759OMA3300

OPERATION & MAINTENANCE MANUAL

BD14W
WHEEL DOZER
APPLICABLE EQUIPMENT SERIAL NUMBER 16199 & UP
(FOR BS6D105-1 ENGINE, ZF MTL AXLES & TRANSMISSION)

BEML LIMITED
INDIA

QUICK REFERENCE INFORMATION

QUICK REFERENCE INFORMATION

Machine model &
serial no.

Engine model &

serial no.

BD14W WHEEL DOZER

BS6D105-1

[Link]..

[Link]

PERIODIC SERVICE

ITEM

Nearest BEML Office &

Telephone no.

DATE

SERVICE METER

DELIVERY
PERIODIC
PERIODIC
PERIODIC
PERIODIC
CONSUMABLE

PARTS NO
355TM 91295

PARTS NAME
TRANS. PRESSURE FILTER

QTY
01

375 HS 02004 ELEMENT HYDRAULIC & STEERING

02

355 AS 00136

AIR FILTER ELEMENT (KIT)

01

950 SK 00027

FILTER ASSY AUTO DRAIN VALVE (KIT)

01

14G 6010645

FAN BELT

02

14G 7010225

COMPRESSER BELT

02

30 Z 5180495

ENGINE OIL CARTRIDGE

01

11 Z 7180235

FUEL FILTER ELEMENT (FINE) (MICO)

01

30 Z 7180369

FUEL CARTRIDGE

01

30 Z 1280296

AIR CLEANER ELEMENT INNER ASSY

01

30 Z 1280133

AIR CLEANER ELEMENT OUTER ASSY

01

30 Z 1260094

O RING FOR DUST PAN

01

30 Z 1280174

AIR CLEANER BLEEDER VALVE

01

FOREWORD

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

Please read this manual carefully BEFORE operating the machine.

Please continue studying this manual until proper operation is

completely reinforced into personal habit.

This manual describes the basic techniques. Skill is performed as the

operator or anyone get the correct knowledge and performance of the
machine.

Operation, inspection, and maintenance should be carefully carried

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

Some photographs and illustration pictures are different from

your machine as technical improvement is continuously
reflected on it. Revision to up-to-date manual's content is
performed in later editions.

BREAKING IN YOUR NEW MACHINE

BREAKING IN YOUR NEW MACHINE

Each machine is carefully adjusted and tested before shipment. However, a new machine
requires careful operation during the first 100 hours to break in the various parts.
If a machine is subjected to unreasonably hard use at the initial operation stage, the potential of
performance will prematurely deteriorate and the service life will be reduced. A new machine
must be operated with care, particularly with regard to the following items.

After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior
to actual operation.
Avoid operation with heavy loads or at high speeds.
Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning
should be avoided.
At the first 250 hours of operation, the machine should be maintained in the
following manner in addition to usual 250 hours service:
Changing all Oils, oil filters and fuel filter elements.
Checking and adjustment of engine valve Clearances.
For replacement procedure and details, see maintenance table in the maintenance
section.

{ When replacing oil filter elements (cartridges) check their interiors for dirt and dust.

If heavily collected, check for possible cause before starting operation.

{ Hours of operation are indicated by the service meter.

CONTENTS

CONTENTS
OPERATION
1

SAFETY HINTS

06

GENERAL LOCATIONS & SPECIFICATIONS

11

OPERATOR'S COMPARTMENT

11

INSTRUMENT PANEL AND CONTROLS

14

CHECK BEFORE STARTING

18

OPERATING YOUR MACHINE

21

11

TOWING

24

12

TRANSPORTATION

24

13

COLD WEATHER OPERATION

25

14

OPENING & CLOSING OF LOCKING CAP

26

15

HANDLING OF BATTERY

26

MAINTENANCE
PERIODIC MAINTENANCE
1

PRECAUTIONS FOR MAINTENANCE

28

BLEEDING AIR FROM BRAKE CIRCUIT

30

MAINTENANCE TABLE

31

EVERY 50 HOURS SERVICE

33

EVERY 100 HOURS SERVICE

33

INITIAL 250 HOURS SERVICE

33

EVERY 250 HOURS SERVICE

34

EVERY 500 HOURS SERVICE

35

EVERY 1000 HOURS SERVICE

35

10

EVERY 2000 HOURS SERVICE

39

11

EVERY 4000 HOURS SERVICE

41

12

WHEN REQUIRED

42

13

TROUBLE SHOOTING GUIDE

46

14

STORAGE

48

15

SERVICE METER

49

16

EQUIPMENT AND ENGINE SERIAL NUMBER

49

17

FUEL, COOLANT & LUBRICANTS

50

18

POWER TRAIN & PARKING BRAKE CONTROL

51

19

DUAL AIR BRAKE SUSTEM SCHEMATIC

52

20

HYDRAULIC CIRCUIT

53

21

ELECTRICAL WIRING DIAGRAM (16199 & UP)

54

23

TRANSMISSIOM OIL CIRCUIT DIAGRAM 4MG-190

55

24

EQUIPMENT COMPONENTS

57

SAFETY HINTS

SAFETY HINTS . . . . .

Protect yourself and others. Safety is always first.

OPERATION
GENERAL

Wear well-fitting helmet, safety shoes

and working clothes. If the nature of the
work requires safety, wear protective
goggles or mask, thick gloves, earplugs
or other protection.

Learn about the safety devices on your

own machine and about how to use
them. Confirm that they are correctly
attached in the prescribed position.

Accidents or injuries are liable to occur

when the operator is careless or slack. It
is most important to bear safe operation
in mind at all times.
Take care of your health. Do not drive
when tired or after drinking.
Learn the prohibitions, cautions and rules
about work procedures in the work site.

Read the Operation and Maintenance

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

When there is a leader, fix standard

signals and always follow these signals
when operating.

If there should be an accident or fire or

any other such unexpected mishap, deal
with it quickly, using the nearest
apparatus.

Exhaust gas is dangerous. When running

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

Learn before and the locations of the first

aid boxes and fire extinguishers and how
to use them. It is also important to know
the emergency contact system.

When operating inside a building, always

be sure of the clearances of the ceiling,
entrances, aisles, etc. and the load limit
of the floor.

Such safety devices include:

Guards Canopies - Protective Devices
Seat Belts, etc.

Never allow other person than the

operator to ride on the machine during
operation.

SAFETY HINTS

BEFORE STARTING OPERATION

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

Examine the lay of the land and the kind

of soil at the work site to determine the
dangerous points and the best method of
operation.

Before operating the machine, check and

fasten the seat belt.

Proceed with the work only after making

safety
arrangements
about
the
dangerous points.

Inspect the seat belt and fittings, replace

any damaged or worn parts.

Inspect leakages from the fuel,

lubricating and hydraulic systems. Check
that the shoe bolts are not loose, and
that no other parts are damaged or
missing. Machines having such failures
should not be operated.
When getting on or off the machine, use
the handrail and step provided. Do not
jump up or down from the machine.

To ensure the safety of workers near the

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

Do not leave parts or tools lying around

in the vicinity of or on the floor of the
operator's
compartment.
Keep
everything in its proper place.

Inspect the inside of the engine room

and remove any dead leaves or paper.
Dead leaves or paper are highly
inflammable and can cause fires.

Wipe off thoroughly any grease, oil or

mud on the step, handrail, floor or control
levers. Failure to do this may cause you
to slip.
Check the level of the fuel, lubricants and
cooling water. Extinguish cigarettes
before checking or replenishing. Check
that the radiator cap and each oil filler
caps or plugs are firmly fitted &tightened.
Adjust the operator's seat until it is in the
most comfortable position for operating.

Before starting the engine, confirm that

all control levers are in "NEUTRAL" or
"HOLD".

Always sit in the seat while operating. Do

not operate the machine from any other
position.

SAFETY HINTS

The work area should be made as flat as

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

AFTER STARTING THE ENGINE

Confirm that all gauges and warning

devices are functioning correctly, and
that the gauge readings are within the
prescribed range.

The machine should always be operated

at a speed where it can be correctly
controlled. Never do the following:
{ Speeding
{ Sudden starting, sudden
breaking, sudden turning.
{ Snaking
{ Coasting

Check the play and travel of each lever

and pedal Operate the Dozer Attachment
to confirm that it is functioning normally.
Move the machine slowly and listen
carefully to the engine or gears to
confirm that they are not making any
unusual noises.

Be careful of those around you, and

always confirm that there is no person or
obstacle in the way before driving or
turning the machine.

Operate the gearshift lever to confirm

that the travel speeds for forward and
reverse are functioning normally. Also
carry out a brake test at each travel
speed.
Choosing a safe place, turn the machine
to the left and right to confirm that the
steering
devices
are
functioning
normally.
If these tests reveal anything wrong,
however slight it may be, contact the
man in charge of the machine and
operate the machine only after obtaining
his permission.

Always operate slowly in crowded

places. On haul roads or in narrow
places, give way to loaded vehicles
When driving the machine, keep the
attachment 40~50 cm above the ground.

DURING OPERATION

Do not allow unauthorized persons into

the work area.

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

Always be aware of the operating

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

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.

SAFETY HINTS

Check the load limits of bridges before

crossing.

The machine condition can be judged

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

After earthquakes, confirm that the

ground is still firm; after blasting, confirm
that there are no unexploded charges
remaining.
When operating on uneven ground or in
places where there are obstacles,
remember the following points:

If the machine breaks down and needs to

be towed, first confirm that the brakes
are working properly, and then tow, using
a wire rope or any other suitable towing
equipment.
When parking the machine after
discontinuing work, put the gearshift
lever into "NEUTRAL", apply the brake
lock, lower the Dozer Attachment to the
ground, and put all safety levers into the
"LOCK" position. Never leave the
operator's seat without switching the
engine off.

When operating on uneven ground,

drive at as low a speed as possible
and avoid sudden changes in
direction.

Wherever possible, avoid traveling

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

When it is impossible to avoid

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

Never mount over an obstacle at an

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

When continuing operations after rain,

remember that conditions will have
changed from those before the rain
started, so proceed with caution.
Be particularly careful when approaching
the shoulder of the road or cliffs, as they
may have been loosened by the rain.

When operating at the edge of a cliff or

on the shoulder of a road, remember the
following points:

SAFETY HINTS

When

When operating in water or in muddy

areas, remember the following points:
At night it is very easy to make
mistakes in assuming the distance and
height of objects and land.
When operating in fog, mist or smoke,
where visibility is bad, be especially
careful to confirm first whether operation
is safe.
When visibility drops below safety level,
stop work and wait for the visibility to
improve.
When operating in snow, remember the
following points:
Even slight slopes can cause
unexpected side slipping, so in such
places, operate with extreme caution.
Never use the service brake to stop
suddenly on slopes. Lowering the
working equipment is a far more
effective way to stopping.
During Operation, use the seat belt.

operating in a place where there is

danger of the machine falling over the side,
be doubly careful. Do not approach the
edge of the cliff or road shoulder by
mistake.
At the instant when the soil is dumped over
the cliff, or when the machine passes the
summit of a slope, the machine speed
suddenly increases. This is dangerous, so
press the decelerator pedal or use the fuel
control lever to reduce the speed, and at
the same time return the gearshift lever to
"NEUTRAL".
When working on river embankments or
other places made of piled soil, there is the
danger that the weight or vibration of the
machine may cause the machine to sink
into the piled soil, so be extremely careful
when operating in such places. When
operating on slopes, remember the
following points:
When driving on a slope, always drive
directly up or down it. Never drive
horizontally or diagonally across the slope,
as this may cause the machine to roll over
or slip sideways.
When going down a slope, use the engine
as a brake. If this is not enough to control
the speed of the machine, use the service
brake as well.
Never coast down a slope with the
gearshift lever in "NEUTRAL".
As far as possible, avoid turning the
machine on a slope. It may cause the
machine to roll over or slip sideways.
In forest areas, do not mount fallen trees or
logs. Piles of leaves or branches are also
very slippery, so proceed with caution.

PARKING

When parking the machine, park it in a

safe place out side the working area, or
in the specified place.
The following factors should be
considered when choosing a parking
place: it should be on flat, firm ground
where there is no danger of rock falls,
land- slides or floods.
If the machine has to be parked on a
slope, it should be parked facing directly
up or down the slope and chocks should
be placed under the tires.

Before going up or down a slope, select a

travel speed most suited to the slope. Do
not change gear on the slope.
If the engine stalls on a slope, first use the
brake to stop the machine, then return the
gearshift lever to "NEUTRAL before
starting the engine again.

When parking the machine, return the

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

10

GENERAL LOCATIONS AND SPECIFICATIONS

GENERAL LOCATIONS AND SPECIFICATIONS

GENERAL LOCATIONS:

1.
2.
3.
4.
5.
6.
7.
8.

OPERATING WEIGHT

Blade attachment
Head Lamp
Front Wheel
Rear Wheel
Lift Cylinder
Canopy
Operators Seat
Exhaust Pipe

ENGINE
Model: BEML BS6D105-1 diesel engine
Rated rpm : 2000 rpm
Flywheel horse power : 126 HP

15000 kg

PERFORMANCE
Travel speed
Forward: Max. 31.4 km/h
Reverse: Max. 22.34 km/h

Note: Specifications are subject to change

without notice

Wheel Dozer (attachment)

Attachment weight : 1880 kg

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

11

OPERATOR'S COMPARTMENT

7. TURN SIGNAL LEVER /

DIMMER SWITCH
This lever operates the turn signal lamps.

1. STEERING WHEEL
Turn the steering wheel to steer the
vehicle to the desired direction.
2. AIR HORN
The Air Horn switch is mounted on the
floor board to the left of the Operator.
Press this by left foot to sound the Air
Horn.
3.

4.

c LEFT TURN :
Push lever
Forward
d RIGHT TURN :
Pull lever
Backward

CLUTCH CUT-OFF PEDAL

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

When the lever is operated, the turn

signal pilot lamp will also light up.
When the steering wheel is turned to
the neutral position, the turn signal
lever to be return to OFF manually.
Operate the switch for head light
dimmer operation.

8. DIRECTION / SPEED CONTROL LEVER

Direction Lever: This lever is used to
change the direction of travel of the
machine (forward or reverse).
The engine cannot be started if the
directional lever is not at N (Neutral).

SERVICE BRAKE PEDAL

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

5. ACCELARATOR PEDAL
This pedal controls the engine speed and
output. The engine speed can be freely
controlled between low idling and high
idling. Press the pedal to increase the
speed of the machine. Release pressure
on the pedal to decrease the speed.
6. BLADE LIFT CONTROL LEVER
a) RAISE: When the lever is pulled
backwards the Dozer Blade is raised.
This position has detent that is
released by hand.
b) HOLD: This is the neutral position and
Dozer Blade does not move.
c) LOWER: When the lever is pushed
forward Dozer Blade is lowered. As
this position has no detent the lever
returns
to
HOLD
position
automatically
d) FLOAT: When the lever is pushed all
the way forward, the Dozer Blade is
moved by an external force. This
position has detent.

When operating the directional lever,

hold the steering wheel and operate the
directional lever with your fingers.
Speed Control Lever: This lever
controls the travel speed of machine.
This machine has 4-Forward & 3Reverse speed. Rotate the speed control
lever in a suitable direction to obtain the
desired range.
1st and 2nd speeds are used for working.
3rd and 4th speeds are used for traveling.
9. THROTTLE LOCK LEVER
Locks the engine throttles at a preset
speed when the lever is pulled towards
operator. The throttle lock is disengaged
by pulling out on the lever front side.

12

OPERATOR'S COMPARTMENT

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

1. Adjust the seat so that the brake pedal

can be depressed all the way with the
operator's back against the backrest.
2. Sit in the seat, Hold buckle (2) and insert
(3) into the buckle (2). Check that the
belt has locked by pulling it.
3. When removing the belt, raise the tip of
the buckle lever to release it.

A. Forward-Backward adjustment

Fasten belt along your body without

kinking it. Adjust the lengths of the belt
on both the buckle and then insert sides
so that the buckle is located at the midpoint of your body front.

Lift lever (1) to move the seat to the

desired position and release the lever.
The Seat can be moved Forward or
Backward within a range 180 mm in 15
steps.

Adjust the belt length in the following

manner.

B. Seat Height & Angle adjustment

Move the lever (2) set the Seat to the
desired height and release the lever. The
seat can be moved up and down within a
range of 60 mm in 5 steps.
Move the lever (2) up, set the Seat to the
desired angle, and release the lever. The
seat can be tilted up or down in steps of
2.5.

i.

C. Backrest adjustment

To shorten the belt, pull the free end of

the belt on either the buckle body or
insert side.

Press the lever (4) set the Seat to the

desired angle and release the lever.

ii. To lengthen, pull the belt while holding it

D. Weight adjustment

at a right angle to buckle or insert.

Rotate the Knob (3) set the Seat to the

desired weight release the Knob. The
seat can be adjusted within a range of
weight from 50 kgs to 120 kgs.

Inspect bolts and fittings on the chassis

for tightness. Retighten any loose bolts
to 2 to 3kgm torque.
If the seat belt is scratched or frayed or if
any of the fittings are broken or deformed
from long service, replace the same
immediately.

SEAT BELT
Before fastening the seat belt, inspect the
securing brackets and belt for abnormal
conditions.
Fasten the belt and remove it in the following
manner.

13

INSTRUMENT PANEL AND CONTROLS

INSTRUMENT PANEL & CONTROLS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Trans. Oil Temp. Gauge

Water Temp. Gauge
Engine Oil Pressure Gauge
Air Pressure Gauge
Ammeter
Hour meter
Dash Board Lamp
Indicator Lamp, Left / Right Turn
Indicator Lamp, Engine Oil Pressure
Indicator Lamp, Parking Brake
Indicator Lamp, Reverse

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Indicator Lamp, Air Pressure

Indicator Lamp, Battery Chare
Indicator Lamp, Preheat (Optional)
Parking Brake with indicator
Transmission Mode Switch
Rocker Switch, Engine Stop
Rocker Switch, Head Lamp
Rocker Switch, Work Lamp
Key Switch
Transmission Display Unit
Fuse Box (Shown separately)

no load at midrange speed until the

needle returns to the green range.

1. Transmission Oil Temp. Gauge :

This indicates temperature of the

transmission oil and temperature should
be between 80 - 100 C.

3. Engine Oil Pressure Gauge :

This gauge indicates the engine oil pressure.

2. Water Temperature. Gauge :

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

14

INSTRUMENT PANEL AND CONTROLS

7. Dash Lamp :

4. Air Pressure Gauge :

Provides illumination for night operation.

8. Indicator Lamp, Left / Right turn :
The gauge records amount of air
pressure in the air tank. The
gauge should read a minimum of
7kg/cm 2 .
5. Ammeter :

Turn signal indicator lamps glow when

turn signal switch is moved to either left
or right by the operator.
9. Indicator Lamp, Engine Oil Pressure :

Records amount of current flow to

and fro from batteries. Reading on
(-) side shows discharge. Reading
on (+) side records charging. At
high idle and with no load on the
electrical system the ammeter
should records a charge.
6. Hour meter :

This indicator lamps glow when low

engine oil pressure. If the alarm buzzer
sounds and this lamp flash, the engine
oil pressure is below the lower limit.
Immediately stop the engine.
10. Indicator Lamp, Parking Brake :

This gauge indicates the total no.

of hours the machine has worked.
The hour meter advances while
engine is running even if the
machine is not working.

This lamp lights up when the parking

Brake is applied.

15

INSTRUMENT PANEL AND CONTROLS

11. Indicator Lamp, Reverse :

15. Parking Brake :

A 2 mode switch provides the operator
control over parking brake.

This lamp lights up when the vehicle is

reversed..
12. Indicator Lamp, Air Pressure :

Position ON : Parking brake is in

applied condition. Parking brake indicator
light on switch glows.
Position OFF: Parking brake is
released. Parking brake indicator light
goes OFF,
Keep the Parking Brake switch in ON
position, before turning the key switch to
on.

This indicator lamps glow when air

pressure in the tank is low.

16. Transmission mode switch :

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

13. Indicator Lamp, Battery Charge :

17. Rocker switch, Engine stop :

18. Rocker switch, Head lamp :
19. Rocket switch, Work lamp :
20. Key Switch :
The monitor indicates an abnormality in
the charging system while the engine is
running.
14. Indicator Lamp, Pre Heat (Optional) :

This is mounted on right side of the

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

Indicates when Pre-heater is used.

16

INSTRUMENT PANEL AND CONTROLS

Remove Cover

21. Display unit (Transmission):

Replace a fuse with another of the same

Capacity.
Before replacing a fuse, be sure to
turn OFF the Starting switch.

The following can be seen in the display

Unit:
a. Display of the Driving direction (right
side) V: Forward, N: Neutral, R: Reverse
b. Display of the engaged gear : Display
1,2,3,4
c. Waiting for Controller-Neutral
NN

Lights, Back-up Horn

Display:

a. Head Lights Front, Rear & Turn signal

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

d. Pre-selected Driving range: 1 Bar,2 Bars,

3 Bars & 4 Bars (All Manual Mode)
e. Display Manual/ Automatic (Arrows are
indicate Automatic Mode: automatic upand down shiftings)
f.

Display
of
Cold-start
phase
Transmission Remains in Neutral

g. Bars are flashing: Downshifting mode

active
h. Error Display: Right side spanner symbol
display
For more details contact Nearest BEML
Office.
22. Fuse arrangement

Note: Fuse Box is fitted in side the

Instrument Panel box.

17

CHECK BEFORE STARTING

CHECK BEFORE STARTING

(Pre-operation checks forestall machine trouble. Never neglect them)
a. Walk around the machine and check for
any trace of oil or water leakage.
Remove radiator cap and check water
level. Examine connections of high
pressure hoses, hydraulic cylinders, final
drive, radiator. If any leakage is evident,
check for the cause and repair. If
difficulty is encountered, consult your
nearest BEML Office.
Check tightness of bolts and nuts and
retighten if required. Particularly checks
are required for mounting of air cleaner
and muffler.
Check for broken electric wirings, short
circuits and loose terminals. If any fault is
detected, retighten/ repair / replace .
In particular check for electric wirings of
the battery, the starting motor and the
alternator.
b. COOLANT

c. CHECK FUEL LEVEL AND REFILL

FUEL IN THE FUEL TANK

1. Check the fuel level using fuel gauge/

dip stick.
2. Upon completion of work, pour in
addition fuel from filler (F) until the
fuel tank is full.
3. Fuel Capacity: 185 liters.
d. CHECK AND CORRECT OIL LEVEL IN
THE ENGINE OIL PAN
Use the dipstick (G) to check the oil level.
If necessary, add oil at the oil filler (F).

Remove radiator cap and check that

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

The type of lubricant used depends

on the ambient temperature. Select
according to the table "FUEL,
COOLANT AND LUBRICANTS".
Make an oil level check before
starting engine or 15 minutes or more
after the engine is stopped. If oil
remains at various portions of the
engine, the correct oil level cannot be
measured.
Stop the engine when checking the
oil level. Checking the oil level with
the engine idling may be allowed, if
the
following
precautions
are
thoroughly satisfied:

To remove cap, release radiator

pressure little by little by loosening
cap slowly; then remove cap.

18

CHECK BEFORE STARTING

Even if a water separator is installed,

be sure to check the fuel tank to
remove water & sediment in the fuel.

i. Check that the engine oil pressure gauge and water temperature
gauge shows green ranges.
ii. Remove the oil filler cap.
iii. Read the dipstick on its reverse
side where it is stamped,
"ENGINE IDLING / STOPPED."

g. HYDRAULIC TANK

e. CHECK DUST INDICATOR

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

When air cleaner element is clogged, the

red piston of dust indicator (1) reaches
service level and gets locked. In that
case, clean element referring to section
"WHEN REQUIRED".

Add Hydraulic oil from oil filler (F) if

necessary.
The type of lubricant used depends
on the ambient temperature. Select
according to the table "FUEL,
COOLANT AND LUBRICANTS".
When removing the cap (F), turn it
slowly to relieve inner pressure.
After cleaning element, push button
(2) to return red piston
f.

Maintenance for every 50 hours

should be carried out at the same
time

CHECK FOR SEDIMENT & WATER IN

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

19

CHECK BEFORE STARTING

1. Check that the oil level in tank (1) at the

right side of the operators seat in
between the MAX & MIN marks.

h. TRANSMISSION OIL LEVEL CHECK

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

necessary.
The type of lubricant used depends
on the ambient temperature. Select
according to the table FUEL
COOLANT AND LUBRICANTS.
Always use SAE10W oil to refill
the brake oil tank.
j.

Check that
properly

Parking

Brake

works

k. Check that Foot Brakes work properly

l.

All measurements must be carried out

with low engine idling speed.

i.

Check that Horn sounds properly

m. Check that Lamps flash properly.

Check for Dirt or Damage.

Park the equipment in horizontally

standing.
Transmission in a neutral position.
In the cold start phase, the engine
must be running about 2~3 minutes
at idling speed, on the marking on the
oil dipstick must then be lying above
the cold start mark COLD.
At operating temperature of the
transmission about 80 ~ 90 C
Loosen dipstick by counter lock
rotation, remove and clean it.
Insert oil dipstick by slowly into the oil
level tube until contact is obtained,
and pull it out again.
On the oil dipstick, the oil level must
be lying in the zone, hot.
Insert the oil dipstick again, and
tighten it by clockwise rotation.

n. Check direction of rear view mirror;

Check for Dirt or Damage. (Optional)
o. Check that Engine Exhaust Gas color
and sound are normal.
p. Check that Gauges and Instruments
work properly. (Refer Page No.14)
q. Check Steering play. Check
Steering works properly.

that

r. Check that Back-up Buzzer sounds

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

CHECK AND REFILL OF OIL IN

BRAKE OIL TANK

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

Please contact your nearest BEML

Office for investigation and correction
of the cause.

20

OPERATING YOUR MACHINE

OPERATING YOUR MACHINE

BEFORE STARTING THE ENGINE

CHECK AFTER STARTING

After starting, make the following checks.
a. Depress accelerator pedal (1) lightly and
run the engine with no load at midrange
speed for about 5 minutes.
b. After warm-up run is completed, check
gauges and caution lamps for proper
operation.
c. Confirm that the engine oil pressure
caution lamp goes off when the engine is
running at low idle.
d. Continue to run the engine at light load
until the green ranges of the engine
water temperature gauge and torque
converter oil gauge are indicated.
e. Check if the exhaust color is normal or
whether there is any abnormal noise or
vibration.
f. Avoid abruptly accelerating the engine
until the completion of warm-up.

Before starting the engine, always check that

the levers and pedals are in the correct
positions.
1. Carry out an initial inspection. (For
details of the inspection, see CHECK
BEFORE STARTING).
2. With your back against the back rest of
the Operators seat, adjust the seat
position so that the pedals can be easily
accessible and depressed.
3. Is work equipment control levers are in
hold position.
4. Are the pilot lamps are working properly?
5. Do not start the engine while Dozer
Blade control lever is in any position
other than hold position.
TO START THE ENGINE

TO MOVE THE MACHINE OFF

1. Check that the caution lamps are OFF.
2. Operate the Dozer blade control lever.
Bring the attachment in the traveling
posture. 500 mm above the ground.

1. Keep gear shift / Forward & Reverse

lever in N (neutral).
2. Depress accelerator pedal (1) lightly.
3. Turn the key of
starting switch to the
ON position to start
engine.

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

parking brake switch to OFF position to
release the parking brake
4. Shift the gear shift lever to 1st or 2nd
speed then shift Forward or Reverse
direction as required.
5. Release brake pedal (2), then depress
accelerator pedal (1) to move the
machine off.
If the machine has to be started on a
slope, always depress the left brake
pedal. Then depress the accelerator
pedal while releasing the left brake
pedal to start the machine off slowly.

4. If engine does not

start,
repeat
the
starting
procedure
after about 2 minutes.
5. When
engine
is
started, release the
key of starting switch
and the key will return
automatically to ON.

21

OPERATING YOUR MACHINE

ZF CONTROLLER DW-3

CHANGING DIRECTION

Reduce the speed and bring down to neutral

before changing between forward and
reverse direction. Place the directional lever
to the desired position.
TURNING
When traveling, use steering wheel (1) to
turn the machine.

After selecting the speed range release the

Forward/Reverse lock lever. If lock lever is
N position Forward/Reverse cant be
operated. If the lock lever is switched to D
position Forward/Reverse direction can be
operated Please Note.

CHANGING GEAR SPEED

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

In this machine, the front frame is joined

to the rear frame at center of machine by
the center pin. The front and rear frame
turn about this point, and the rear wheels
follow in the same track as the front
wheels when turning.
Turn the steering wheel lightly to follow
the machine as is turns. When turning
the steering wheel fully, do not turn it
beyond the end of the stroke.
It is dangerous to turn the machine
suddenly at high speed, or to turn on
steep hills.
If the engine stops when the machine is
traveling, the steering cannot be used.
Since the machine is not equipped with
emergency steering system.

While changing speed use brake pedal

before rotating lever.

22

This is particularly dangerous on hills,

so never stop the engine when the
machine is traveling.

OPERATING YOUR MACHINE

When working in water or on swampy

ground, do not let the water come above the
bottom of the axle housing.

TO STOP THE MACHINE

After finishing the

operation, wash
and check the
lubricating points.

IF WHEEL BRAKE DOES NOT WORK

If the machine is not stopped by depressing
brake pedal, use the parking brake to stop
the machine.
1. Release accelerator pedal (1) or release
Throttle Lock Lever forward direction and
depress brake pedal (2) to stop the
machine.

PRECAUTIONS WHEN DRIVING UP OR

DOWN SLOPES
Lower the centre of gravity when turning
When turning on slopes, lower the Dozer
attachment to lower the center of gravity
before turning. It is Dangerous to turn the
machine with the Dozer Blade Attachment
raised.

2. Place direction control lever in neutral.

3. Put parking brake switch to ON position.
4. Operate Dozer Blade attachment lever
(3) and lower the attachment to ground.
Stop the machine in a safe place on
firm level ground. If the machine has
to be stopped on a slope, put blocks
under the wheels. In addition to dig
the attachment into the ground to
increase the safety.

BRAKING ON DOWN HILL SLOPES

TO STOP THE ENGINE

1. Run the engine at low idle speed for
about 5 min. to allow it to cool down
gradually.
2. Return starting switch to the OFF
position and remove the key. (for Fig.
see next page)

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

When driving down slopes put the speed

control lever in a low speed position and fully
apply service brake. To apply the service
brake, depress the right brake pedal.
If the speed control lever is not placed in
proper speed position, the torque converter
oil temperature may rise. If it overheats,
place the speed control lever in the next
lower speed to lower the oil temperature.
If the temperature gauge does not
indicate the green range of the scale
even with the lever in the 1st speed
position, stop the machine, place the
lever in neutral and run the engine at
medium speed until the gauge indicates
the green range.

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

In particular, if the engine has

overheated, do not abruptly stop it but
run it at medium speed to allow it to cool
gradually, then stop it.

MAXIMUM DEPTH OF WATER

23

TOWING / TRANSPORTATION

4. Apply the parking brake on the trailer and

insert blocks beneath the tyres to ensure
that it does not move. Then fix the
gangplank in line with the centers of the
trailer and the machine.

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

If there is a failure in the brake system, the

brakes cannot be used, so be extremely
careful when towing.
When engine can be used.

Make sure the gangplank has

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

When transmission cut-off switch is

put in OFF, the brake pedal and
accelerator pedal are operated at the
same time.
3. Determine the direction of the gangplank,
then slowly load or unload the machine.

Always keeps the engine running when

towing the machine. So that the steering
and braking can be used.
When engine cannot be used.
No lubrication oil flows in the
transmission, so disconnect the front and
rear drive shafts before moving the
machine.

Do not on any account change the

direction of the machine while it is
on the gangplank. To change the
direction of the machine, first take
it down from the gangplank

The steering cannot be used, so

disconnect the steering cylinder and
steering linkage.

4. When transporting the machine, place

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

The machine should be towed only to the

nearest place for inspection and
maintenance. Do not tow the machine for
long distance.

Determine the route for transporting

the machine by taking into account
the width, height and weight of the
machine.

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

Before locking (Front & Rear frame)

When loading the machine, park the

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

After locking (Front & Rear frame)

1. Correctly load the machine onto the

specified part of the trailer.
2. Lower the Dozer Attachment and bring
gear shift lever neutral lock .
3. Lock front frame and rear frame with
safety bar provided on the equipment as
shown in the figure.

24

COLD WEATHER OPERATION

COLD WEATHER OPERATION

PREPARATION FOR LOW
TEMPERATURE

Standard requirements
antifreeze.

Replace lubrication oil by that with

prescribed viscosity.
Fuel of low pour point shall be used.
ASTM 0975 No.1 diesel fuel should be
used at atmospheric temperature lower
than -10 C.
Add antifreeze in the cooling water. When
the atmospheric temperature drops lower
than 0C while the machine is stopped,
prevent freezing by adding antifreeze to
the cooling water. The mixing rate of
antifreeze is determined according to the
expected minimum temperature. The
following table shall be used.

SA J1034
FEDERAL STANDARD
O-A-548D
Never use any antifreeze made from
methyl alcohol or ethyl alcohol which
may be a cause of engine trouble.
Where no permanent antifreeze is
available, ethylene glycol antifreeze
without corrosion inhibitor may be used
only for the cold season. In this case,
coolant must be changed two times a
year (at the beginning and at the end of
the cold season).
Do not mix antifreeze with one of
different brand.
Absolutely avoid using any water leak
preventing agent irrespective of whether
it is used independently or mixed with
antifreeze.

Mixing rate of water and antifreeze

o

Min atmospheric temp ( C)

-5

-10

-15

-20

49.5

59

68

126.5 121.5

106

97

Amount of antifreeze (litre) 38.5

Amount of water (litre)

for

permanent

Battery

Coolant capacity: 45 liters

As ambient temperature drops, battery

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

Cautions for using antifreeze

1. Permanent type antifreeze shall be used.
2. Soft water (ex: city water) shall be
used as mixing water.
3. Cooling systems must be thoroughly
flushed before filling with antifreeze
mixture.

Measure specific gravity of fluid and

obtain rate of charge from the
following conversion table:

4. When the climate becomes warmer

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

change

Temp of Rate of fluid

Take care for fire as antifreeze is

inflammable.

100%
90%
80%
75%

20 C

0C

-10 C

-20 C

1.28
1.26
1.24
1.23

1.29
1.27
1.25
1.24

1.30
1.28
1.26
1.25

1.31
1.29
1.27
1.26

When electrolyte level is low, add

distilled water in the morning before work
instead of after the day's work. This is to
prevent fluid from freezing at night.
When temperature rises, change
lubricating oil in each unit to that of
recommended viscosity.
Completely drain antifreeze from
cooling system and fill with soft water
(for example, city water) after
thorough flushing.

Care in using antifreeze

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

25

OPENING AND CLOSING A LOCKING CAP / HANDLING OF BATTERY

OPENING AND CLOSING OF LOCKING CAP

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

2. To lock the cap

Turn the cap into place.
Turn the key clockwise and take the
key out.

1. To open the cap

Insert the key into the cap
{ Insert the key as far as it will go.
If the key is turned before it is
inserted all the way, it may break.
Turn the key counterclockwise and
bring the rotor groove in line with the
aligning mark on the cap. Turn the
cap slowly until a "clicking" sound is
made. This releases the lock and
allows the cap to be opened.

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

PRECAUTIONS FOR CHARGING BATTERY

1. Before charging, disconnect the cable from
the negative (-) terminal of the battery.
Otherwise an unusually high voltage will
damage the alternator.
2. While charging the battery, remove all
battery plugs for satisfactory ventilation.
To avoid gas
explosions, do
not bring fire or
sparks near the
battery

7. When inspecting or servicing a battery,

be sure to stop the engine and turn the
starting switch key to
(OFF) position.
8. When performing any service to battery
besides checking the electrolyte level or
measuring
the
specific
gravity,
disconnect cables from the battery.

3. If the electrolyte temperature exceeds 45

C, stop charging for a while.
4. Turn off the charger as soon as the battery
is charged.

REMOVAL AND INSTALLATION OF

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

Overcharging the battery may cause

followings:
a. Overheating the battery
b. Decreasing the quantity of electrolyte
c. Damaging the electrode plate
5. If the electrolyte gets on your skin or clothes,
immediately wash with plenty of clean water.

26

HANDLING OF BATTERY

When installing battery, the ground cable

should be connected to the ground
terminal as the last step.

When connecting the cables, never contact

the positive (+) & negative (-) terminals
Make sure that the booster cable
connections are correct. Connect the
booster cable to the body as far as
possible from the battery.

STARTING ENGINE WITH A

BOOSTER CABLE
When starting up the engine with a
booster cable do as follows:

3. Starting the engine

1. Before connecting the booster cable

a. Turn the starting switch key to START

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

a. Size of booster cable and clip should

be suitable for the battery size.
b. Check cables and clips for breaks,
corroded surfaces, etc.
c. Make sure cables and clips are,
firmly secured.
d. Keep the starting switch key in (OFF)
position.
e. The battery of the running engine
must be the same capacity as that of
engine to be started.

After the engine has started, the booster

cables should be disconnected in the
reverse order in which they were connected.
1. Disconnecting the booster cables.
a. Disconnect the clip of booster cable B
from the body of the machine which
was started.
b. Disconnect the other clip from the
negative (-) terminal of the running engine
c. Disconnect the clip of booster cable A
from the positive (+) terminal of the
running engine.
d. Disconnect the other clip from the
positive (+) terminal of the engine
which was started

2. Connect the booster cables in the

following manner.
a. Connect one clip of booster cable A
to the positive (+) terminal of the
engine to be started.
b. Connect the other clip to the positive
(+) terminal to the engine which is
running.
c. Connect one clip of booster cable (B)
to the negative (-) terminal of the
engine which is running.
d. Connect the other clip to the body of
the machine to be started.
Make sure the clips are firmly connected
to battery terminals. Then, start the
engine.

27

PRECAUTIONS FOR MAINTENANCE

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

instructions. Do not perform any

maintenance beyond the agreed work.

PRECAUTIONS FOR MAINTENANCE

GENERAL

1. Wear well-fitting helmet, safety shoes

and working clothes. When drilling,
grinding or hammering, always wear
protective goggles.

4. Do not handle electrical equipment while

wearing wet gloves, or in wet places, as
this can cause electric shock.
5. During maintenance do not allow any
unauthorized person to stand near the
machine.

2. Fuel or oil is dangerous substances.

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

6. Exhaust gas is dangerous. When

working inside, be particularly careful to
have good ventilation.

As preparation in case of fire, always

know the location and directions for use
of fire extinguishers and other fire
fighting equipment.

3. When working with others, choose a

group leader and work according to his

28

PRECAUTIONS FOR MAINTENANCE

7. Unless you have special instructions to

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

DURING MAINTENANCE
1. Park the machine on firm, flat ground.
Lower the Dozer Attachment to the
ground and stop the engine. Return the
gear shift lever to "NEUTRAL", apply the
brake lock and set each control lever to
"LOCK". When maintenance has to be
carried out with the Attachment raised,
they must be securely supported by
blocks.
2. Thoroughly wash the machine. In
particular, be careful to clean the filler
caps, grease fittings and the area around
the dipsticks. Be careful not to let any dirt
or dust into the system.
3. Hang a caution sign in the operator's
compartment (for example "Do not start"
or "Maintenance in progress").

8. Always remember that the hydraulic oil

circuit is under pressure. When feeding
or draining the oil or carrying out
inspection and maintenance, release the
pressure first.

This will prevent anyone from starting or

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

9. The procedure for releasing the hydraulic

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

5. Immediately remove any oil or grease on

the floor of the operator's compartment,
or on the handrail. It is very dangerous if
someone slips while on the machine.

10. Always use BEML genuine parts for

replacement.
11. Always use the grades of grease and oil
recommended by BEML. Choose the
viscosity specified for the ambient
temperature.
12. Always use pure oil or grease, and be
sure to use clean containers.

6. When check an open gear case there is

a risk of dropping things in. Before
removing the covers to inspect such
cases, empty everything from your
pockets. Be particularly careful to
remove wrenches and nuts.

13. When checking or changing the oil, do it

in a place free of dust, and prevent any
dirt from getting into the oil.

7. Before draining the oil, warm up it to a

temperature of 30 to 40 C.

29

PRECAUTIONS FOR MAINTENANCE / BLEEDING AIR FROM CIRCUIT

8. Be particularly careful when removing

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

1. Operate each hydraulic cylinders 4 to 5

times, stopping 100 mm from stroke end.
2. Next, operate each cylinder 3 to 4 times
to the stroke end.
If the engine is run at high speed at
first, or if the cylinder is moved to the
end of its stroke, the air in the
cylinder may damage the piston
packing, etc.,

9. After replacing oil, filter element or

strainer, bleed the air from the circuit.
10. When the strainer is located in the oil
filler, the strainer must not be removed
while adding oil.
11. When adding oil or checking the oil level,
check that the oil is at the correct level.

BLEEDING AIR FROM THE BRAKE

CIRCUIT

12. After greasing up, always wipe off the old

grease that was forced out.
13. When changing the oil or filter, check the
drained oil and filter for any signs of
excessive metal particles or other foreign
materials.
14. When removing parts containing O-rings,
gaskets or seals, clean the mounting
surface and replace with new sealing
parts.
15. When the Tyres are removed, never put
your fingers in the rim mounting holes.

Open the bleeder (B) as shown in the figure

one by one .

16. Special measuring apparatus is needed

for testing hydraulic pressure.

slowly depress the brake pedal until oil flows

out of the bleeder.

17. When changing the electrical circuit,

adding additional or new equipment, or
when replacing parts with parts which
are not BEML genuine parts, please
contact your nearest BEML office.

Close the bleeder again.

Slowly pressurize the brake and hold the
pressure for some seconds.
Note: The brake piston extends and the
cylinder chamber fills up with oil. The air
accumulates in the upper section of the
cylinder chamber.

When carrying out other difficult

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

Release the brake pedal and loosen the

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

BLEEDING AIR FROM CIRCUIT

Open the bleeder plugs again

BLEEDING AIR FROM HYDRAUILIC

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

Slowly depress the pedal until oil flows out of

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

30

MAINTENANCE TABLE

MAINTENANCE TABLE
No

ITEM

a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r
s

Walk-around check
Coolant
Fuel tank
Engine oil pan
Dust indicator
Water separator
Hydraulic tank
Transmission oil
Brake oil tank
Parking brake
Foot brake
Horn
Lamps
Rear view mirror (Optional)
Exhaust gas & colour
Instruments
Steering wheel
Back-up buzzer
Electric wiring

a
b

SERVICE
CHECK BEFORE STARTING
Check
Check & supply
Check & supply
Check & supply
Check
Check
Check & supply

PAGE

Check & supply

Check & supply
Check function
Check function
Check function
Check function
Check
Check
Check
Check play
Check function
Check & retighten

18
18
18
18
19
19
19
20
20
20
20
20
20
20
20
20
20
20
20

Fuel Tank
Tyres

EVERY 50 HOURS SERVICE

Drain water and sediment
Check air pressure and damages

33
33

Rear axle pivot pin

EVERY 100 HOURS SERVICE

Lubricate 2 points

33

a
b
c
d

INITIAL 250 HOURS SERVICE

Fuel pre filter and fine cartridge
Replace cartridge
Transmission oil cartridge
Replace cartridge
Engine oil pan and cartridge
Change oil & replace cartridge
Engine valve clearance
Check and adjust

33
33
33
33

a
-1
-2
-3
-5
b
c
d
e
f
g

EVERY 250 HOURS SERVICE

Lubricating
Blade Brace Screw
Lubricate 2 point
Blade cylinder pin
Lubricate 2 point
Cylinder Support / Yoke
Lubricate 6 points
Steering Cylinder pin LH&RH
Lubricate 4 points
Engine oil pan & cartridge
Change oil & replace cartridge
Fuel Strainer
Check and clean
Fuel pre filter and fine cartridge
Replace cartridge
Fan belt/ Compressor belt
Check tension
Wheel Nuts
Check and retighten
Battery Electrolyte level
Check and supply

34
34
34
34
34
34
35
35
36
36
36

31

MAINTENANCE TABLE

No

ITEM

SERVICE
EVERY 500 HOURS SERVICE

PAGE

Lubricating

37

-1

Center drive shaft (Engine & Trans.)

Lubricate 3 points

37

-2

Center hinge pin

Lubricate 2 points

37

Transmission oil cartridge

Replace element

37

EVERY 1000 HOURS SERVICE

a

Lubricating

-1

Front drive shaft

Lubricate 3 points

37

-2

Center Drive shaft

Lubricate 3 points

37

-3

Rear Drive shaft

Lubricate 3 points

37

-4

Intermediate drive

Lubricate 3 points

37

-5

Damper

Lubricate 1 point

38

Transmission

Change oil

38

Transmission case breather

Clean breather

38

Hydraulic and steering filter

Replace element

38

Turbocharger clamping joint

Check and retighten

38

EVERY 2000 HOURS SERVICE

a

Front & Rear Axle

Change oil

39

Hydraulic tank & Breather

Change oil & Replace element

39

Engine breather

Clean element

40

Alternator and starting motor

Check

40

Engine valve clearance

Check and adjust

40

Turbocharger

Check & clean

40

Brake disc

Check

40

EVERY 4000 HOURS SERVICE

a

Water pump

Check

41

Vibration damper

Check

41

Air Compressor

Check

41

Damper (Chassis)

Check

41

WHEN REQUIRED
a

Air cleaner element

Check, clean or replace element

42

Electrical intake air heater (Optional)

Check

43

Coolant

Clean

43

Transmission oil

Check & refill

44

Axle Oil / Case breather

Clean, check and supply

44

Lubricating

-1

Accelerator pedal linkage

Lubricate 2 points

44

Radiator fin

Clean

44

Water separator

Clean drain water

45

32

EVERY 50 / 100 / INITIAL 250 HOURS SERVICE

EVERY 50 HOURS SERVICE

EVERY 100 HOURS SERVICE

a. FUEL TANK

Apply grease to the grease fittings shown by

arrows.
Maintenance for every 50 hours should
be carried out at the same time.
Rear axle pivot pin

( 2 points)

Loosen drain valve on the bottom of the

fuel tank, so that the precipitation and
mixed water will be drained in
accompaniment with fuel.
Maintenance Drain
starting the engine.

water

before

INITIAL 250 HOURS SERVICE

b. TYRES

Perform the following maintenance after

running the machine for the first 250 hours.
a. REPLACE FUEL PRE FILTER / FINE
CARTRIDGE
b. REPLACE TRANSMISSION OIL &
CARTRIDGE
c. REPLACE ENGINE OIL AND
CARTRIDGE
d. CHECK ENGINE VALVE CLEARANCE

Measure the inflation pressure before

operating the eqpt., when the tyres are
cool

For details of the method of replacing or

maintaining, see the section on EVERY
250, 500 & 2000 HOURS SERVICE.

33

EVERY 250 HOURS SERVICE

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

EVERY 250 HOURS SERVICE

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

Maintenance for every 50 hours

should be carried out at the same
time.
b. Engine Oil Pan & Cartridge

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

Open oil filler (F) and remove drain plug

(1) to drain oil. After draining, tighten the
drain plug.

2. Blade Lift Cylinder

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

3. Cylinder Support / Yoke

(6 Points)

34

EVERY 250 HOURS SERVICE

Apply a dab of oil to the gasket of the new

cartridge, and contacts the gasket with the
seal face.

d. FUEL PRE-FILTER & CARTRIDGE

1. Remove drain plug (P) on the bottom
of the Fine filter (F) and Cartridge (C)
to drain fuel.

To refit the cartridge, place the gasket

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

After replacing the cartridge, pour in

the specified quantity of engine oil
from oil filler (F).
After pouring in oil, run the engine for several
minutes, then once again check the oil level
and ensure that it is correct.

For the method of checking the oil level,

refer to CHECK BEFORE STARTING.
Refill capacity: 24 Liters.
The type of lubricant used depends on the
ambient temperature. Select according to
the table "FUEL, COOLANT AND
LUBRICANTS".
Use a genuine BEML cartridge.
Change the engine oil every 6 months or
every 250 service hours
Before installing a filter cartridge, be sure
to fill the cartridge with engine oil.

2. Using a filter wrench, remove

cartridge (C) by turning it counter
clockwise.
3. Fill the new cartridge with fuel and
refit it after applying a dab of oil to the
gasket face.
4. Remove the fine filter housing /
inner element by removing the bolt
on filter head, clean the housing
and replace the inner element, fill
the fuel and refit.
5. After fitment, both the filter /
cartridge loosen the air bleed
screws on top of the filter /
cartridge housing, loosen and
move the feed pump (1) up and
down to bleed the air from the
system. When no air bubbles
comes out of the air bleeding screw
/ plug, tighten the screw/plug. Tight
the knob (1)

c. FUEL STRAINER

Remove the Strainer from the Strainer

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

35

EVERY 250 HOURS SERVICE

e. Fan Belt

f. Wheel Nut

The Belt tension should normally deflect

by about 5 to 10 mm when pressed with
the finger at a point midway between the
alternator pulley and the fan pulley
(approx. 6 kg).
To adjust
the belt
tension,
loosen bolt
(B) and nut
(N) and shift
alternator
(A) slightly.

If wheel nut are loose, tyre wear and

damage to rim will be increased and
accidents may be caused. If any wheel
Nuts are loose, tighten them to the
specified tightening torque.
Tightening torque : 94.5 10.5 kgm
If any wheel Studs are broken,
replace the Wheel Studs .
Always rotate in the direction of
tightening when checking for loose bolt.
g. ELECTROLYTE LEVEL IN BATTERY
If the electrolyte level is lower than the
prescribed level (10 to 12mm above the
plate), supply distilled water. Should any
of the acid be spilt, have it replenished
by the nearest battery shop with acid of
the correct specific gravity.

After adjustment, tighten bolt (B) and nut

(N) securely.
e. When adjusting the V-belt, do not
attempt to push alternator (A) directly
with a bar or the like, nut use a wood
pad to prevent damage to the core.
f. Check each pulley for damage, and
V-grooves and V-belt for wear.
Particularly, check whether V-belt is
in contact with bottom of V-groove
through wear.
Replace belt if it has stretched,
leaving no allowance for adjustment,
or if there is a cut or crack on belt.

When inspecting electrolyte level, clean

the air hole of the battery cap.
Never use metal funnel for electrolyte
supply.

36

EVERY 500 / 1000 HOURS SERVICE

The maintenance for every 50, 100, 250 & 500

hours should be carried out at the same time.

EVERY 500 HOURS SERVICE

EVERY 1000 HOURS SERVICE

a. LUBRICATING

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

Lubricate grease to the grease fittings

shown by an arrow.
1. Center Drive Shaft

(3 point)

2. Centre hinge pin

(2 points)

1. Front drive shaft

(3 points)

2. Centre Drive shaft

(3 points)

3. Rear Drive shaft

(3 points)

b. TRANSMISSION OIL CARTRIDGE

Park the equipment in level ground put of
the engine and remove the cartridge by
using cartridge remover tool.
g. Use a genuine
Cartridge

BEML

Supplied

h. Replace the new cartridge by applying

small qty of oil in the Gasket. Start the
engine and check for any leakage.
4. Intermediate drive

37

(1 point)

EVERY 1000 HOURS SERVICE

5. Damper

(1 point)

d. HYDRAULIC AND STEERING FILTER

ELEMENT

Remove the bolts and cover, take out the

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

b. TRANSMISSION

Use genuine BEML elements.

After replacing the elements, start the
engine and check the system for any
leakage.
e. TURBOCHARGER
Periodically inspect all joints for looseness.
Tighten if necessary.

Park the equipment at level ground, bring

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

Remove the breather, clean and refit.

38

EVERY 2000 HOURS SERVICE

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

EVERY 2000 HOURS SERVICE

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

a. FRONT AND REAR AXLE

1. Remove Front and Rear Axle oil filler

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

3. Open drain valve (D) to drain oil.

After draining, tighten the drain valve.
When removing the cap, turn it
slowly to relieve inner pressure

2. After draining the oil, clean drain plugs

(2), then install them.
3. Add oil to the specified level through the
oil filler ports of the axle housing (1).

4. Open the hydraulic tank strainer

cover, remove the strainer clean and
fit back.
Check that there is no foreign
matter inside the tank before
cleaning it.
5. Fill the specified quantity of hydraulic
oil through filler (F). Check the oil
level through gauge (G).
6. Start the engine and run at a low idle
speed for 5 minutes, then operate the
system 2 ~ 3 times and check the oil
level, If required top up the oil upto
gauge level.
The type of lubricant used depends
on the ambient temperature. Select
according to the table FUEL,
COOLANT AND LUBRICANTS.
Refill capacity: 195 litres.
Check that there is no oil leaking
from
the
hydraulic
tank
components.

4. Check the oil level and ensure.

Refill capacity 45 litres each axle.
The type of lubricant used
depends
on
the
ambient
temperature. Select according to
the table FUEL, COOLANT AND
LUBRICANTS.
b. HYDRAULIC TANK AND
BREATHER
1. Lower the Dozer Blade attachment to
the ground and apply parking brake,
then stop the engine.
2. Remove the oil filler cap (F) and
replace the breather element (B) .
It is possible to replace the
element with the breather
installed in the tank. However, if
the breather is removed, do not

39

EVERY 2000 HOURS SERVICE

c. ENGINE BREATHER

f. TURBOCHARGER
Excessive carbon or oil sludge
adhering to turbocharger blower
impeller may lead to deterioration of
normal charger performance, and
possible damage. Have turbocharger
cleaned by BEML.
g. MULTI DISC BRAKE
(Wear measurement)

1. Loosen the clamp and remove the

hose, then remove the breather
from the cylinder block.

A wear measurement has to be made on

both output sides once a year or every
2000 hours.

2. Put the breather in diesel oil and

rinse.

If dimension X 3.5 mm, the lined

discs on both output sides have to be
replaced.

3. After rinsing, pour in clean diesel

oil through the hose. Then dry
with compressed air & install.
4. Check the breather hose, if there
is any sediment for deteriorated
oil (sludge) inside, replace with a
new hose.
d. ALTERNATOR & STARITNG MOTOR

As the hours of engine employment

indicate that the brushes are already
worn out, you should request repair from
a BEML office.
They should be repaired every
1000 hours, if the machine is
frequently operated at night.
e. ENGINE VALVE CLEARANCE
As special tool is required for
removing and adjusting the parts,
you shall request nearest BEML
office for service.

40

EVERY 4000 HOURS SERVICE

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

EVERY 4000 HOURS SERVICE

a. WATER PUMP

c. AIR COMPRESSOR

Inspect the water pump for play in the

pulley, oil leakage and water leakage.

Check the Compressor which produces

air for operating, Brake system and Air
horn .

If any fault is detected, ask nearest

BEML office to disassemble and repair or
replace.
b. VIBRATION DAMPER

d. DAMPER (Chassis)

Check that there are no cracks in the

damper. If there is any abnormality,
contact your nearest BEML Office for
repairs or replace.

Check for any leakage. If necessary

contact your nearest BEML Office for
repairs.

41

WHEN REQUIRED

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

a. CHECKING, CLEANING AND

REPLACING AIR CLEANER ELEMENT

Checking

4. Push the dust indicator (1) reset button

to return the red piston to the original
position.

When the dust indicator red piston

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

Replace the outer element, which

Cleaning or replacing outer element

has been cleaned 6 times repeatedly

or used throughout a year. Replace
the inner element at the same time.

Remove one sticker from the outer

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

Check inner element (10) mounting

nut (8) with washer (9) for looseness
and, if necessary, retighten.

Replace washer (9) or wing nut (8) if

Whenever the red piston in the dust

indicator (1) appears, clean the air
cleaner element. Stop the engine when
cleaning the element.

they are broken.

Replacing inner element
1. First remove the cover (4) and the outer
element (7), and then remove the inner
element (10).
2. Place the cover over the air intake part to
prevent dust entering.
3. Clean the air cleaner body interior.
Remove the cover from the air inlet port.
4. Fit the new inner element (10) and
tighten it with washer (9) and nut (8).
5. Install the outer element (7) and the
cover (4). Push the dust indicator reset
button.

1. Loosen wing bolt (2) and clamp (3) and

remove cover (4). Loosen wing nut (5)
with washer (6) and remove the outer
element (7).

NOTE: Do not attempt to reinstall a

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

2. Clean the air cleaner body interior and

the removed cover (4).

42

WHEN REQUIRED

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.

Cleaning outer element with

compressed air

Direct dry compressed air (less than

7kg/cm2) to element from inside along its
folds, then direct it from outside along its
folds and again from inside, and check
element.

b. CHECK ELECTRICAL
HEATER (Optional)

INTAKE AIR

When using compressed air, wear

safety glasses and other things
required to maintain safety.
The following methods require spare parts.
With water :
Dash city water (less than 3kg/cm2) on
element from inside along folds, then
from outside and again from inside.
Dry &
check it.

Check electrical intake air heater once a

year before commencing work in the cold
season.

With cleaning agent :

For removing oils and fats as well as carbon
etc. attached on the element, the element
may be cleaned in lukewarm solution of mild
detergent, then rinsed in clean water and left
to drip dry.
Drying can be speeded up by blowing
dried compressed air (less than 7kg/
cm2) from the inside to the outside of the
element.
Never attempt to heat the element.
Using warm water (about 40C) instead
of soapy water may also be effective.
If small holes or thinner parts are found
on element when it is checked with an
electric bulb after cleaning and drying,
replace the element.

Remove electrical intake air heater from

the engine intake connection, and check
it for possible open-circuits and dirt.
When inspecting and replacing electrical
intake air heater, replace the gasket with
new one.
Ask your BEML distributor to check
electrical intake air heater.
c. CHANGE COOLANT
Perform twice a year in spring and
autumn (when cleaning antifreeze
solution).
In case antifreeze is not used, change
coolant every 1000 hours.

43

WHEN REQUIRED

d. CHECK AND REFILL TRANSMISSION OIL

(Measurements only with engine running)

Remove oil level plug (1), and check that

the oil level reaches the bottom of the
plug hole. If necessary, add oil through
the hole of plug (2).

f.
Oil level check must be carried out as
follows:
1. Park the equipment in level ground &
shift Gear shift lever to N, Start the
engine and remove the oil filler (G).
2. Use dipstick (G) to check the oil level.
3. In the cold start phase, the engine must
be running about 2~3 minutes at idling
speed, and the marking on the oil
dipstick must, then be lying above the
cold start mark, COLD.
4. Check
at
operating
temperature
transmission (about 80 ~ 90 C). on the
oil dipstick, the oil level must be lying in
zone HOT.
If the Oil level is dropped in operating
temperature condition below the
HOT zone, it is absolutely necessary
to replenish the oil.
An oil level above the HOT
marking,is leading to a too high oil
temperature. .
When checking the oil level, apply
the parking brake.

The type of lubricant used depends

on the ambient temperature. Select
according to the table FUEL,
COOLANT AND LUBRICANTS.
LUBRICATING
Apply grease to the grease fittings by
arrows.
1. Accelerator pedal linkage (1 point)

g. CLEAN RADIATOR FINS

1. Loosen bolt (1) and remove Radiator
grille (2).
2. Clean the Radiator fins and Oil
Cooler fins clogged with mud, dust
and leaves with compressed air.
Steam or water may be used instead
of compresses air.

e. CHECK AND REFILL AXLE OIL

The rubber hose should be

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

44

WHEN REQUIRED

h. WATER SEPARATOR

When the Float (3) If it is at the above

Red line (2) (Allowable water level) drain
the water according to the following
procedure:
1. Loosen either of the air bleeding (!)
plug.
2. Loosen the drain plug (4) and drain
the accumulated water until the Float
(3) (Floats on water to indicate the
water level) reaches the bottom.
3. Tighten the Drain plug (4) and Air
bleeding plug (1)

45

TROUBLE SHOOTING GUIDE

TROUBLE SHOOTING GUIDE

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

ELECTRICAL SYSTEM

ENGINE

The Ammeter is not stable while the

engine is running at a constant speed.

The engine oil pressure caution lamp

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

Lamp does not glow brightly even when

engine runs at high speed.
Lamp flickers while engine runs.
Check for loose terminals and charging
circuit wiring.
Adjust belt tension if necessary

Steam is emitted from the top part of the

radiator (the pressure valve).
The engine cooling water temperature
gauge indicates red range.
Supply the cooling water and check
leakage.
Adjust fan belt tension.
Wash out inside of cooling system.
Replace the thermostat.
Tighten the radiator cap firmly or replace
the gasket of it.
Replace the gauge.

The Ammeter does not move even when

engine speed rises.
Replace the ammeter.
Replace the alternator
Check and repair wiring.
Starting motor turns the engine
sluggishly.
Charge the battery.
Replace the starting motor.
Starting motor disengages before the
engine starts up.
Check and repair wiring.
Charge the battery.

The engine cooling water temperature

gauge indicates red range.
Replace the thermostat.
Check or replace fan belt.
Replace the gauge.

Starting motor does not turn when

starting switch is turned on.
Inspect and repair the wiring.
Charge the battery.
Replace the starting switch.
Replace the battery relay switch.
Put directional lever in neutral position.

The engine does not start when the

starting motor is turned over.
Add fuel.
Repair air leaking into fuel system.
Replace the injection pump or the
nozzle.
Check valve clearance.
Check engine compression pressure.
Refer to the section of electrical system.

The heater signal glow white.

Check preheating time.
Replace electrical intake air heater.

The exhaust gas is white or blue.

Add to specified oil quantity.
Repair with specified fuel.

The engine oil pressure caution lamp

does not light up when engine is
stationary when the starting switch is in
ON position).
Replace the pressure switch.
Replace the caution lamp switch.

The exhaust gas occasionally turns

black.
Clean or replace the air cleaner element.
Replace the nozzle.
Check engine compression pressure.

46

TROUBLE SHOOTING GUIDE

Combustion noise occasionally changes

to breathing sound.
Replace the nozzle.

Brake drags or stays applied.

Check the multi disc brake. Wear and
replace if necessary.
Clean air vent of master cylinder.

Unusual combustion noise or mechanical

noise.
Replace with specified fuel.
Check over-heating
Replace with muffler.
Adjust valve clearance.

Brake slips.
Replace disc.

Parking brake.

CHASSIS

Brake does not work properly.

Adjust clearance.
Check brake pad.

Transmission

Steering

Engine is running but machine will not

move.
Release parking brake.
Put directional lever in position properly.
Add oil to transmission case to the
specified level.

Steering wheel is heavy.

Check steering hydraulic system.
Check for steering cylinder pins for
proper lubrication.

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

Even at full throttle, machine moves

slowly and lacks power.
Add oil to transmission case to the
specified level.

Many bubbles from the oil.

Oil overheats
Add oil to transmission case to the
specified level or drain oil.
Use a suitable gear speed.
Reduce time using torque converter at
stall speed.
Check engine.

Replace with specified oil.

Add oil.
Bleed air from hydraulic system.

Oil pressure is too low.

Abnormal noise is produced.

Add oil to transmission case to the
specified level.

Add oil and bleed air. Check the pump

pressure.

Cylinder vibrates when operating.

Axle
Abnormal noise is produced.
Add oil to axle case to the specified level.

Multi disc brake.

Brake does not work when pedal is
depressed.
Check the multi disc brake. Wear and
replace if necessary.
Add brake oil.
Bleed air from brake system.

47

Add oil.
Check the play in hing pins & cylinder
pins.

STORAGE

STORAGE
BEFORE STORAGE

AFTER STORAGE

To place the machine in storage for an

extended period of time, the following
measures must be taken to insure that it can
be returned to operation with minimum of
service.

After storage (when it is kept without cover

or the rust-preventive operation once a
month is not made), you shall apply the
following treatment before operation.

After every part is washed and dried, the

machine shall be housed in a dry
building. Never leave it outdoors.
In case it is Indispensable to leave it
outdoors, lay wood plates on the ground,
and park the machine on the wood plates
and cover it with canvas etc.

Completely fill fuel tank, lubricate and

change oil before storage.

Apply a thin coat of grease to metal

surface (hydraulic piston rods

As to batteries, remove the terminals and

cover them, or remove them from the
machine and store separately.

When the ambient temperature is

anticipated to drop below 0oC, always
add antifreeze in the cooling water.

Set each control levers to neutral or hold

position, lock them and apply the parking
brake.

Operate the engine and move the

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

Before operating the working equipment,

wipe off the grease on the hydraulic
cylinder piston rod.

Wipe off the grease on the hydraulic

cylinder rod.

When using the machine without carrying

out the monthly rust prevention
operation, please contact your BEML
office

After the engine is started, operate it until

it is warmed up completely.

Engine with turbocharger only

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

DURING STORAGE

If it is unavoidably necessary to carry

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

48

SERVICE METER / SERIAL NUMBER PLATE

SERVICE METER

EQUIPMENT AND ENGINE

SERIAL NUMBER

Service meter indicates the integrated work

hours. So, use it according to the following
instructions.

When calling for service of mechanic or when

making replacement parts order, be sure to
give your nearest BEML office the equipment
and engine serial numbers as well as the
service meter reading before mentioned.
These numbers are found on the plates
shown in the photos below.

Record the readings at the start and the

end of work, this is the work record of the
machine.

This record will indicate, when periodical

maintenance is due.

It also indicates the integrated working

hours when machine problems are
encountered.

The engine serial number is impressed on the

left side of the cylinder block of the engine.

How the meter progresses

This meter shows the total operation
hours of the machine.
The service meter progresses by 1 when
the engine is operated for one hour,
regardless of the engine speed.
Consequently, if the engine is running
the service meter will advance even of
the machine does not move.

Location of the engine serial number plate

The machine serial number is on the right
side of the front chassis.

While engine is running, green pilot lamp

on the service meter flashes to show the
service meter advances.
Location of the machine serial number plate

49

FUEL, COOLANT AND LUBRICANTS

FUEL, COOLANT AND LUBRICANTS

P R O P E R S E L E C T I O N O F F U E L , C O O L AN T A N D L U B R I C AN T
RESERVOIR

KIND OF
FLUID

AMBIENT TEMPERATURE
32
50
68
86F
0
10
20
30C

14
-10

CAPACITY (Litre)
Specified
Refill
amount
capacity

CF-4/SG 00000000000000000000000000SAE 15W 40000000000000000000000

Engine Oil

Transmission
Axle (Front & Rear)

CF-4

24

27

0000000000000000000SAE 30000000-00000000000

API-CD

0000000000000000000000SAE 15W-400000000000000000000000000

APL-GL5 00000000000000000000000000LLS 80W 9000000000000000000000000 45(each)

45(each)
-

Hydraulic system

API-CD

00000000000000000000000000SAE 10W0000000000000000000000000

195

Brake Oil

API-CD

00000000000000000 000 S A E 1 0 W 0000000000000000000

2.8

Pins (Stg. Lift&Dump

Cyl. Tyre hand
linkages, intermediate
drive U-joint etc.

NLGI-2

000000000

Fuel Tank

HSD

Cooling System

Water

0 0 M O L Y B D E N U M D I S U L P H I D E 000000000000

0000
000000 00000 00ASTM D975 No.2000000000000000
Add antifreeze

185

45

ASTM D975 No. 1

NOTE:
1. When fuel sulphur content is less than
0.5%, change oil in the oil pan every
periodic maintenance hours described in
this manual.

2. When starting the engine in the an

atmospheric temperature of lower than
C, be sure to use engine oil of SAE10W,
SAE10W-30 and SAE15W-40, even though
an atmospheric temperature goes up to 10
C more or less in the day time.

Change oil according to the following table

if fuel sulphur content is above 0.5%.

Fuel sulphur
content

Change interval of oil in

engine oil pan

0.5 to 1.0 %

of regular interval

Above 1.0 %

of regular interval

3. Use API classification CD as engine oil and

if API classification CC, reduce the engine
oil change interval to half.
ASTM : American Society of Testing and
Material
SAE : Society of Automotive Engineers
Specified capacity :
Total amount of
oil including oil for components and oil in
piping.
Refill capacity : Amount of oil needed to
refill system during normal inspection
and maintenance

50

POWER TRAIN

POWER TRAIN

PARKING BRAKE CONTROL

51

DUAL AIR BRAKE SYSTEM SCHEMATIC

DUAL AIR BRAKE SYSTEM SCHEMATIC

52

HYDRAULIC CIRCUIT

HYDRAULIC CIRCUIT

53

ELECTRICAL WIRING DIAGRAM

ELECTRICAL WIRING DIAGRAM

54

TRANSMISSION OIL CIRCUIT DIAGRAM 4WG-190

TRANSMISSION OIL CIRCUIT DIAGRAM 4WG-190

FORWARD 1ST SPEED

55

TRANSMISSION OIL CIRCUIT DIAGRAM 4WG-190

TRANSMISSION OIL CIRCUIT DIAGRAM 4WG-190

MAIN OIL CIRCUIT

56

EQUIPMENT COMPONENTS

EQUIPMENT COMPONENTS
1. Air Chamber

7.

2.

8. Air filter

14. Battery relay

3. Relay valve

9. Automatic drain valve

15. backup alarm

4. Air tank

10. Condenser & Auto drain valve

16. Engine stop solenoid

5. Pressure reducer valve

11. Horn

17. Flasher unit

6.

Master cylinder with Air cylinder

Quadruple system protection valve

Unloader valve with tyre inflator

13. Flow amplifier

12. Steering unit

18. Transmission controller

57

EQUIPMENT COMPONENTS

19. Speedometer (Optional)

22. Parking brake adjusting screw

20. Transmission Cooler

23. Fire extinguisher

21. Axle brake bleeder

24. Parking brake control

58

25. Battery