED

GREEN

OFF

ON

Machine condition _

OPERATOR’S SEAT

This device indicates clogging of air cleaner  element. When red pistons appear in the transparent part of indicators, elements are clogged. Immediately clean elements. After cleaning, push indicator buttons to return red pistons to original position.

Set operator’s seat as follows for maximum comfort. Backward – and – for ward  Adju  Ad just st ment Set the seat in the desired position by moving lever 

13

(a) to right, then release the lever. The seat can be adjusted forward or backward 140 mm in 7 steps.

Depress button (1) in the buckle, and the buckle and the mating plate will disengage. The belt length can be adjusted in the following manner.

Seats Seats up and dow n Adj ustment

1.

Turn Knob (2) Match operator’s weight to the scale (50 to 100 kg) for optimum seat adjustment.

Short horten eniing the the belt belt Pull the free end of the buckle body or of the mating plate.

Reclining Reclining adjustment

2.

Move lever (3) upwards, set the seat back in desired position and release lever.

Leng engthen theniing the belt. elt. Pull the belt on the fixed side of the buckle (2) or  on the mating plate holding the belt at right angles 3 the buckle or the mating plate.

The max. adjustment is 24 degrees forwards and backwards each. (12 stages) SAFETY SAFETY BELT BELT (how to use i t) Before using seat belt, make sure that no unusual cond ition s are observed in the belt belt fitti ng and the belt belt its elf.

2

To avoid accidents do not put on the belt while the machine is running

1.

2.

3.

Sit in the the seat seat and adju adjust st the the seat seat so that that the operator’s back could come into close contact with the back rest with the parking brake valve lever kept on. Make Make sure sure that that the belt belt is not kicked kicked at all all and engage the buckle and them mating plate positively with each other until they give a clicking sound.



Check bolts (3) on attachment hardware or fittings secured or the chassis for looseness. Retighten bolts, if ne cessary. cessary.



If the outer surface of the seat belt is marred or  nappy or if, the hardware is damaged or deformed, replace the bolt immediately.

CHECK B EFORE STARTING STARTING The check befor e starting sh all never be neglected as troubles are prevented before hand by the check. a.

How to disenga disengage ge the the buckle buckle and the mating mating plat.

Walk around machine body and check whether  there is any trace of leakage of oil or water. In particular, joint of high pressure hose, hydraulic, joint of air hose, radiator, and an air  tank should be paid special attention. In case leakage in found, inspected the leaking location and stop the leakage. When leakage is not stopped, you are begged to request repair  to BEML distributor.

1

b.

14

Inspect tightening of nuts and bolts on every section. When loosened ones are found apply increase tightening. In particular, attachment positions of air cleaner, muffler, muffler, turbocharger, engine, transmission, hub nut, and drive shaft should be paid a special attontion.

c.

g. CHECKIN CHECKING G OIL OIL LEVEL LEVEL AND REFI REFILL LL IN ENGI ENGINE NE OIL PAN

Inspect disconnection and short-circuit of (before electric wirings, and loosened terminal connections should be paid special attention.

d.

Check for any exhaust emission or noise.

e.

CHEC CHECK K CO COOLIN OLING G WATE WATER R LEVE LEVEL L

Park machine in flat ground, remove cap and confirm that radiator is filled with cooling water up to the prescribed level. if insufficient, refill water. ∗

Refer to section “When Required”

1.

Use Use dips dipsti tick ck (G) (G) to to chec check k the the oil oil leve level. l.

2.

The oil oil leve levell shou should ld be be betw betwee een n mark mark L and and H, H, if  necessary, and oil from oil filler (F).



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



Before adding oil, be sure to draw the oil level gauge off the guard to that air in the crankcase can be released.



Each oil level with the engine stopped or idles is marked respectively on each side of the oil level gauge.



The oil is normally check with the engine stopped and with the level gauge surface marked “Engine Stopped”. It is also possible to check the oil with the engine idled. But, in this case, observe the following precautions.



The engine water temperature gauge should be within the green range.



Use the oil level gauge with its surface marked “Engine Idling”.



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

h.

CHEC CHECK K TRANS TRANSMI MISS SSIO ION N CASE CASE OIL OIL LEVE LEVEL L

When When the water temperature temperature is hi gh turn the cap slowly to release the inside pressure before removing. Donot open when temperature temperature is hi gh

f.

CHECK FUEL L EVEL Check fuel level with fuel gauge or sight gauge (G). at the end of a day’s job, be sure to refill fuel from (F) so that fuel tank will be filled.



If the breather in the fuel tank cap becomes clogged, the fuel may stop flowing, so clean breather periodically. periodically.

Start the engine and run at low idle. Check the oil level with sight gauge (G2). Add oil through oil filler if oil level is low. 15





1.

Use sight gauge (G1) when changing oil (before starting the engine) or after engine has been stopped for 8 hours or more.

DRAIN DRAIN WA WATER TER FRO FROM M AIR AIR RESE RESERV RVOI OIR R

With the engine running, open the drain valvesindicated with arrow’s to drain water.

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



Drain water just after the end of work when the air  reservoir is still warm, to prevent the possibility of  freezing in clod weather.

 An alcohol injector that protects the pneumatic system from freezing is optionally available. available.

i.

CHEC HECK OIL OIL LE LEVEL VEL IN HYDR HYDRAU AULI LIC C TAN TANK K

Running the engine at low idle with the dump body lowered, check sight gauge (G). the oil level must be within the red circle. If necessary, and engine oil front oil filler (F). m .  DRAIN ∗

 j.

Refer to section “EMERGENCY BRAKE”.

CHECK FRONT BRAKE BRAK E OIL LEVEL

n. CHECK HUB NUTS FOR TIGHTNESS

TANK

Tighten any loose hub nuts 3to4 times in the order  illustrated below to a torque of 175 + 20 Kgm. A tightening force of 175 kg applied at one meter on a box wrench away from the center of box produces a torque of 175 Kgm.

Confirm oil level with oil gauge (G). if necessary and engine oil from (F) when oil level has been gone out from the level. ∗

If oil decrease after added, check oil line.



The type of lubricant used depends on the ambient temperature. Select according to the table “Fuel, Coolant and Lubricants”

13 3 11 9 6 1 2 7 8 5 4 12 10

1



k.

WATER FROM EMERGENCY BRAKE

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

DRAIN DRAIN WA WATER TER AND AND SED SEDIM IMEN ENT T FRO FROM M FUE FUEL L

Open drain of fuel tank to drain accumulated water and sediment.

When a wheel has been remounted, as after tire replacement, tighten the hub nuts once again after  running for 5 or 6 kilometers, Compared with the front wheels, the rear wheel take longer for the contact surfaces to fit well with each oth er. Repeat retightening the hub nuts unit about 50 hours after  replacing the wheels.

Rear  13 3 11 9 6 1 2 7 8 5 4 12 10

16

o.

When recognizing abnormality in warning device, functional check should be carried carried out as follows:

CHECK TYRES FOR AIR PRESSURE AND



DAMAGE

Check the air pressure before starting work when they are cold. Also inspect type surfaces for cuts. Hollows, sticking nails or pieces of metal that might lead to puncture. Standard air pressure.

2.

Checking the rear brake oil temperature detecting circuit. Disconnect the writing from the rear brake oil temperatures sensor and ground the sensor  to the chassis. A pilot lamp and the central warning lamp should come on the buzzer  sound.

24.00-49-48PR (STD): 97 psi 3.

p. CHECK DUST LEVEL INDICATORS If the air cleaner elements are clogging, the redcolored pistons of dust level indicators (1) will reach the service level and lock. Clean the eleme nts even if  they section WHEN REQUIRED for how to clean the elements. After cleaning, depress buttons (2) to reset the red pistons.

Checki Checking ng the torque torque conver converter ter oil tempera temperatur ture e detecting circuit. Disconnect the wiring from the torque converter oil temperature sensor and ground the sensor to the chassis. Then, both a pilot lamp and the central warning lamp should come on and at the same time, the buzzer  should cease.

4.

Checking the engine oil pressure detecting circuit. When engine comes to a complete stop with the starting switch kept in ON position, both a pilot lamp and the central warning lamp come on and at the same time the buzzer  sounds.  As soon so on as the th e engi en gine ne star st arts ts up, up , the th e lamp la mp goes out and the buzzer ceases.

5.

q. CHECK MACHINE MA CHINE WARNING DEVICE With the starting switch at the On position (engine stopped), check the following items. 1.

C he h e ck c k f or o r b lo lo wn w n l am a m p bu b u lb l b s (C ( C HE H E CK CK S BEFORE STARTING). Put the lamp test switch. The pilot lamps (*7) and the oentral warning lamp will light up, and the buzzer will sound.

Checking the engine water temperature detecting circuit. Disconnect the wiring from the engine water  temperature sensor. Then, ground the sensor  to the chassis. Both a pilot lamp should come on, and at the same time, the buzzer should sound.

6.

Checking the radiator water level detecting circuit Drain the water slowly from the radiator lower  tank. When approximately 22 liters of water  is drained out, both the water level pilot lamp and the central warning lamp should come on and at a the same time, the buzzer should sound.

17

7.

Checking the air pressure detecting circuit. circuit . If the pressure in an air reservoir is below the 2 specified value (5.2 kg / cm ), both a pilot lamp and the central warning lamp come on and the buzzer sounds. If the air pressure 2 exceeds 5.2 kg/cm , the lamps go out and the buzzer ceases sounding.

8.

Checking condition of lamp bulbs. bulbs . Pushing the lamp test switch causes pilot

lamps (6 lamp) and the central warning lamp to come 0 and the buzzer to should. (Be sure to make this check at the daily inspection) 9.

OPERATING YOUR MACHINE BEFORE STARTING THE ENGINE

Chec Checki king ng the the parki parking ng brak brake e warni warning ng cir circui cuit. t. If the the gear shift lever is in any position other than “N” and the parking brake valve is BRAKE position, both a pilot lamp and the central warning lamp come on and the buzzer sounds.

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

2

If the parking brake valve is placed in RELEASE position or if the gear shift lever is in “N” the lamps go out and the buzzer ceases sounding. This circuit is provided to prevent seizure of the parking brake.

1

r. CHECK FOOT FOOT BRAK E If it does not work well, adjust, refer to section “ADJUSTMENT” S.

CHEC CHECK K THE THE ACTI ACTION ON OF THE THE REAR REAR BRAKE BY OPERATING THE RETARDER CONTROL LEVER.

T.

CHEC CHECK K THE THE ACTI ACTION ON OF THE THE PARK PARKIN ING G BRAKE BRAKE VALVE LEVER.

U.

CHEC CHECK K THAT THAT THE THE STEE STEERI RING NG SYS SYSTE TEM M WORKS WORKS PROPERLY.

V.

CHEC CHECK K THAT THAT THE THE REAR REAR AND UNDE UNDER R VIE VIEW W MIRRORS ARE WELL ADJUSTED. A DJUSTED.

W.

CHEC CHECK K THAT THAT ALL LAMPS LAMPS WOR WORK K PROPE PROPERL RLY Y.

X.

CHEC CHECK K THE THE HOR HORN N AND AND TUR TURN N SIG SIGNAL NAL LAMPS LAMPS

Y.

CHEC CHECK K THAT THAT THE THE INS INSTR TRUM UMEN ENTS TS FUNC FUNCTI TION ON PROPERLY IN OPERATION.

Z.

CHEC CHECK K FOR FOR SED SEDIM IMEN ENT T AND WATER TER

1.

With Without out your your bac back k agai agains nstt the the back back-re -rest st of of the the operator’s seat, adjust the seat position so that the brake pedal can be easily depressed.

2.

Park Parkin ing g brak brake e valv valve e leve leverr (1) (1) shoul should d be pla place ced d in “BRAKE” position.

3. Gear Gear shift shift lever lever (2) shoul should d put “NEUT “NEUTRAL RAL”” positio position. n.

The water separator separates water mixed in the fuel. If float is at or above red line, drain the water . For the draining procedure refer to section " WHEN REQUIRED". Even if a water separator is installed, be sure to check the fuel tank to remove water and sediment in the fuel. 18

TO START START THE ENGINE ENGIN E

CHECKS AFTER STARTING STARTING  After engine starts, do not attempt to operate machine immediately, but be careful to observe the following.

1.

Insert Insert star startin ting g switc switch h key key (1). (1). Turn Turn itit to STAR START, T, and engine starts.

2.

Releas Release e switc switch h key key, and and it return returns s to ON automatically. Keep key in this position.



When starting, run engine and confirm the deflection of oil pressure gauge pointer.



If starting motor does not turn (non-engaged condition) but only makes a clicking noise when key is put in “START” position, repeat starting procedure once again.



Do not leave key in START for more than 20 seconds.



If engine will not start, repeat the starting procedure after an interval of about 2 minutes.



To start engine in cold weather, lightly depress accelerator pedal ha lfway. lfway. In this m anner, it may by easier to start.

19

1.

Keep Keep engin engine e runni running ng at a low-id low-idlin ling g speed speed until until engine oil pressure gauge pointer enters green range, indicating the sufficient circulation of  lubrication oil around various engine parts.

2.

Keep Keep eng engin ine e runni running ng at at medi medium um spee speed d under under no load approx. 5 minutes.

3.

Keep Keep engin engine e runni running ng unti untill water water temper temperatu ature re gauge pointer the machine immediately immediately.. The pointer of air pressure gauge indicates in green range, and central warning lamp and buzzer turn off.



These steps are called warm-up run. Immediately after starting a cold engine, oil pressure gauge pointer may swing beyond green range. In this case, wait for pointer to come back down into the green range and then continue warm-up running.

TO START START MACHINE



Do not accelerate rapidly during warm-up run.



If it is necessary to continue warm-up run for more than 20 minutes, for the pointer of the engine water  temperature gauge swings into green range, run the engine occasionally with medium speed. In 0 case atmospheric temperature is below 10 C attach radiator curtain (if equipped).

4.

Once Once engin engine e has has been been heat heated ed up up to the operat operating ing temperature, check the gauge (oil pressure gauge, water temperature gauge, air pressure gauge and ammeter):

5.

Chec Check k exha exhaus ustt colo colour ur,, any any stra strang nge e nois noise e or  vibration.

6.

Check Check leakag leakage e of lubric lubricati ating ng oil, oil, coolant coolant or fuel. fuel.

4. TO STOP THE ENGINE

1.

Fast Fasten en the the seat seat belt belt..

2.

Alwa Always ys mak make e sure sure that that the the dump dump bod body y opera operati tion on indicating lamp FLOAT FLOAT is on.

3.

Confi Confirm rm that that the pointe pointerr of air pressu pressure re gauge gauge (20 is in the green renge.) Then, put parking brake brake valve lever in the “RELEASE” position. (parking indicator lamp goes off).

1.

Run Run the the engi engine ne at at low low idli idling ng spe speed ed for for abou aboutt 5 to 10 minutes to allow it to gra dually cool down.

2.

Oper Operat ate e toggl toggle e swit switch ch to off off posit positio ion. n.

3.

Retur Return n star starin ing g swit switch ch Key Key to to OFF OFF posit positio ion n and and remove key.



If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency emergenc y. BE SURE TO APPLY PARKING BRAKE WHEN LEAVING MACHENE

20

4.

Push Push retar retarder der cont control rol level level to to relea release se the the retar retarder  der  brake and make sure retader retader indicator lamp lamp goes off.

5.

Soun Sound d horn horn and and mak make e sur sure e ther there e are are no no per perso sons ns or obstacles around the machine.

6.

Shift Shift gear shift shift lever lever to a suitabl suitable e gear gear positi position on and depress accelerator pedal , and the machine will start running.

In case gear shift lever is placed in any position other than Neutral while parking brake is applied, central warning lamp lights and warning buzzer buzzer sounds. MACHINE WITH AUTOMATIC TRANSMISSION

Because of automatic transmission, the gears will automatically according to the machine speed when gear shift lever lever is placed in the desired desired position. ∗

Depress the button at the head of the lever to shift the lever (except between N and 5).



When reversing the direction of travel. Stop the machine completely. then proceed in the opposition direction.

Shift up (Increasing the traveling speed) When the travel speed is accelerated by stepping on accelerator pedal, the lockup clutch will engage to from direct drive. Further acceleration will cause the transmission to shift up automatically. automatically. SHIFT DOWN (Decelerating the traveling speed)

SKIP SHIFT

 As you remove remove your your foot foot from from the accele accelerato ratorr pedal, pedal, the machine begins decelerating and the transmission automatically shifts down. Down shift inhibit This prevents engine overrun caused by mistaken operation of the gear shift lever.

This is used when traveling at high speed and starting to go up a slope. The operator uses it when he wishes to travel smoothly and shift down in one step to a speed range which matches the slope. 1. Skip Skip shif shiftt oper operat atio ion n Keep the accelerator pedal depressed down and move the gear shift lever to a position po sition to match the slope. (Use the positions in the following table as a guide).

21

correct position. Guide for selection of positions when traveling uphill loaded.

Grade  

22-3% 3-5% 5Over 6%





2.

Afte Afterr trav travel elin ing g uphi uphill ll wit with h skip skip shi shift ft Return the gear shift lever to the position before it was set, or to position D. the transmission will then be shifted up.

Position 5 4

3.

Skill killfu full use use of shif shift. t.



If the brake is operated during skip shift oper ation, the transmission will be automatically locked at the speed range which match the actual speed of  the machine at the moment.



If the gear shift lever is set to an unsuitable position, the shift controller will lock the gear at a suitable range, so the final position may not be the same as the set position.



When traveling, the skip shift may not function directly after shifting gear or when the engine speed is low. This does not indicate a failure.

3 2

 After the gear shift lever is operated, the shift controller driver the machine distinguishing between direct range and torque converter range until it reaches a travel speed which matches the speed matches the set position. When the travel speed matches the speed range, the shift controller  shifts down in one step. If the gear shift lever is operated with the accelerator  pedal depressed, this operation can be repeated several times.

TO STOP THE MACHINE

BACKING-UP 5

When the machine has come to a complete stop, move the gear shifts lever to R and back the machine slowly, slowly, carefully watching the rea r. TURNING Before entering a curve, slow down enough for  the transmission to adjust to a low-speed range. Slightly accelerate while negotiating the curve. D0 not enter and negotiate a curve at high speed. The shift controller will down to the final set gear  speed, so there is no need to worry if you make a mistake. Simply move the gear shift lever to the 22

2

1

3 3

4

1.

Rele Release ase your your foot foot from from acc accele elera rator tor peda pedall (1) (1) and depress brake pedal (2) to stop the machine.

2.

After After the the machi machine ne stop stops s comple completel tely y, move move the gear shift lever (3) to NEUTRAL.

3.

When When leav leavin ing g machi machine ne,, parki parking ng brak brake e valve valve lever (4) should be placed in BRAKE position and Park the machine.



Pull retarder control lever (5) fully when operator stays on the seat.

ped al (1) and operate retarded retarded control lever (2) to slow the machine down to a safe speed for the downhill slope.

2.

Move Move gear gear shif shiftt lever lever (3) to a positi position on (5,4 (5,4,3or ,3or 2) which matches the maximum permissible speed for the capacity of the retarder brake.

3.

When When trav traveli eling ng down downhil hill, l, operat operate e the the reta retarde rder  r  control lever to keep the engine revolution at 155 0 to 2300 rpm, and travel at a speed which keeps the retarder oil temperature in the green r ange.



Do not operate the retarder control lever abruptly, lever abruptly, otherwise there will be a sudden change in the travel speed with severe jerks.



 As far f ar as possible, limit use of the brake pedal while traveling downhill for a long distance.



 Apply the retarder control lever slowly to avoid large impact or tire slippage.

PRECAUTIONS FOR DOWNHILL TRAVEL

DOWNHILL TRAVELLING



The maximum allowable travel speed when going downhill with the retarder applied depends on the downhill travel distance and the hill gradient. (refer  to the brake performance graph.)



If the machine continues traveling downhill at a speed exceeding the maximum allowable value indicated in the brake performance graph, it may damage the retarder brake, resulting in a ser ious accident.



When the pointer of the torque converter oil temperature gauge is in the red range, stop the truck immediately, in so doing, the engine sho uld be kept operated at a speed of 2000 rpm, with

2

1

When traveling downhill, maintain a safe speed according to road conditions: Consider the road grade, the grade of the path, the road surface, degree of curves and road width. 1.

Befo Before re star starti ting ng down downhi hill ll,, relea release se acce accele lera rato tor  r 

23

the gear shift lever put in the “NEUTRAL” position, p osition, until the pointer returns to the green range.

3. Apply Apply the the parkin parking g brake brake valve valve lever lever..



(Refer to section TROUBLE SHOOTING GUIDE)



If the retarder oil temperature gauge pointer enter  the red range of the scale while the retarder is applied, shift down the gear shift lever. (At this time, the central warning lamp will light and the warning buzzer will sound). If the gauge pointer  does not yet move into the green range, stop the machine immediately and keep the engine speed at 2000 rpm until the gauge pointer moves into the green range.



If the retarder control lever is applied while traveling downhill, the machine can be shifted down faster than in ordinary deceleration and without the necessity of shifting up the gear shift lever.



If the retarder should stop working while traveling downhill, do the following:

1.

Comple Completel tely y rele release ase the retarde retarderr contr control ol lever lever once once and then operate the lever again.



Immediately place chocks under tires when the machine stops. ∗

The maximum allowable travel speed and the speed range can be determined from the brake performance curve as shown in the following example where the downhill distance is 1500 m, the travel resistance is minus 11% (gradient resistance is minus 13% and rolling resistance 2%) and the haul Load is 78 tons. 1.

Use Use the the brake brake perfo perform rmanc ance e cur curve ve for for dow downhi nhill ll distance of 1500 m. (See the graph at left on the next page).

2.

Pilot Pilot mach machine ines s gross gross weight weight A in the the graph graph and draw a line straight d down own from point A.

3.

Find Find point point B where where the vertic vertical al line line interse intersects cts the minus 11% travel resistance line, and draw a horizontal line from point B.

4.

Find Find point point C wher where e the the horiz horizonta ontall line line inters intersect ects s the performance curve. Draw a line straight down from point C, and find the machine speed scale line.

5.

Through Through the above above process process,, the the foll followi owing ng values values can be obtained. From point D, the maximum permissible speed is 33 km/h and from point C, the gear speed should be F5.



This value for the maximum permissible spe ed is only a rough target value based on the retarder  brake performance. At the actual job site, however, the safe driving speed will almost always be lower than the maximum permissible speed because of the road conditions and other factors. Therefore, select a speed at which the retarder  brake oil temperature gauge will be kept in the green range.

OVERRUN PREVENTIVE MECHANISM If the machine is accelerated beyond the maximum speed for any gear position while going downhill, the over preventive mechanism actuates, causing the retarder to work to slow down the machine. EMERGENCY STOP In an emergency, such a fault of the foot brake, emergency stop the machine at described below:

2.

Determine the cause and repair on the spool as much as possible.

HOW TO USE THE GRAPH

2. If the repe repeated ated oper operati ation on of the reta retaeder eder contr control ol level fails to actuate the re tarder, tarder, return the lever  to RELEASE position and stop the machine be depressing the brake pedal. Then ask BEML distributor to make the repair.

1.

When the operator is in the operator is in the operator’s compartment, he should pull the retarder lever fully to apply the retarder. When leaving the machine, apply the parking brake.

Pull Pull the the ret retard arder er con contr trol ol lev lever er ful fully ly..

Actua Actuate te the emerge emergenc ncy y brake brake valve valve lever lever..

24



Brake performance (length of slo ps : 450 m)



B r a k e p e r f o r m a n c e (l (l e n g t h o f s l o p s : 6 0 0 m )

Standard tire (24.00 – 49)

Standard tire (24.00 –49)

Gross weigth (ks x 1000) 1000)

Gross weigh t (ks x 1000) •

Brake performance (length of slops : 900m)

Standard tire (24.00 – 49)



Brake performance (length of slops : 900m)



Brake performance (length of slops : 1500m)

Standard tire (24.00 – 49)

Standard tire (24.00-49) Gross weight (ks x 1000) 1000)

 Gross weigt h (ks x 1000) 1000)

25



care to prevent the tires from slipping or sticking in mud.

Brake performance (length of slops : 1500 m)

Standard tire (24.00 – 49)

The load load should be dumped in accordance with the instruct ions of the signal man. man.

Gross weigth (ks x 1000) 1000)

HOW TO DRIVE MANUALLY MANUA LLY IF TROUBL TROUBL E OCCURS IN THE ELECTRICAL SYSTEM OF THE TRANSMISSION CONTROL a)

Even Even if electri electrical cal circuit circuit fail fail durin during g travel travel,, the the transmission will hold the current speed range while the engine is running. If you cannot contro l the speed with the gear shift lever, lever, do not stop the engine. Continue traveling up to a place where repair is possible. If you stop the engine, the transmission will automatically return to neutral.

b)

If you you have have detect detected ed befo before re the the start start of opera operate te because of trouble in electrical circuits, loosen lock nuts (1) and (2) of the transmission valve and then hold plug by one turn. The transmission will be shifted to forward second speed wherever the gear  shift laver is placed, and you can travel to where service is available.

OPERATION INSTRUCTIONS ∗

When there is curve in the road, release the accelerator pedal before reaching the curve and let the gears shift down to the lowest possible gear  speed, then step on the accelerator pedal again to keep on traveling. Do not let the machine coast at high speed.



When loading the machine, take care to distribute the load evenly over the entire dump body. Do not overload the front section of the dum p body. body.



When traveling on roads with puddles, the brake mechanism may be soaked with water. This causes the efficiency of the front brake to drop extremely. When this happens, apply braking force several times to the front wheel to burn the brake lining slightly. This helps to dry the brake mechanisms.

Be sure to firmly screw in hold plug after repair. ∗

To check for troubles in the automatic autom atic transmission, special checkers, etc. are required. Contact your  Beml when necessary to check the automatic transmission.

HANDLING THE TIRES Ton – km – per – hour Rating



When traveling in rain or snow or on muddy or  silty road, special attention to prevent the machine from slipping or being mired in mud. It should be operated in consideration of the loaded conditions when traveling on such roads.



When the engine stops during running of the machine, stop the m machine achine immediately. Move the gear shift lever to neutral and start the engine.



When driving the machine in the rain or snow fall, on a muddy road, or on a swamp, use greater 

26

Tires of construction machinery are used under  conditions incomparably serve with passenger  cars, buses and trucks. They are specially designed to survives such working conditions. OR tires generate much more heat in t he rubber  layer during operation than ordinary tires. If they are used continuously in excess of their load and speed limits exceed the permissible limit, the inside temperature might exceed the permissible limit, leading to softening of rubber and separation of layers layers .

The ton-km-per-hour rating serves as a standard to use tires safely and prevent such trouble.

D = Tire load on the empty machine

If a tire is forced to work beyond its ton- km- perhour rating, troubles will occur frequently.

E = Tire load on the loaded machine F = Turnaround distance

In such cases, take the following measures:

G = Turnaround frequencies for one day

1)

Ease Ease the the work working ing condit condition ions s : reduce reduce the ton-km ton-km-per-hour rating of the work.

2)

Replac Replace e the the tires tires with with those those having having a highe higherr tontonkm-per-hour rating.

H = Total Total operation hour for one day  A = BxC B = D+E 2

CALCULATION METHODS OF ACTUAL T.K.M.P.H. VALUE :

C = FxG H

 A = Actual T.km.P T.km.P.H. .H. B = Average load per tire

The total operation hour for one day includes the operator’s break time and the time and the time during which the the machine is is not in oper ati on.

C = Average traveling speed per day

Ton-km-per-hour fire rating and maximum continuous traveling speed. Tire ton-km-per-hour  ton-km-per-hour  rating with ambient ambient temperature

Tire 0

16 C

0

27 C

0

38 C

Maximum continuous traveling speed  (km/h) with ambient temperature 0

0

49 C

16 C

0

0

27 C 38 C

0

49 C

Without load (front-wheel basis)

37

35

32

30

Structure : GP Cord No. (TRA) :E3

With load ( re rear-wheel basis)

22

21

19

181

If equipped Size : 24.00-49-48PR

Without load ( fr fr on ont-wheel  basis)

33

31

28

26

With load (rear-wheel basis)

19

18

17

16

44

42

39

With load (rear-wheel basis)

27

25

23

22

Without load (front-wheel basis)

36

34

32

29

20

18

18

Standard Size : 24.00-49-42PR 495

445

465

416

430

387

400

358

Structure : GP Cord No. (TRA) :E3

If equipped Size : 27.00-49-42PR 605

565

525

Without load (front-wheel 485 basis)

Structure : GP Cord No. (TRA) :E3

If equipped Size : 27.00-49-48PR 495 Structure : GP Cord No. (TRA) :E4 ∗

463

431

399

With load (rear-wheel  basis)

22

36

The values ton- km-per-hour rating given above vary somewhat with tire makers. If you must travel near near the maximum speeds given, consult consult your  Kom\atsu distributor.

Defective tires as shown 1) to 6) below should be replaced replaced with n ew tires for safe operations. 1)

Tires Tires with with cuts cuts,, broken broken,, or exce excessi ssivel vely y deform deformed ed bead wire.

2)

Excess Excessive ively ly worn worn tires tires in in which which the carcas carcass s ply ply (Excluding breaker) is exposed along ¼ the 27 circumference.

3)

Tires Tires whos whose e carca carcass ss dama damaged ged more more than than 1/3 1/3 the the tire width.

4)

Tire Tires s wit with h ply ply sep separ arat atio ion. n.

5)

Tires Tires with with radia radiall cracks cracks which which reach reach the carc carcass ass..

6)

Aged, Aged, defor deformed med or or abnorm abnormall ally y damage damaged d tires. tires.

INSTRUCTIONS WHEN TRAVELING OVER A LONG DISTANCE

distance surpasses that limit, be sure to remove the drive shaft between the transmission and the differential case.

When the machine travels continuously continuou sly over a long distance at high speed, the tires produce extreme heat, this may cause the tires to be worn. To To prevent this, the following instructions should be observed : Without load or with the minimum load.



The towing speed must be within 8 km/h.



The hook for towing a machine is installed under  the front frame.



The emergency steering is available as an option, which is designed to facilitate steering in towing when the engine is out of operation.

3)

When When air air pressu pressure re in air air reser reservoi voirr abnorm abnormal ally ly drop drops s due to leakage from air circuit, parking brake and emergency brake operate. When towing machine, release both brakes.

The tire inflation pressure should be checked and adjusted, when the tires are still cold before operation. •

Correct inflation pressure : 24.00 x 49 – 48PR (97 Psi) The tire inflation pressure should not be re duced during operation •

EMERGENCY STEERING

The machine should be operated in either one of  the following two traveling conditions :



1)

Continu Continuous ous travel travel can be perf performe ormed d at at shown shown to previous page.

2)

When When the the max maxim imum um trav travel elin ing g speed speed is 40 40 km/h km/h,, and the machine should be stopped for at least one hour after every 60 km at 38%C.



The emergency steering system is operated by electricity. It is used when the engine stops when traveling, or there is an abnormality abnormalit y in the steering pump.

The machine should not be operated with the tires filled with water or dry – ballast.

The emergency steering system becomes operable when the emergency steering switch makes steering possible.

TOWING

Placing the switch in ON starts the electric pump with the current from the battery, battery, and thereby makes steering possible. Cautions Cautions for op eration eration

If towing is the sole means to convey a machine, it must be made, giving full attention to the following. 1)

When When the the eng engin ine e is is in in ope operat ratio ion n: Be sure to keep the engine running and be r eady for steering and braking. (Take full care that the brake never work in the case of the defective air  circuit).

2)

When When the the eng engin ine e is is out out of opera operati tion on :

1)

Do not not use use cont continu inuous ously ly for for more more than than 3 minu minutes tes.. (It is not designed for continuous operation)

2)

The The trav travel el spe speed ed shal shalll be 5 km/h km/h or or less less..

3)

Turn Turn off the switch switch immedi immediate ately ly afte afterr stopp stopping ing the machine  Although the emergency steering system is used only in an emergency, inspect the system every day so that it is always ready for operation.

Inspection Method Place the switch in ON when the machine is not loaded, and makes sure that the steering wheel can be operated for 20 seconds (with the engine stopped). Do not use emerge mergency ncy stee steering continuo continuously usly for mor e than 3 minutes

Never haul the machine over 800 in. if the towing

28

EMERGENCY BRAKE RELEASE OF PARKING BRAKE

Function of Emergency Emergency brake

If the parking brake can not be released after its emergency application even if the parking brake valve lever is put in RELEASE position, take the following actions to release the parking brake. 1.

Remov Remove e air air chan change ge soc socke kett (1) (1) from from the the fron frontt reservoir.

2.

Instal Installl air air charg charge e socke sockett (1) (1) in positi position on afte after  r  removing the air hose connected to parking brake chamber (2).

If the emergency brake valve lever is shifted in to BRAKE position because of trouble with, or air leakage from the air compressor and the air circuit, or if the air  pressure in the main air reservoir d rops below 2.2 kg/ 2 cm , the emergency relay valve will actuate so that the rear brake is operated by the air from the emergency air  reservoir, causing the machine to stop automatically. automatically. Handlin Handlin g Cautio Cautio ns Be careful not to start the machine traveling when air pressure in the main reservoir d rops below 2.2 kg/ 2 cm  and the emergency brake is operating. If the machine travels even with the brake on, the brake disc will burn because of the brag on the brake. ∗

while emergency brake is applied, warning lamp lights and buzzer sounds.

Releasing procedure of emergency brake Front

3.

Conne Connect ct one one end end of of whee wheell air air Char Charge ge hos hose e (3) (3) to air Charge socket (1). (The hose can be connected to the socket in one touch).

4.

Press Press other other hose hose (3) end to wheel’ wheel’s s valv valve e (4) (4) and and the brake will be released as air is supplied to the brake chamber.

5.

When When the the parki parking ng brak brake e is rele releas ased ed,, remov remove e the air charge house. The air in the parking brake chamber will not be discharged because it is protected by the air charge socket. Immediately move the machine to a safe place by traction.



Rear 

Special care should be paid when towing the machine by an another machine, refer to section “TOWING”, When releasing the parking brake on a slope, put chocks against against t he tires. tires .

 After preparing preparing for towing the machine, machine, open drain valves of rear emergency brake to bleed air pressure. Stop machine completely and bleed air  from emergency emergency s ystem.

29

When releasing the emergency brake on slope, put chock s against against th e tires.



Check before before startin g Start Start engine and drain water from emergency air  reservoir and main air reservoir. ∗

During cold weather, Drain water after the day’s work has ended to prevent freezing.

To prevent impact load to the hydraulic hy draulic circuit circui t and hoist cylinders when tilting the dump body, bo dy, reduce the engine revolutions as the body is about to reach re ach its maximum incline. To inspect the dump body in the raised positio n, be sure to use the safety wire and depress depress the “ HOLD” HOLD” bu tton. When check the machine, be sure to use the dump control sw itch but ton cover (1). (1).

Periodic maintenance (Every 2000 hours or every year) Disassemble the emergency valve and clean it. Replace worn and damaged parts for new ones. Replace all rubber parts with new ones. Dump Body Operation Operate the dump body in the following anyway: 1.

Move Move the the gear gear shif shiftt lever lever to neut neutral ral and the parkin parking g valve lever to BRAKE.

2.

The The dump dump bod body y rise rises s when when the the dum dump p cont contro roll switch button “RAISE” is pressed.



Once the RAISE button is pressed, the dump body keeps rising even after the button is released.

3.

The tiltin tilting g spee speed d vari varies es proport proportion ionall ally y with with the speed of engine revolution.

During travel, make sure that the “ FLOAT” FLOAT” lamp (green) (green) is on. TO protect t he hydraulic devices and main frame from needless load. Reduce the dumpin g speed when dumpi ng large rocks. Do not loads while the dump body is tilted. In case the dump body stops on the way for  whatever reasons, be sure to depress the “ HOLD” HOLD” button, and check the machine. When checking the machine with dump body kept raised, always lock the dump lever at “ HOLD” HOLD” p osition w ith safety lock and lay the safety air between dump body and rear rear axle housing .

4.

As the dump dump body body reac reaches hes a prede predeter termin mined ed “kic “kick k out” position, it returns to HOLD automatically and the dump body remains stationary there.

5.

To stop stop the the risin rising g of the dump body halfway halfway,, press press the “HOLD” button.

6.

The The dump dump bod body y goes goes dow down n when when dum dump p cont contro roll switch button “LOWER” is pressed. When the dump body is lowered to a certain degree (be yond the dead point), release the “LOWER” button (float stage). The dump body will fall by its own weight. To stop the lowering of dump body half way press the “HOLD” button. To restart lowering, repeat re peat the above operation.

30

HANDLING OF BATTERY

3) Make sure cables and clips are are firmly secured.

PRECAUTIONS FOR CHARGING

4) Keep the starting starting switch switch in “OFF” “OFF” position. position.

BATTERY

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

1.

2.

Befor Before e chargi charging, ng, dis disco conne nnect cting ing the the cabl cable e from from the negative (-) terminal of the battery. Otherwise, an unusually high voltage will damage the altern ator.

2.

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

While While char chargi ging ng the the batte battery ry,, remov remove e all all batte battery ry plugs for satisfactory ventilation.

2) Connec Connectt the other other clip clip to the the positi positive ve (+) terminal to engine which is running.

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

3) Connec Connectt one clip clip of boos booster ter cabl cable e B to the the negative (-) terminal of the engine which is running.

0

3.

If the the ele elect ctro roly lyte te temp temper erat ature ure exce exceeds eds 45 C stop charging for a while.

4.

Turn Turn off off the char charge gerr as soo soon n as the the bat batter tery y is charged.

Connec Connectt the the boost booster er cabl cable e in the follow following ing manner manner..

4) Connect Connect the the other other clip to the the body body of the machine to be started.

Overcharging the battery may cause followings:



1 : Overheating Overheating the the battery battery

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

2 : Decreasing Decreasing the quantity quantity of electrolyte. electrolyte. 3 : Damaging Damaging the electrode electrode plate 5.

If the the elec electro trolyt lyte e gets gets on on your your ski skin n or clo clothe thes, s, immediately wash with plenty of clean water.

6.

Do not not mix up cables cables (pos (positi itive ve (+) (+) to to negat negative ive (-) or negative (-) to positive (+), as it will damage the alternator.

7.

When When inspe inspecti cting ng or or servi servicin cing g a batt battery ery,, be sure sure to stop the engine and turn the starting switch to (OFF) position.

8.

When When perfo performi rming ng any servic service e to to batt battery ery,, besi besides des checking the electrolyte level or measuring the specific gravity, disconnect cables from the battery.

REMOVAL REMOVAL A ND INSTALLATION OF B ATTERY ATTERY •



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

When connecting t he cables, never never contact the positive (+) terminals and negative (-) terminals. Make sure that the booster cable connections are correct. Connect the boost er cable to the body as far as possible from t he battery. battery. 3.

St ar ar ti ti ng ng th th e en gi gi ne ne

1)

Turn Turn the the star starting ting switch switch to ST START ART posit position ion and start up the engine.

2)

If the the engi engine ne does doesn’t n’t start start at at first first,, try try again again after after 2 minutes or so.  After the engine has started, the booster cables should be disconnected in the reverse order in which they were connected.

When installing battery, the ground cable should be connected to the ground terminal as the last step. 1.

STARTING ENGINE WITH A BOOSTER CABLE When starting up the engine with a booster  cable, do as follo ws: 1.

Disc Discon onne nect ctin ing g the the boos booste terr cab cable les. s. 1)

Disc Discon onne nect ct the the cli clip p of boos booster ter cabl cable e B fro from m the body of the machine which was star ted.

2)

Disc Discon onne nect ct the the othe otherr clip clip form form the the nega negati tive ve (-) terminal of the running engine.

3)

Disc Discon onne nect ct the the cli clip p of boos booster ter cable cable A fro from m the positive (+) terminal of the running engine.

Befo Before re conn connec ecti ting ng the the boo boost ster er cabl cable e 1) Size of booster booster cable cable and clip clip should should be suitable for the battery size. 2) Check cable cable and clips clips for breaks, breaks, corroded corroded surfaces, etc. 31

4)

out any maintenance. However, if the nature of the maintenance requires require s the dump body to be raised for inspection or maintenance, always use the safety pin, and lock the dump lever in the HOLD position.

Disc Disconn onnec ectt the the ethe etherr clip clip from from the the posi positi tive ve (+) (+) terminal of the engine which was started.

PERIODIC MAINTENANCE Proper lubrication and maintenance assure trouble – free operation and long machine life. Time and money spent for scheduled periodic maintenance will be amply compensated by prolonged machine operation and reduced operating cost.  All hourly hourly figures figures given given in the following following descripti descriptions ons are based on service meter readings. In practice, however, it is recommended to rearrange all of them into units of days, weeks and months to make the maintenance schedule mare convenient. Under rough  job site or operating opera ting conditions, condit ions, it is necessary neces sary to somewhat shorten the maintenance intervals stated in this manual.



Park the maintenance on firm, flat ground and lower  the dump body. Stop the engine, return the gear  shift lever to Neutral and apply the parking brake before carrying out the maintenance.



When working with others, choose a group leader, decide the work procedure and work according the leader’s instructions. Check with the others before doing anything. Do not move any part without warning and do not perform any maintenance beyond the agreed work.



 Always  Alw ays sto p the eng ine bef ore or e was hin g the machine or charging the oil.



Flames should never be used instead of  lamps.



Never use a naked flame to check leaks of the level of oil, fuel antifreeze or electrolyte.



Highly Inflammable gas is given off by batteries. Do not smoke make sparks or bring naked flames near the battery. Never check whether the battery is charged by striking the terminal with metal.

PRECAUTIONS FOR MAINTENANCE For safety maintenance

when

carrying

During charging, gas is given off. To prevent it from collecting, make sure there is good ventilation. In addition, do not allow sparks or  flames near the battery. Never smoke or allow naked flames near when handing fuel or oil.

out

Even simple operations, if carried out carelessly, can be the cause of injuries. At least the following points should be followed, but safety should always be borne in mind when carrying out any operation. •



Wear a well – fitting hard hat, safety shoes and working clothes. If the nature of the work so requires, wear protective goggles, goggl es, gloves or other  protection. Never wear loose or unbuttoned clothes a they may catch on protruding parts of the machine. Never wear clothes covered in oil.





Unless you have special instructions to the contrary, maintenance should always be carried out with the engine stopped. If maintenance is carried out with the engine running, there must be two men present: one sitting in the operator’s seat and the other one performing the maintenance. Both should confirm the operation is safe. The body should always be lowered before carrying

32

Never inspect the fan belt or attempt any maintenance when the engine is running.  Alway  Alw ays s sto p the engin en gin e befor be for e car rying ryi ng out maintenance on this or other moving parts, or near  any moving parts.



When working under the machine, hang a caution sign in the operator’s compartment, and if  necessary, necessary, also put signs around aroun d the machine.



Do not remove the raditor cap when the water is hot. There is danger that boiling water may spurt out. First release the internal pressure before removing the cap.



When carrying out maintenance, pay careful attention to persons in the vicinity. In particular, do not allow anyone to approach the machine unnecessarily.

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



When replacing parts, always use the genuine BEML parts specified in the part Book.



 Al wa ys us e th e gr ad es of gr ea se an d oi l recommended by BEML. Choose the viscosity specified for the ambient temperature.



 Always use pure oil or grease, and be sure sure to use clean containers, to prevent any dirt from getting in.



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



Before draining the oil, warm it up to temperature 0 of 30 to 40 C.



Be particularly careful when removing the radiator  cap or the hydraulic oil tank filler cap.



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



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



There should be neither too mach not too little lubricant. 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 the drained oil and filter for any signs of excessive metal particles or other foreign materials.



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



Special measuring apparatus is needed for testing hydraulic pressure. When carrying out other  difficult maintenance work, carrying them out carelessly can cause unexpected is too difficult, always request Beml engineers to carry out it.



Bleed the air from the hydraulic brake line.

GENERAL POINTS TO BE B ORNE IN MIND WHEN CARRYING OUT MAINTENANCE



If there is air in the hydraulic brake line, the braking effect will be poor.

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



If this happens, bleed the air fully from the circuit.















When carrying out maintenance, pay careful attention to other workers and persons in the vicinity. vicinity. Care is particularly needed nee ded when grinding, wilding, or swinging a sledge hammer. When working on top of the machine, be careful not to lose your balance and fall. Arrange things before hand so that no one starts the engine or  moves the machine by mistake. Immediately remove any oil or grease on the floor  of the operator’s compartment, or on the handrail. It is very dangerous if someone slips on floor  plates. If air gets into the hydraulic brake line, the brakes will not work properly. In such cases bleed all the air from the circuit. If the air pressure in the air  brake line drops, the brakes will not work. Check for leaks in the air circuit, and if any faults are found, repair them. When leaning over to inspect cases, there is a risk of dropping things in. before removing the covers to inspect such cases, empty every thing from your pockets. Be particularly careful to remove wrenches and nuts.

Precautions Precautions wh en changing tires •

 Always block the wheels on the opposite side before jacking up the machine.  After jacking up the machine, always insert blocks under the machine to prevent it from falling.





Do not loosen or remove any part except those needed to be removed when taking off the tire. The tire is under high pressure, so it is e xtremely dangerous to loosen anything carelessly. In particular, repair of tires should be left to the tire manufacture’s dealer.

33



Check the air circuit for any leakage of air, and repair if any defect is found.

PERIODIC REPLACEMENT OF COMPONENT PARTS FOR THE SAFETY DEVICES . To ensure safety in the machine driving and dump body operation, the users of Beml dump trucks are requested to perform periodic maintenance of their own trucks securely. Fabricated in the safety devices these parts are liable to change in quality with a long lapse of time. They are also worn or fatigued gradually during continuous use of them. However, Howe ver, since it is somewhat difficult to determine accurately the progres s of change in quality, wear of fatigue of them, waver will exist in  judgment whether some parts

No.

Unit composed of replacement parts

come to a time to be replaced or not. Necessary replacement of used parts may be neglected even by the period inspection of the machine. Therefore, these parts are necessary to be replaced periodically even if  they do not show any faulty symptom at that time. Of  course a part found out for any abnormality should be repaired or replaced, irrespective of the time it has been used. It must be noted that this recommendation to the replacement of parts for the safety devices is not concerned in guaranteed period of time given to them.

Interval

Remarks

1.

Service brake valve parts

Every 2000 hours or one year

Replace as a service kit

2.

Retarder valve parts

ditto

ditto

3.

Parking brake valve parts

ditto

ditto

4.

Emergency brake valve parts

ditto

ditto

5.

Emergency brake valve parts

ditto

ditto

6.

Air governor parts

ditto

ditto

7.

Front brake chamber parts

ditto

ditto

8.

Rear brake chamber parts

ditto

ditto

9.

Parking brake parts

ditto

ditto

10.

Quick release & inversion valve parts

ditto

ditto

11.

Rubber hoses of brake

Every 4000 hours

-

or one year 

34

MAINTENANCE TABLE No. Item

Service

Page

No.

CHECK BEFORE B EFORE STARTING STARTING

Item

Service

Page

EVERY 50 HOUSE SERVICE

a. Oil, water and air

Check leakage

14

a.

Lubricating

b. Nuts and bolts

Check and retighten

14

-1

Lubricate 2 points

37

c . Electric wirings

Check and retighten

14

Dump body hinge pin

d. Exhaust gas

Check colour and noise

15

-2

Rear suspension

Lubricate 4 points

37

-3

Front suspension

Lubricate 4 points

37

e. Cooling water

Check and supply

15

-4

Hoist Cylinder pin

Lubricate 4 points

37

f.

Check and supply

15

-5

Differential support Lubricate 8 points

37

Check and supply

15

-6

Steering cylinder

Lubricate 13 po points

37

h. Transmission case Check and supply

15

b.

Battery electrolyte

Check fluid level

38

i.

Hydraulic tank

Check and supply

16

 j.

Front brake tank

Check and supply

16

k

Fuel tank

Drain water and sediments

16

Drain water

m Emergency brake tank n

Fuel

g. Engine oil pan

37

a.

INITIAL 250 HOURS SERVICE Hydraulic tank Change oil

38 38

b

Transmission case Change oil

38

16

c

Differential case

Change oil

38

Drain water

16

d

Final drive case

Change oil

38

e

Hydraulic filter

Replace element

38

Hub nuts

Check and retighten

16

o

Tires

Check air pressure and damage

17

q

Machine warning device

Check

17

r

Foot brake

Check function

18

s

Retarder control lever 

Check function

18

t

Parking brake valve lever 

Check function

18

u

Steering

Check function

18

v

Rear view and under mirrors

Check

18

w

Lamps

Check

18

x

Horn and turn signal lamps

Check

y

Instrument

z

Water separator

l

Air reservoir

EVERY 250 HOURS SERVICE a.

Lubricating

38

-1

Output shaft

Lubricate 2 point

38

-2

Drive shaft

Lubricate 5 point

38

b

Transmission oil filter 

Replace element

38

c

Belt tension

-1

Alternator belt

Check tension

39

-2

Compressor belt (if equipped)

Check tension

39

d

Breathers

-1

Differential case breather 

Clean

40

18

-2

Hydraulic tank breather 

Clean

40

Check

18

-3

40

Check

18

Transmission case Clean breather 

e

Check the oil level

40

-1

Differential case

Check and supply

40

-2

Final drive case

Check and supply

40

f

Drive shaft

Check

40

g

Parking brake

Check clearance

41

39

40

* For engine side PM details refer engine maintenance manual 35

No.

Item

Service

No.  

Page

EVERY 300 HOURS SERVICE a.

Lube Oil Filter

Change

b

By-pass filter

Change

c

Crank case oil

d

Fuel fifilter an and st strainer

Item Page

Service

EVERY 50 HOURS SERVICE

41 a.

Turbocharger

Change

b

Turbocharger rotor Check play

45

Change

c

Vibration damper

Check

45

d

Emergency relay valve

Clean

45

EVERY 500 HOURS SERVICE 41

Clean blower impeller 

45

 a

Lubricating

-1

Fan pully ass’y

Lubricate 1 point

41

e

Brake disc

Check

45

-2

Tension pully ass’y Lubricate 2 point

41

f

Check

45

 d

Rediator fins

Check & clean

42

Alternator and starting motor 

 e

Front Brake

Check liner / disc

g

Engine breather pipe

Check and replace

45

 d

Radiator fins

Check and clean

42

EVERY 4000 HOURS SERVICE

EVERY 1000 HOURS SERVICE 42

a.

Water pump

Check

45

b

After-cooler (if equipped)

Clean element and deflector  

45

a.

Lubricating

-1

Steering column

Lubricate 3 points

42

-2

Transmission mount

Lubricate 1 points

42

c

Fan pulley and tension pulley

Check

45

-3

Parking brake linkage

Lubricate 2 points

42

d

Air compressor

Check

46

WHEN REQUIRED

b

Transmission case Change oil

42

c

Hydraulic tank

Change oil

43

d

Differential case

Change oil

43

e

Final drive case

Change oil

43

f

Transmission oil strainer 

Clean

43

g

Hydraulic filter

Replace element

44

h

Rear brake

Check wear

44

i.

Turbocharger various fas fasteners

Check and retighten

44

36

a.

Air cleaner element

Check, clean or replace when required

46

b

Coolant

Change twice a year or every 1000 hours

47

d

Water separator

Drain water

48

4.

Hois Hoistt cyli cylind nder er (4 poin points ts))

5.

Diff Differ eren enti tial al supp suppor ortt (8 (8 poi point nts) s)

6.

Steerin teering g cyli cylinde nderr pin pin and linkag linkage e (13 (13 points points))

EVERY 50 HOURS SERVICE a. L UBRICATING UBRICATING  Apply  Apply grease grease to the grease grease fittings fittings show by arrows: arrows: 1.

Dump Dump body body hing hinge e pin pin (2 poin points ts))

2.

Rear Rear susp suspen ensi sion on (4 poin points ts))

3.

Fron Frontt sus suspe pens nsio ion n (4 (4 poi point nts) s)

37

d. FINAL DRIVE CASE, CHANGE CHANGE OIL OIL e . HYDRAULIC FILTER FILTER,, REPLACE REPLACE ELEMENT For details of method of replacing or maintaining, see the section on EVERY 1000 HOURS SERVICE

EVERY 250 HOURS SERVICE a. LUBR LUBRIICATING  Apply grease to the grease fittings show by arrows: b. BATTE BATTER RY ELEC ELECTR TROL OLYT YTE E

1.

Out Out put put shaf shaftt (2 poin point) t)

 Add distilled water if the surface of electrolyte is lower than the designated level (10 to 20 mm above the battery plates ). If electrolyte has spilled, have a service shop specializing in batteries supply sulfuric acid solution of the same concentration.

 At the same time, clean the battery cap breather  openings and check the terminal connections. Use a non-metallic funnel to handle distilled water  or electrolyte.

Maintenance for every 50 hours should be carried out at th e same tim e. 2.

Drive rive shaf shaftt (5 (5 poi point nts) s)

b.

TRANS RANSM MISS ISSION ION OIL OIL FIL FILT TER

INITIAL 250 HOURS SERVICE SERVICE Perform the following maintenance after  running t he machine for the first 250 250 hours. a. HYDRAULIC HYDRAULIC TANK, CHANGE CHANGE OIL OIL b. TRANSMISSIO TRANSMISSION N CASE, CHANGE OIL OIL c. DIFFEREN DIFFERENTIAL TIAL CASE, CHANGE CHANGE OIL OIL

Drain oil after removing filter drain plug (1) on the right side of the machine body, remove bolt (2) and cover  (3) and take out the filter elemant.

38

Clean the inside of the compartment ad removed parts, apply lubricant on the seal surface and install in the new element ∗

Use a genuine Beml filter element.

2.  After installing the cover, run the engine with airbleed bolt (4) kept loose ad tighten it when oil overflows. When the element has been replaced, check the transmission oil level.

Compre Compresso ssorr belt belt for car cooler cooler (if equipp equipped) ed) saggin sagging g of about 10 mm in the middle of the compressor  pulley for cooler (1) and accessory pulley (2) when depressed with your thumb (at about 6 kg) indicates the tension is proper.  Adjustment: Loosen bolt (3) and lock nut (4). Turn bolt (5) turn bolt (5) to adjust tension. After  adjustment, retighten bolt (3) and nut (4)

c. BEL BELT TE TENSION ION 1. Alte Alternator rnator belt belt Checking The belt tension should normally deflect by about 15mm when pressed with the finger at a point midway between the alternator pulley and the drive pulley (approx. 6 kg)

 Ad just ju st ment Loosen bolts (1) and (2) and displace alternator  (3) as required. ∗

Check for pulley damage, wear of the V-groove and v-belt, and especially that the V-belt is not in contact with the bottom of the V-grove.



Replace the belt if it stretched beyond the point of  adjustment or if it has cuts or fissures.



When adjusting the V- belt, do not attempt to push alternator (3) directly with a bar or the like, but use a wood pad to prevent damage to the core.

39



Check for pulley damage, wear of the V- groove and V- belt and especially that the V-belt is not in contact with the bottom of the V-groove.



Replace the belt if it has stretched beyond the point of adjustment or if it has cuts or fissures.

d.

BREATHERS

1.

Diff Differ eren enti tial al case cases s bre breat athe her  r 



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

Remove the differential case breather and wash out dirt form the inside with clean diesel fuel.

G

2.

2.

Final drive case

1)

Stop the machin machine e so that that cast cast line line (1) comes comes into into horizontal.

2)

Remove Remove plug plug (G) (G) and and check check for the oil level. level. If the the oil level is not near the lower edge of the plug hole, add engine oil through the same plug hole.



The type of lubricant used depends on the ambient temperature. Select according to the tale “FUEL, COOLANT AND LUBRICANT”.

Hydr Hydrau auli lic c tan tank k brea breath ther  er  Remove snap ring (1) of the breather and cover (2) and clean element (3).

G

3.

1

Tran Transm smis issi sion on case case brea breath ther  er  Remove the breather and wash out dirt from the inside with clean diesel fuel.

f.

DRIVE SHA FT Check the drive shaft for any abnormality such as loose joints, worn splines or bearing, unusual vibration of the shaft, etc., if any, have the shaft, etc. if any have the shaft service by BEML.

Front

e.

CHECK TH THE OI OIL LEV LEVEL

1.

Di ff ff er er en en t ia ial c as as e

Removing plug (G) and check the oil level. If the oil level is not at or near the lower end of the plug hole, refill engine oil through plug hole.

40

Rear 

g.

Check the lining for wear and replace the pad, if the thickness of the lining is reduced to less than 3mm,

PARKING BRAK BRAKE E

Take care not to stain the brake pad and the disc surf ace with oi l or grease. grease.

If the parking brake fails to work properly, adjust it in the following manner.

EVERY 300 HOURS SERVICE a) Lube oil filter

:

Change

b) By pass filter

:

Change

c) Crank case oil

:

Change

d) Fuel filter and Strainer

:

Change

EVERY 500 HOURS SERVICE 1.

Confir Confirm m that that the the indic indicati ation on of of the the air air pressu pressure re gauge is in the green range and the n release the parking brake.

2.

Turn Turn bolt bolt (1) clockw clockwise ise and lot pads pads (2) (2) on both both sides come to lose contact with disc (3).

3.

Back Back off off bolt bolt (1) (1) a half turn turn count countercl erclock ockwis wise. e.

a.

L UB RI RICATING

 Ap pl y gr e as e to th e gr ea se fi tt in gs sh ow n by arrows. 1. Fan pulley ass’y 2. Tension pulley ass’y When When adjusting the parking b rake, rake, be sure to put chocks on the tires so that the Slippage can be prevented. Maintain the air pressure at a sufficiently high-pressure to prevent the parking from operation automatic automatic ally while adjust adjust ing the brake. To prevent a third person from operation the parking brake by mistake, besure to attach a caution tag to the parking brake switch.

41

d. RADIA ADIAT TOR FIN FINS S Blow off mud, dust or leaves blocking radiator fins with compressed air. Steam or water can be substituted for compressed air. ∗

 Also check rubber connections to radiator. radiator. If they have cracks or become fragile, replace with a new one. In addition, check hose clamp for loosening 2

 Air pres pr essu sure re shou sh ould ld be less le ss than th an 10kg 10 kg / cm 2 and steam pressure is less than 4 kg/ cm

Never touch the nozzle of the air or steam to the radiator fins ∗

3.

Park Parkin ing g bra brake ke lin linka kage ge (2 (2 poi point nts) s)

b

TRANS ANSMISSION CAS CASE E

When washing the radiator, always direct air or  0 steam at 90 C to the radiator.

Remove drain plug (1) and loosen plug (2) to drain from the case. Clean the transmission oil filter  element. Then fill the transmission case with the specified amount of oil through the oil filter.

EVERY 1000 HOURS SERVICE ∗



Refill capacity: 110 litres



The type of lubricant used depend on the ambient temperature. Select according to the “FUEL, COOLANT AND LUBRICANTS”.



For the method of checking the oil level refer to section CHECK BEFORE STARING.



Change oil every 1000 hours or 1000 km whichever comes earlier.

Maintenance for every 50, 250 and 500 hours should b e carried carried out at the same time.

a. LUBRICAT LUBRICATING ING  Apply grease to the grease fittings fittin gs shown by arrows: 1.

Steer teerin ing g col colum umns ns (3 poi point nts) s) Loosen Bolts, remove cover and apply grease.

42

c.

HYDRAULI AULIC C TANK ANK Lower the dump body, stop the engine and wait for  lowering of oil temperature. Remove drain plug (1) and loosen plug (2) to drain the oil. Then, refill the rank with engine oil through oil filler (F)



Refill capacity : 490 litres.



The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL COOLANT AND LUBRICANTS” When removing the cap, turn it slowly to relieve inner pressure.



For the method of checking the oil level. Refer to section CHECK BEFORE STARTING.



Change oil every 1000 hours or 1000 km whichever comes earlier.



Change oil every 1000 hours or 1000 km which ever comes earlier.

e.

FINAL DRIVE CASE ASE

1.

Stop the machine machine so that that case case line line (1) become becomes s horizontal.

2.

Remov Remove e dra drain in plug plug to drain drain the the oil oil..

3.

Refill Refill the case case with with fres fresh h oil oil throu through gh oil oil fill filler er (G). (G).



Refill Capacity: 90 litres (Each side)



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

For the method of checking the oil level, refer to section EVERY 250 HOUSE SERVICE. d.

DIFFERENTIAL CAS CASE E

Remove the drain plug (P), then drain oil throu gh the plug hole. Fill the differential differentia l case with the specified oil through the oil filler (F). ∗

Refill capacity : 100 litres.



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



Fir the method of checking the oil level, refer to section EVERY 250 HOURS SERVICE.

43



Change oil every 1000 hours or 1000 km whichever comes earlier.

f.

TRAN TRANS SMISS ISSION ION OIL OIL STRA STRAIN INE ER

1.

The strain strainer er shou should ld be be clean cleaned ed when when the elemen elementt is replaced after changing oil. Remove bolt (1) at the lift side of transmission case. Remove cover  (2), then remove the strainer and spring. Upon completion of cleaning the strainer and magnet, reinstall them.

2.

Loosen Loosen two two bolt bolts s (1) (1) for for trans transmis missio sion n oil oil strai strainer  ner  (pilot) take out stainer (2) and clean it.

g.

HYDRAULIC HYDRAULI C FILTER FILTER

3.

Turn Turn sta starti rting ng swi switc tch h to “ON “ON”, ”, chec check k air air press pressur ure e gauge pointer indicates in green range. When air  pressure is low, turn the engine as to kee p 2000 rpm till the air pressure gauge indicates in the green range, then, turn off the starting key to “OFF”. At the same time, pull retarder control lever  to full stroke and push the wear gauge in till it contacts with the piston (See illustration below).

4.

When When mark mark (A) (A) shown shown on the gauge gauge passe passes s through in the valve case, this means wear of disc is in the limit of wear.

The filter should be replaced when changing oil. Removing bolt (1) and remove cover (2). Remove the inside spring and take out element from filter, and install new element. Before replacing element, turn t he tank cap slowly to release inner inner pressure. *

Use Use a genu genuin ine e Beml Beml filt filter er elem elemen ent. t.

In such a case, contact Beml for maintenance. 5.

2



1

*

The above above proced procedure ures s shou should ld be done done to to the the another rear brake.  Af te r fi ni sh th e we ar ch ec k, bl ee d ai r ou t completely. (Refer to section “ADJUSTMENT”).

When When oil oil fitt fitter er cau cauti tion on lam lamp p light lights, s, rep repla lace ce fil filte terr. It is normal even if the lamp lights when the oil temperature is low or when the dump body is being lowered. Replace the filter element if the lamp lights with the engine running at high idle and the oil temperature is high.

h.

i.

TURBO TURBO CHARG CHARGER ER VARIO VARIOUS US FASTE FASTENE NERS RS

 Any leaky joint connecting to the engine exhaust pipe will cause a lowering of oil pressure, resulting in seizing of bearings. Periodically inspect all joints for  looseness and, if necessary, retighten.

REA R B RA RA KE KE WEA R Carry Carry out inspection w hen the engine engine oil temperature is below 60%C. 60%C.

1.

Shif Shiftt parki parking ng bra brake ke val valve ve lev lever er to to BRA BRAKE KE and and secure foot brake does not work.

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

2.

Remo Remove ve air air ble bleed edin ing g valv valve e of rea rearr brak brake e and and inse insert rt disc wear gauge in to the air bleeding valve

Tightening torque torque as follows. 1.

Clam Clamp p bol boltt for for tubi tubine ne hous housin ing: g: 0.8 – 0.1 kgm

2.

Clam Clamp p bolt bolt for for blo blowe werr hou housi sing ng:: O.55- 1.0 kgm

3.

Connec Connectin ting g bolt bolt for turboch turbocharge argerr exha exhaust ust manifo manifold ld and turbine housing: 10.0 – 12.5 kgm

4.

Mounti Mounting ng bolt bolt for for turboch turbocharge argerr oil oil pipe pipe (inl (inlet): et): 2.0-3.5 kgm

5.

Mounti Mounting ng bolt for turbo turbo char charge ge oil oil pipe pipe (outl (outlet): et): 6.0 – 7.5 kgm

44

c.

EVERY 2000 HOURS SERVICE

VIBRA BRATION DAMP AMPER



Maintenance for every 50, 250, 500 and 1000 hours s hould b e carried carried out at the same time.

Check decrease of damper fluid, dent or out of  flat. If there is any abnormality, contact Beml for repair.

a.

TURB OC OCHA RG RGER

d.

Excessive carbon or oil sludge adhering to turbocharger blower impeller may deteriorate normal performance of turbo charger and may sometimes damage it.

1.

Remove Remove the turboch turbocharg arger er oil supply supply tube tube and and the drain tube. Then, remove the connection area of  the intake manifold and the blower housing so that the blower impeller can be seen.

2.

Using Using ligh lightt oil, oil, wash wash the impell impeller er to to elimi eliminat nate e carbon adhered on the surface.

a.

Do not use use wire brushe brushes or the the like to pre prevent vent damage to th e impeller surface.

3.

Pour Pour light light oil through through the turboc turbocharg harger er oil oil fill filler er.. Turn the blower impeller several turns so that foreign materials such as sludge can be washed away.

4.

Using Using your your finge fingers, rs, turn the impelle impellerr vigor vigorous ously ly for one revolution or more. If there is no sigh of  interfering with or being caught in somewhere, the impeller is normal. If the impeller seems to turn heavily, contact BEML to ask to repair or replace it.

5.

Refer to section EMERGENCY BRAKE. Request service to BEML because special tools are required for removing parts and adjustments. e.

Contact BEML.

If the impell impeller er is found found norma normall afte afterr this this check, check, supply engine oil to the turbocharger.

b. TURBOCHARGER ROTOR PLAY Request BEML for this service or proceed as follows, after washing the turbocharger and checking the blower impeller for smooth turning. (for this check, see previous point b above).

f.

ALTE ALTERN RNA ATOR AND START STARTIN ING G MOT MOTOR OR

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

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

g.

ENGINE BREATHER PIPE

1.

Remove Remove breathe breatherr pipe pipe from from cyli cylinde nderr block blocks s of right right and left banks.

2.

Check Check ther there e is no adhe adherenc rence e of oil sludge sludge inside inside of the pipe.

3.

When When oil oil sludge sludge adheres adheres,, repl replace ace with with new new pipe. pipe.

EVERY 4000 HOURS SERVICE a.

WATER PUMP



Mainten ance f or ev ery 50, 350, 1000 1000 and and 2000 2000 hours s hould be carried out at t he same time. time.

Inspect the water pump for play in the pulley, grease leakage and water leakage. If any fault is detected, ask BEML to disassemble and repair or replace AFT AFTER – COOLER LER (if (if equip equippe ped) d)

Rotor axial play Loosen bolt (2) remove top cap (1) and take out filter (5). Next remove nut (3) and pull out deflector (4) clean filter (5) and deflector (4).

Move the rotor in the axial direction, and using a dial gauge, measure the axial play. It should be between 0.08 and 0.18 mm. •

B RA K EDISC  Ask BEML to check and repair brake disc.

b. •

EMER EMERGE GENC NCY Y RELA RELAY Y VALVE VALVE

c.

Rotor radial play Grasp both ends of the rotor by your hand, and move the rotor in the radial direction. Using a dial gauge, measure the radial play. It should be between 0.25 and 0.60 mm.

45

FAN PULLE PULLEY Y AND TENS TENSIO ION N PULLE PULLEY Y

Check the pulley to see if there is any leaking grease. If any abnormality is found ask Bmle to repair  as replace it.

d.

CHECK HECK AIR AIR COMPRES PRESSO SOR R

4.

Push Push the the dust dust indica indicator tor reset reset butt button on (2) (2) to return return the red piston to the original position.



Replace the inner element which has been cleaned 6 times repeatedly or used through out a year.



Replace the inner element at the same time.



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



Replace both inner and outer elements when the air cleaner warning lamp blinks soon after  installing the cleaned outer element even though it has not been cleaned 6 times.

 Ask BEML to check and repair it.

WHEN REQUIRED a. AIR CLEANER ELEMENT

Check inner element mounting nuts for loose ness and if, necessary, retighten.

Checking

Replacing inn er element element

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

1.

Firs Firstt remo remove ve the the out outer er ele eleme ment nt,, and and then thenremove remove the inner element.

2.

Cover over the the air air inle inlett por port. t.

3.

Clean Clean the the air air cleaner cleaner body interi interior or.. Remo Remove ve the the cover from the air inlet port.

4.

Fit Fit a new inner inner elemen elementt to to the the connec connector tor and tighten it with nuts.

5.

Inst Instal alll the the oute outerr ele eleme ment nt..

NOTE: NOTE: Do not attempt to reinstall a cleaned inner  element. Cleaning or replacing outer element 1.

Loos Loosen en bol boltt and and remo remove ve ban band d and and remo remove ve cov cover  er  and remove the outer element.

2.

Clean Clean the the air air cleane cleanerr body body interi interior or and the removed cover.

3.

Do not clean or replace the air cleaner  element element with the engine running. Cleaning outer element With compressed air 

Clean Clean and inspect inspect the elemen element: t: (See (See page page 47 for  Direct by compressed air (less than 7 kg/ cm2) to the cleaning procedure). Install the cleaned element. element from inside along it folds, then direct it form outside along it folds and gain form inside, and check element. When using composed air, wear safety glasses and other things required to maintain safety.

46

b. CHANGE COOLANT Change coolant once a year (autumn) when permanent type antifreeze solution is used.



Change coolant twice a year (spring and autumn) when other permanent type antifreeze of ethylene glycol base is used. •

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



The following methods require spare parts. Change water after first parking the machine on a • level surface.

With water  2

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

WATER FILL FILLER ER

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

Drying can be speeded up by blowing dried 2 compressed air (less than 7 kg/ cm ) from the inside to the outside of the element.

5.

When When the the wate waterr reac reache hes s the the vici vicini nity ty of of the the wate water  r  filler, filler, put the engine engine at low idling, idling, open t he drain dra in valves, then pass water through the cooling system until clean water comes out from the drain valves for 10 minutes.



When doing this, adjust the amount of water  supplied and drained to keep the radiator full at all time.

Never attempt to heat the element. 0



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



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



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



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



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

47

DRAIN VALVE VA LVE (RADIATOR) (RADIATOR)

6.

When When the the water water becomes becomes comple completely tely clean, clean, stop stop the engine and close valves (2) and (3).

7.

After After draining draining off the coolin cooling g water water,, wash wash out out the the cooling system using commercially available detergent. Follow the instructions on the detergent container.

8.

After After washin washing g the the coolin cooling g syst system, em, drain drain off all the water, then close up drain valves or plug and pour  in clean water (ex. City water) slowly up to the vicinity of the water filter.

DRAIN VALVE (Cylinder block)

When float is at or above red line, drain the water  according to the following procedures

9.



When When the the water water reache reaches s the the vicin vicinity ity of the water  water  filter, put the engine at low idling, open the drain valves, then pass water through the cooling system until clean water comes out from the drain valves. When doing this, adjust the amount of water  supplied and drained to keep the radiator full at all times.

Loos Loosen en drain drain plug plug and and dra drain in the the acc accumu umula late ted d water until the float reaches the bottom.

2.

Tigh Tightten drai drain n plug lug

3.

If air air is is sucke sucked d into into fuel fuel line line when when drai drain n the water water,, be sure to bleed air in the same manner as for the fuel filter.

(See Fuel Filter Cartridge in Every 500 hours Service section).

 ADJ  AD J USTMENT

10. When the water becomes becomes completel completely y clean, clean, stop the engine and close the all drain valves.

FAN BELT BELT  Adjust  Adj ust ment

11. Replace Replace the corro corrosion sion resist resister er cartridg cartridge e and open open valve (1). 12. Supply water until, it overflow overflows s from water filler. filler. 13. Run the the engin engine e 5 minutes minutes at low low idling idling and and hen for another 5 minutes at high idling to eliminate air trapped in the cooling system (leave radiator  cap off during this operation). 14. 14. Stop the the engine engine and and wait wait for for about about 3 minute minutes. s. Supply cooling water up to the specified level (up to the lower end of the water supply tube). tu be). Tighten the cap. ∗

1.

 As this machine is provide with a device which keeps a constant fan belt tension without regard to elongation of the V- belt, no adjustment is required unti l the belt is broken. Check the size a to see that it is maintained within 50 ± 5mm. If not, adjust the fan belt as f ollows: Tighten adjusting bolt (2) until size a becomes 50 ± 5mm, and tighten lock nut (1) securely.

Be sure to replace the corrosion resistor cartridge. If the water temperature is high, do not remove the cap. This is because of the possibility of scalding water spurting out. Remove the cap after after raisi ng the cap lever  to relieve internal internal pressure.

c.

Replacement

WATE WATER R SEP SEPARA ARATOR (if equipped) quipped)

48

1.

Loos Loosen en loc lock k nut (1) (1) and and compl complet etel ely y rele releas ase e the spring.

2.

Press Press tension tension pulley pulley (3) (3) in in the the direc directio tion n indic indicate ated d by the arrow in the figure to remove the V- belt. Then install a replacement.



Replace three V – belts at the same time.

  Front

2)

Rear b r ak e

  Rear 

1.

Pull Pull the the retarde retarderr cont control rol lever lever,, and and loose loosen n air air bleed bleed plug (1) to bleed the air from the circuit. After closing plug (1), release the retarder control lever.

2.

Repeat Repeat this this proce procedur dure e until until no more more bubble bubbles s come come out from air bleed plug (1). After bleeding the air, tighten plug (1) securely. securely.



When bleeding the air from the system, raise the oil temperature to make the bleeding of air easier. easier.

SUSPENSION CYLINDER During operation, the following abnormalities may be noticed the machine bounces greatly, grea tly, the suspension cylinder is shortened and hits against the stopper, or  the operator senses an Excessive bouncing caused by unleveled ground surfaces. when these troubles are noticed, stop the machine immediately immediately,, and unload. Check the cylinder length in the before operation inspection. ∗

1. Check Check for cylinder l ength See if the bottom end of the suspension cover is within the proper range with the machine on level ground without load. ∗

The suspension cylinder is filled with high pressure nitrogen gas and oil. Adjustment and repair (such as filling oil) require special tools. Request service to BEML.

49

b. 2.

Check heck for for cyli cylind nde er oil oil amo amoun untt

a.

Front

Rear  

If oil is short, signs of being hit are found on differential case and stopper.



If oil is short the distance from the top of the sliding trace (glossy surface) of plated surface of rod to rod head shoulder becomes less than 180 mm.

If any abnormality is found by checking contact BMEL.

TROUBLESHOO TROUBL ESHOOTING TING GUIDE

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





ENGINE Oil pressure gauge pointer will not return to red (left (left s ide) when when the engine is shut down. •

Defective oil pressure gauge.

Oil pressure gauge pointer fluctuates abnormally. •





Defective water temperature gauge.



Defective thermostat or its seal.



Leaky thermostat seal.



Loose radiator filler cap.

Water Water temperature gauge point er stays in the red range (left (left on di al during engine running.

Oil leakage due to damaged piping, loose piping  joints or connections. Defective oil pressure gauge



Oil leakage from full-flow filter.



Defective thermostat.



Defective water temperature gauge.



Too cooled engine

Engine fails fails t o start •

Stem spurts out t he pressure valve on the radiator. Water temperature gauge pointer stays within the red range (right) on dial, •

Clogged rediator fins or fins out of place.

(when operating at high altitude)

Insufficient oil in oil pan.



 Accumulated dust or fur in the cooling system.



Insufficient oil in pan

Oil pressure gauge pointer stays withi n the red range (left) on dial. •

Loose fan belt.



 Air in fuel line.



Insufficient torque of starting motor to crank up engine.



No fuel in fuel filler. filler.

Insufficient coolant or coolant leakage.

50

Insufficient fuel in fuel tank

Engine emits emits white or blue-white blue-white exhaust gas.

Starting Starting mot or crakes engine too slow .



Excessive oil in oil pan.



Wiring is defective.



Improper fuel use.



Batteries are discharged.



Oil leaks out of turbocharger piping.

Starting motor becomes disengaged just before cranking engine. engine.

Engine emits emits black exhaust smoke. •

Clooged air cleaner elements

Engine runs but operates operates erratically (Hunting) (Hunting) •

Wiring is defective.



Batteries are discharged.

CHASSIS

 Air leakage in fuel supply line.

Torque converter converter malfunct ion

Engine creates creates knock ing •



*

Use of improper fuel.

Torque converter oil pressure remains low 0

0

oil temperature: 70  - 90  C. •

Over heat.

Fuel Fuel sometimes stops flowi ng. •

Small hole in fuel tank cap clogged.



Breather tube of fuel tank clogged.

ELECTRICAL CIRCUITS CIRCUITS  A m m et er d ef l ec t s w i d el y w h en en g i n e r u n s constantly.



oil t emperature emperature at at t orque converter inlet : 2 8.0± 1.0 kg/cm



Oil pressure at toque converter outlet Engine ngine idling idling slow: slow: 2. 2.5 ± 0.5 kg /cm

b)

Engine ngine at full full thrott throttle le : 40 40 ± 1.0 kg / cm



 Air or oil leaking from loose joints of oil pipe or  broke pipe.



Ger pump worn or sticking.



Wiring is defective



Lack of transmission oil.



Improper belt tension.



Transmission oil filter element is clogged.



Fan belt is loose.



Water temperature is high.



Oil cooler is clogging.



Oil pressure is low.



Lack of oil circulation due to worn gear pump.



Long use of “automatic” drive.

 Am met er do esn’t esn ’t deflec def lec t w hen engin eng ine e is runn ru nnin ing. g.



 Ammeter is defective Wiring is defective

 Al ternat ter nator or is noi n oisy. sy. •

 Alternator is defective.

Starting motor doesn’t operate when turning on starting switch. •







2

Torque co nverter ov erheats. erheats.

Head lamps are dark when engine speed is at maximum. Head lamps flicker when engine is running.



2

a)

Steering is hard.

Wiring is defective. •

Gear pump is defective



Demand valve is misadjusted.



Oil pressure valve is defective.



Internal leakage occurs in steering cylinder. cylinder.

Starting switch is defective. Batteries are discharged. Battery switch is defective.

Brake operates poorly. •

51

Brake shoes improperly adjusted.

Brake is unbalance. •



If any abnormality occurs as listed on the left, stop the machine, Parking brake valve lever should be placed in BRAKE position, check the LED display of the controller, controlle r, and then contact BEMl for repair.



Please contact BEML for repair of any abnormalities other then those listed on the left.



If the starting procedure of the engine is wrong the display will show “STARTING SAFETY” and the engine will not start.

Brake shoe adjustment is improper.

Dumping speed speed is sl ow. Dumping time should be 13.0 ± 2.0seconds when 0 0 oil temperature is 70 - 90 C. Response Response of dump bo dy to operation is s low. •

Gear pump is defective.



Oil is lacking



Demand valve is defective.

(refer to section sectio n OPERATING YOUR MACHINE). •

Suspension Suspension is rough. •

Gas is leaking from broken U – packing



Gas is leaking from valve core.

“TM / OVERRUN” does not mean the failure of the machine. Please try again to start the engine.

  TRANSMISSION SHIFT CONTROLLER LED display No.

Failure mode

Contents of failure

Red

Green

1.

Lighting

Lighting

2.

Flashing alternately STARTING SAFETY

Engine starts at other than N

3.

Lighting

Fast flashing

SOLENOID VALVE  SAFETY

Defect of solenoid valve and / of output side harness

4.

Lighting

Slow flashing

T/M SOLENOID VALV VALVE E Defect of solenoid valve and / or output side harness SAFETY

5.

Lighting

Off  

T/M FAST ROTA RO TATION TION

MODEL SELECTION  SAFETY

SAFETY

Defect of input side harness

T/M overrun

6.

Fast flashing

Off  

T/M OUTPUT SENSOR Failure of T/M output side sensor system SAFETY

7.

Slow flashing

Off  

SHIFTPOSITION SAFETY

Failure of shift position sensor system

8.

Slow flashing

Lighting

THROTTLE SAFETY

Failure of throttle switch system

9.

Fast flashing

Lighting

T/M INPUT INPUT SENSOR SENSOR  SAFETY

Failure of T /M input side  sensor system

10.

Simultaneous flashing PROGRAM SAFETY

11.

Off

Off  

POWER SOURCE OFF Failure of power circuit

12.

Off

Lighting

NORMAL

Failure of AESC

In operation

T/M: Transmission

52

STORAGE



Remove the rocker housing and fully lubricate the valves and rocker levers. lever s. Also, check the valves for correct operation.



 After every part is washed and dried, the machine should be housed in a dried building. Never leave it out doors.

Before stating the engine, remove the lubricating oil inlet flange from the turbocharger and pour  fresh oil through the opening. Remove connectors and hoses to expose the blower impeller. Rotate the impeller with hands so that all components in the turbocharger can be lubricated thoroughly. thoroughly.



In case it is indispensable to leave it outdoors, search a float ground and lay wood plates on the ground, and the machine shall be placed on the wood plates and covered by canvas etc.

Loosen the oil pipe flange at the tur bocharger oil inlet port and rotate the engine with a starting motor. If any oil is found spilled out of the loose connection, retighten the pipe flange.



 After starting, idle the engine securely to allow the lubricating oil to circulate throughout the various parts of the engine.



Perform other “CHECK BEFORE STARTING” section.

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



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



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



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



The gear shift lever should be set to NEUTRAL position.



The retarder control lever should be set to “RELEASE” position.



Since low pressure tire would be easily damaged, 2 check tire pressure (from 4 kg/ cm  to the specified pressure for the tire).

MACHINE AND ENGINE SERIAL NUMBERS When calling for the services of a mechanic or  when ordering replacement parts, be sure to give Beml the machine and engine serial numbers as well as the service meter reading mentioned before. These numbers are stamped in the locations shown in the figures on the right. •

Location of the machine serial serial number.

DURING STORAGE •

Operate the engine and move the machine for a shoot distance once a month 30 that new oil film will be generated and exhaustion of oil film in a long period will be prevented.

 AFTER  AFTER STORAGE STORAGE •

Carefully observe the following procedure when taking the machine out of long- term storage. These procedure are, however, not required for a machine which has been properly stored under  cover and run for rust prevention once a month.



Drain water from the engine oil pan and other  reservoirs.

53

The machine serial number is stamped on the front part of the left side bumper.

Location of the engine serial number.

The engine serial number is stamped on the upper  left side of the cylinder block.

NOTE: (1) (1)

When When fuel fuel sulphu sulphurr content content is is less less than 0.5% change change oil in the pan every periodic maintenance house described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%

(2)

(3) (3)

Use Api class classifi ificat cation ion CD as as engine engine oil and and if API classification CD as engine oil and if API clasification CC, reduce the engine oil change interval to half.

Specif Specif ied capacity : capacity  : Total Total amount of oil for components and oil in piping

When When starti starting ng the engi engine ne in an atmo atmosph spheri eric c temperature of lower than 0c, be sure to use engine oil of SAE 10W, SAE 10W –30 and SAE 15W-40 even though an atmospheric temperature goes to 10 c more or less in the day time.

54

Refill capacity : capacity  : Amount oil needed to refill system during inspection and maintenance.

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