REN785O& M112009- 02

OPERATION & MAINTENANCE

MANUAL

BH85 - 1 REAR DUMPER

APPLICABLE SERIAL NO. 8454 & UP

BHARAT EARTH MOVERS LIMITED

INDIA
 CONTENTS

OPERATION

SAFETY HINTS ................................................................................................................ 1

GENERAL LOCATIONS AND SPECIFICATIONS ........................................................... 5
INSTRUMENT AND CONTROLS .................................................................................... 5
CHECK BEFORE STARTING ......................................................................................... 14
OPERATION YOUR MACHINE ....................................................................................... 18
HANDLING THE TIRES .................................................................................................. 26
TOWING ......................................................................................................................... 28
EMERGENCY STEERING ............................................................................................. 29
RELEARSE OF PARKING BRAKE ................................................................................ 29
EMERGENCY BRAKE ................................................................................................... 29
DUMP BODY OPERATION ........................................................................................... 30
HANDLING OF BATTERY ............................................................................................. 30

MAINTENANCE

PERIODIC MAINTENANCE .......................................................................................... 32

PRECAUTIONS FOR MAINTENANCE ......................................................................... 32
PARTS OF THE SAFETY DEVICES ............................................................................ 34
MAINTENANCE TABLE ................................................................................................ 35
EVERY 50 HOURS SERVICE ....................................................................................... 37
EVERY 250 HOURS SERVICE ..................................................................................... 38
EVERY 300 HOURS SERVICE ..................................................................................... 41
EVERY 500 HOURS SERVICE ..................................................................................... 41
EVERY 1000 HOURS SERVICE.................................................................................... 42
EVERY 4000 HOURS SERVICE .................................................................................... 45
WHEN REQUIRED ......................................................................................................... 46
ADJUSTMENT ................................................................................................................ 48
TROUBLE SHOOTING GUIDE ...................................................................................... 50
STORAGE ...................................................................................................................... 53
MACHINE AND ENGINE SERIAL NUMBERS ............................................................... 53
FUEL, COOLANT AND LUBRICANTS ........................................................................... 55

com/3.D/Beml 85
 SAFETY HINTS . . .
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 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. Take 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.
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.
When selecting a place for storing them, take care
to choose a place away from where fire is used.
Exhaust gas is dangerous. When running the
engine for long periods in a poorly ventilated area,
there is a danger of gas poisonings, so open the
windows or doors to ensure a good supply of fresh
air.
1
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.
BEFORE STARTING
OPERATION
Examine the lay of the land and the kind of 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 operators 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 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 operators
compartment. Keep everything in its proper place,
to avoid any hindrance while driving.
 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. Do not smoke or use naked flames when
checking. Extinguish cirettes before checking or
refilling.Check that the radiator cap and all oil
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.
ARRANGEMENT BEFORE STARTING OPERATIONS
PLANNING 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 to allow trucks
to pass each other easily.
Where it is impossible to make the road wide
enough, lay-bys should be constructed at frequent
intervals.
Roads must always be constructed to allow loaded
trucks to ass on the inside (away from the edge).
Place convex mirrors at blind curves or places
with poor 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.
MAKE THE HAUL ROAD LEVEL
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. Especially after heavy
rain, remember that conditions may have changed
from those before the rain.
Fill in holes, remove humps, and correct any
tilting of the road to side. Strengthen the road and
correct sagging shoulders. Remove rocks, trees
or other obstacles.
2
The best method is to use bulldozes or motor
graders occasionally to maintain the haul road
surface.
Dust can reduce visibility, so it is important to use
a sprinkler periodically to keep the dust down.
MAKE THE HAUL ROAD AS STRAIGHT
AS POSSIBLE
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 particularly
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,
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.
CROSSROADS OR SLOPING ROADS ARE
DANGEROUS
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 dangerous.
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.
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.
 When driving, sit in the operators seat correctly
so that the truck can be operated properly.
During while standing in the operators seat, or
driving while standing are dangerous.
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
* Snaking
* Coasting
LOADING
As far as possible sudden stopping or sudden
starting should be avoided except in emergencies.
Be careful to avoid repeated 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 of the lining).
This can be the cause of unexpected accidents,
so do not use the brakes in this way.
Where visibility is bad, such as at corners, or when
entering or leaving a narrow road, slow down and
sound the horn.
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 &
3
maintenance Manual for instructions on how to
use the retarder. Then, descend the hill using the
engine and retarder to brake the machine.
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 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.
Be sure to load the dump truck 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 becomes
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 loosened
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 the machine with a suitable towrope
or cable. When towing on roads, always follow
 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 leaders instructions.
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,
stop work and wait for the visibility to improve.
This table shows the relation between visibility
speed.
Forward visibility Traveling speed (max)
20m. 15 km/h
40m. 30 km/h
60m. 40 km/h
Safe speed (km/h)=
Forward visibility (m)x 0.7
Use, a sprinkler when necessary to keep the dust
down and maintain good visibility.
Always use lights when driving at night or in
tunnels, etc. always dip your light when meeting
an oncoming vehicle.
At night it is very easy to make mistakes in
estimating the distance and height of objects and
land.
When driving in fog, mist or smoke, where visibility
is poor, drive safely, following the precautions and
instructions given in traffic regulations.
4
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.
AFTER OPERATION
Stopping the machine
Apply the brake lock.
Return the gearshift lever to NEUTRAL.
Never fail to lower the dump body.
Stopping the Engine
Run the engine at low idling to cool the engine
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.
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 the machine has to be parked on a slope,
chokes must always be placed under the wheels.
 GENERAL LOCATIONS AND SPECIFICATIONS
WEIGHT
1. Under mirror 5. Hydraulic tank
Gross weight (empty truck weight + maximum
2. Operators cab 6. Front Wheel
3. Dump body 7. Head lamp pay-load) 1,41,000 kg

4. Rear wheel Empty truck weight: 56.000 kg

1 2 3 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 AND CONTROLS

3 4
6 5 1. Accelerator pedal
2. Brake pedal
3. Turn signal / dimmer switch
4. Steering wheel
5. Horn button
6. Retarder control lever
7. Gear shift lever
7

2 1

5
1. AIR PRESSURE GAUGE 26. DUMP BRAKE LEVER
2. AMMETER 30. CUMMINS CLUSTER GAUGE
3. SPEEDOMETR 30a. TACHO METER
4. T/C OIL TEMP GAUGE 30b. CAN CONVERTOR
5. BRAKE OIL TEMP GAUGE 30c. GAUGE TEMP.
6. VOLTMETER 30d. LIGHT 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
14. DIAGNOSTIC DATA LINK CONNECTOR(ENGINE)
15. RS 232 DATA LINK CONNECTOR FOR UEC/PAYLOAD UNIT
16. SWITCH MOUNT PLATE
17. WARNING CLUSTER-1
18. GAUGE PANEL LH
19. GAUGE PANEL
20. SPEEDOMETER CABLE
21. UEC DISPLAY SYSTEM
22. FIRE SUPPRESSION CONTROLL
23. FRONT BRAKE CUT OFF
24. EMERG. STG. SWITCH
25. CAP

6

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.
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
into the red range during operation of the engine,
the machine (with the engine held running) hold
the engine to revolve at 2000 rpm with the gear
shift lever in neutral until the pointer goes back to
the green range and the retarder oil temperature
indicator lamp goes out.
ENGINE WATER TEMPERATURE GAUGE
Water temperature is normal if pointer stays in
the green range during running of the engine.
After starting the engine, warm up the engine
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.
If the green range is not reached, the central
warning lamp will light red and a buzzer will
7
sound. When this happens, stop the machine and
keep the engine speed raised until the pointer
enters the green range.
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.
Dont 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 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.
AMMETER
Deflection of the pointer in green range indicates
battery charging.
Deflection of the pointer in red range indicates
battery discharging.
The battery charging circuit is normal, if the pointer
shows the green range during engine operation.
SERVICE METER
Indicates the total machine operation hours. When
the engine is running, a current flows to advance
the meter reading even if the machine is not
moving.
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.
When the engine is running, the meter indicator
turns to show that the meter is operating.
SPEEDOMETER
 The speedometer indicates the machine running downhill
speed in kilometer per hour. An odometer is built in
(The retarder should not be used as a
the speedometer.
parking brake. (When leaving machine,
MACHINE WARNING DEVICE apply parking brake lever and dont use
the retander control lever).
Central warning lamp (Red)
5. Hydraulic oil level
In case, the following abnormality occurs, this
warning lamp and pilot light, also warning buzzer 6. Body up
sounds.
7. Right turn
Then, immediately stop the machine and check
8. Parking Brake: Lamp lights up when the parking
causes.
brake is applied by operation of the parking brake
1. Oil filter element for steering or hoist is clogged. valve lever.

2. Rear brake oil temperature exceeds the allowable

limit.

3. Torque converter is overheating.

4. Engine oil pressure is less than specified value

(1.0 0.2 kg/cm2).

5. Engine is overheating.

6. Cooling water capacity is less than specified level.

7. Air pressure is less than the specified value

(5.2 0.5 kg/cm 2).

8. Gear shift lever is placed in any speed range other

than the NEUTRAL position, during parking brake
valve is applied.

9. Attempting to start off a machine with the parking

brake left on.

Warning Cluster

1. Left Turn: Lamp flashes when the turn signal is

operated.

2. High beam: Lamp comes on when the headlamp

is on high beam.

3. Float: Lamp comes on when the dump control

LOWER button is pressed, and the dump body
will automatically float.

4. Retarder brake: Lamp lights up when the retarder

brake is on.

For the details, refer to section Driving on a

8
STARTING SWITCH For the releasing method of the emergency braking
force, refer to section RELEASE OF PARKING BRAKE.

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, 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.

If the brake air pressure drops to 5.2 kg/cm2 or

less, the parking brake is automatically applied as an
emergency brake.

9
 HAND RETARDER LEVER EMERGENCY BRAKE LEVER
F R O N T- B R A K E
CUT-OFF LEVER

DUMP-BRAKE LEVER

FRONT BRAKE 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 BRAKE 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 only.

Cautions For Handling

Do not run the machine if the pressure 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

10

TURN SIGNAL SWITCH
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, the signal pilot lamp on the instrument
panel starts to blink.
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
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 CONTROL LEVER
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
forward.
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 until the gauge indicator
returns to the green renge.
GEAR SHIFT LEVER
This lever shifts the transmission according to
traveling conditions.
POSITIONED:

For ordinary traveling, the torque converter will If the gear shift lever is placed at a position other
automatically adjust the traveling speed, shifting gears than N with the parking brake or emergency brake
from second to seventh as necessary. locked, the central warning lamp lights up and the
alarm buzzer sounds.
The maximum traveling speed is 65 kg/ h
(62km/h) at this setting. Placing the gear shift lever at a position other than
N with the dump lever at a position other than float
( ) : with large size tire.
lights up the central warning lamp and sounds the
alarm buzzer.
Positions 5-2 Never move back the gear shift lever to N while
traveling.
These positions are used when road conditions
are not suitable for high-speed traveling, when traveling,
DUMP BUTTON
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.

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 position is as shown in the table below.
Posi Max.
tion Transmission range Speed
(Km/h)

5 1st torque converter 35(33) The dump button is provided to shift the dump body
-5th direct position.
4 1st torque converter 26 (25)
-4th direct Button:
3 1st torque converter 19 (18)
-3rd direct
1. RAISE (RED)

2 1st torque converter 15 (14) 2. HOLD (BLUE)

-2nd direct
( ) : with large size tire
* When using the skip shift (for details, refer to
section OPERATING YOUR MACHINE),
These positions are used to select a speed range to
match the slope.
Position R:
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:
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
The dump body is kept held where it is.
3. LOWER (GREEN)
Before traveling, always make sure that the dump
body operation indication lamp FLOAT is on.
If the RAISE button is pressed once, the dump will
keep on rising.
To stop, press the HOLD button.
If the LOWER button is released, the dump body
will automatically float.
For more details, refer to section DUMP BODY
OPERATION.
When checking the machine with dump
body kept raised, always lock the dump
lever at HOLD position with 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 abnormality 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.

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

The steering wheel is adjustable with an angle abnormal, refer to section Trouble Shooting Guide.
of back and forth and 30 mm up and 20 mm down When normal
to allow operator to select the best posture for
operation. Loosen lever and determine the best LED display
position by moving the wheel then tighten lever. Machine
condition
RED GREEN
DUST LEVEL INDICATORS (RESTRICTION
INDICATOR) OFF ON _

OPERATORS 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 Set operators seat as follows for maximum
original position. comfort.

Backward and forward

Adjustment

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.
Seats up and down Adjustment
Turn Knob (2) Match operators weight to the scale (50
to 100 kg) for optimum seat adjustment.
Reclining adjustment
Move lever (3) upwards, set the seat back in
desired position and release lever.
The max. adjustment is 24 degrees forwards and
backwards each. (12 stages)
SAFETY BELT (how to use it)
Before using seat belt, make sure that no
unusual conditions are observed in the belt
fitting and the belt itself.
1. Sit in the seat and adjust the seat so that the
operators back could come into close contact
with the back rest with the parking brake valve
lever kept on.
2. Make sure that the belt is not kicked at all
and engage the buckle and them mating plate
positively with each other until they give a
clicking sound.
3. How to disengage the buckle and the mating
plat.
1 location and stop the leakage. When leakage
14
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.
1. Shortening the belt
Pull the free end of the buckle body or of the mating
plate.
2. Lengthening the belt.
Pull the belt on the fixed side of the buckle (2) or
on the mating plate holding the belt at right angles
the buckle or the mating plate. 3
2
To avoid accidents do not put on the belt
while the machine is running
Check bolts (3) on attachment hardware or fittings
secured or the chassis for looseness. Retighten
bolts, if necessary.
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 BEFORE STARTING
The check before starting shall never be neglected
as troubles are prevented before hand by the
check.
a. Walk around machine body and check whether
there is any trace of leakage of oil or water. In
pa r t i c u l a r, j o i n t o f h i g h p r e s s u r e h o s e ,
hydraulic, joint of air hose, radiator, and an air
tank should be paid special attention.
In case leakage in found, inspected the leaking
is not stopped, you are begged to request repair
to BEML distributor.
b. 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, turbocharger,
engine, transmission, hub nut, and drive shaft
should be paid a special attontion.
c. Inspect disconnection and short-circuit of (before g. CHECKING OIL LEVEL AND REFILL IN ENGINE
electric wirings, and loosened terminal connections OIL PAN
should be paid special attention.
1. Use dipstick (G) to check the oil level.
d. Check for any exhaust emission or noise.
2. The oil level should be between mark L and H, if
e. CHECK COOLING WATER LEVEL necessary, and oil from oil filler (F).

Park machine in flat ground, remove cap and The type of lubricant used depends on the ambient
confirm that radiator is filled with cooling water up to temperature. Select according to the table FUEL
the prescribed level. if insufficient, refill water. COOLANT AND LUBRICANTS.

Refer to section When Required Before adding oil, be sure to draw the oil level gauge
off the guard to that air in the crankcase can be
When the water temperature is high turn the released.
cap slowly to release the inside pressure
before removing. Donot open when
temperature is high

Each oil level with the engine stopped or idles is

marked respectively on each side of the oil level
gauge.
f. CHECK FUEL LEVEL

Check fuel level with fuel gauge or sight gauge

(G). at the end of a days 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.

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. CHECK TRANSMISSION CASE OIL LEVEL

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

Use sight gauge (G1) when changing oil (before
starting the engine) or after engine has been
stopped for 8 hours or more.
The type of lubricant used depends on the
ambient temperature. Select according to the
table FUEL, COOLANT AND LUBRICANTS
1. DRAIN WATER FROM AIR RESERVOIR
With the engine running, open the drain valvesindicated
with arrows to drain water.
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.

i. CHECK OIL LEVEL IN HYDRAULIC TANK

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 WATER FROM EMERGENCY BRAKE
The type of lubricant used depends on the ambient TANK
temperature. Select according to the table FUEL,
COOLANT AND LUBRICANTS Refer to section EMERGENCY BRAKE.

j. CHECK FRONT BRAKE OIL LEVEL n. CHECK HUB NUTS FOR TIGHTNESS

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.
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.

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
1 7 8
5
12 10 4

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
k. DRAIN WATER AND SEDIMENT FROM FUEL contact surfaces to fit well with each other. Repeat
retightening the hub nuts unit about 50 hours after
Open drain of fuel tank to drain accumulated water and
replacing the wheels.
sediment.
Rear

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

16
o. 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.
24.00-49-48PR (STD):
97 psi
p. CHECK DUST LEVEL INDICATORS
If the air cleaner elements are clogging, the red-
colored pistons of dust level indicators (1) will reach
the service level and lock. Clean the elements even if
they section WHEN REQUIRED for how to clean the
elements. After cleaning, depress buttons (2) to reset
the red pistons.
q. CHECK MACHINE WARNING DEVICE
With the starting switch at the On position
(engine stopped), check the following items.
1. Check for blown lamp bulbs (CHECKS
BEFORE STARTING). Put the lamp test
switch. The pilot lamps (*7) and the oentral
warning lamp will light up, and the buzzer will
sound.
17
When recognizing abnormality in warning
device, functional check should be carried out as
follows:
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.
3. Checking the torque converter oil temperature
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 as the engine starts up, the lamp
goes out and the buzzer ceases.
5. 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.
7. Checking the air pressure detecting 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.
Pushing the lamp test switch causes pilot
 lamps (6 lamp) and the central warning lamp to OPERATING YOUR MACHINE
come 0 and the buzzer to should. (Be sure to make
this check at the daily inspection) BEFORE STARTING THE ENGINE

9. Checking the parking brake warning circuit. If the Carry out an initial inspection. (For details of the
gear shift lever is in any position other than N inspection see CHECK BEFORE STARTING)
and the parking brake valve is BRAKE position,
both a pilot lamp and the central warning lamp
come on and the buzzer sounds.

If the parking brake valve is placed in RELEASE 2

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 BRAKE

If it does not work well, adjust, refer to section

ADJUSTMENT

S. CHECK THE ACTION OF THE REAR BRAKE BY

OPERATING THE RETARDER CONTROL
LEVER.

T. CHECK THE ACTION OF THE PARKING BRAKE

VALVE LEVER.

U. CHECK THAT THE STEERING SYSTEM WORKS

PROPERLY.

V. CHECK THAT THE REAR AND UNDER VIEW

MIRRORS ARE WELL ADJUSTED.

W. CHECK THAT ALL LAMPS WORK PROPERLY. 1. Without your back against the back-rest of the
X. CHECK THE HORN AND TURN SIGNAL LAMPS operators seat, adjust the seat position so that
the brake pedal can be easily depressed.
Y. CHECK THAT THE INSTRUMENTS FUNCTION
PROPERLY IN OPERATION. 2. Parking brake valve lever (1) should be placed in
BRAKE position.
Z. CHECK FOR SEDIMENT AND WATER

3. Gear shift lever (2) should put NEUTRAL position.

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 RE-
QUIRED". 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 THE ENGINE
1. Insert starting switch key (1). Turn it to START,
and engine starts.
2. Release switch key, and it returns 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 halfway. In this manner, it may
by easier to start.
19
CHECKS AFTER STARTING
After engine starts, do not attempt to operate
machine immediately, but be careful to observe
the following.
1. Keep engine running at a low-idling speed until
engine oil pressure gauge pointer enters green
range, indicating the sufficient circulation of
lubrication oil around various engine parts.
2. Keep engine running at medium speed under no
load approx. 5 minutes.
3. Keep engine running until water temperature
gauge pointer the machine 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.
 Do not accelerate rapidly during warm-up run. TO START MACHINE

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 engine has been heated up to the operating

temperature, check the gauge (oil pressure gauge,
water temperature gauge, air pressure gauge and
ammeter):

5. Check exhaust colour, any strange noise or

vibration.

6. Check leakage of lubricating oil, coolant or fuel.

4. TO STOP THE ENGINE

1. Fasten the seat belt.

2. Always make sure that the dump body operation

indicating lamp FLOAT is on.

3. Confirm that the pointer of air pressure gauge (20

is in the green renge.)

Then, put parking brake valve lever in the

RELEASE position.

(parking indicator lamp goes off).

1. Run the engine at low idling speed for about 5 to

10 minutes to allow it to gradually cool down.
4. Push retarder control level to release the retarder
2. Operate toggle switch to off position. brake and make sure retader indicator lamp goes
3. Return staring switch Key to OFF position and off.
remove key. 5. Sound horn and make sure there are no persons
or obstacles around the machine.

6. Shift gear shift lever to a suitable gear position

and depress accelerator pedal , and the machine
will start running.

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.

BE SURE TO APPLY PARKING BRAKE

WHEN LEAVING MACHENE

20
 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 sounds.

MACHINE WITH AUTOMATIC TRANSMISSION

Because of automatic transmission, the gears

will automatically according to the machine speed
when gear shift lever is placed in the 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.

SHIFT DOWN (Decelerating the traveling speed)

As you remove your foot from the accelerator pedal,
the machine begins decelerating and the transmission
automatically shifts down.
Down shift inhibit
SKIP SHIFT
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.

This prevents engine overrun caused by 1. Skip shift operation

mistaken operation of the gear shift lever.
Keep the accelerator pedal depressed down and
move the gear shift lever to a position to match the
slope. (Use the positions in the following table as
a guide).

21
 correct position.
Guide for selection of positions when traveling
2. After traveling uphill with skip shift
uphill loaded.
Return the gear shift lever to the position before it
was set, or to position D. the transmission will
Grade Position then be shifted up.
2-3% 5 3. Skillful use of shift.
3-5% 4 If the brake is operated during skip shift operation,
the transmission will be automatically locked at
5- 3
the speed range which match the actual speed of
Over 6% 2 the machine at the moment.

If the gear shift lever is set to an unsuitable position,

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.
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.

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, carefully watching the rear.

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 2 1

22
 3
1. Release your foot from accelerator pedal (1)
and depress brake pedal (2) to stop the
machine.
2. After the machine stops completely, move the
gear shift lever (3) to NEUTRAL.
3. When leaving machine, parking brake 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.
DOWNHILL TRAVELLING
2 downhill with the retarder applied depends on the
1 speed exceeding the maximum allowable value
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. Before starting downhill, release accelerator
3
pedal (1) and operate retarded control lever (2) to
slow the machine down to a safe speed for the
downhill slope.
2. Move gear shift lever (3) to a position (5,4,3or 2)
which matches the maximum permissible speed
for the capacity of the retarder brake.
3. When traveling downhill, operate the retarder
control lever to keep the engine revolution at 1550
to 2300 rpm, and travel at a speed which keeps
the retarder oil temperature in the green range.
Do not operate the retarder control lever abruptly,
otherwise there will be a sudden change in the
travel speed with severe jerks.
As far 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
The maximum allowable travel speed when going
downhill travel distance and the hill gradient. (refer
to the brake performance graph.)
If the machine continues traveling downhill at a
indicated in the brake performance graph, it may
damage the retarder brake, resulting in a serious
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 should
be kept operated at a speed of 2000 rpm, with
23
 the gear shift lever put in the NEUTRAL position,
until the pointer returns to the green range.
(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. Completely release the retarder control lever once
and then operate the lever again.
2. If the repeated operation of the retaeder control
level fails to actuate the retarder, return the lever
to RELEASE position and stop the machine be
depressing the brake pedal. Then ask BEML
distributor to make the repair.
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:
1. Pull the retarder control lever fully.
2. Actuate the emergency brake valve lever.
24
3. Apply the parking brake valve lever.
When the operator is in the operator is in the
operators compartment, he should pull the
retarder lever fully to apply the retarder. When
leaving the machine, apply the parking brake.
Immediately place chocks under tires when the
machine stops.
Determine the cause and repair on the spool as
much as possible.
HOW TO USE THE GRAPH
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 the brake performance curve for downhill
distance of 1500 m. (See the graph at left on the
next page).
2. Pilot machines gross weight A in the graph and
draw a line straight down from point A.
3. Find point B where the vertical line intersects the
minus 11% travel resistance line, and draw a
horizontal line from point B.
4. Find point C where the horizontal line intersects
the performance curve. Draw a line straight down
from point C, and find the machine speed scale
line.
5. Through the above process, the following 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 speed 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.
 Brake performance (length of slops : 450 m) Brake performance (length of slops : 600m)
Standard tire (24.00 49) Standard tire (24.00 49)

Gross weight (ks x 1000) Gross weigth (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)

Gross weigth (ks x 1000)

25

Brake performance (length of slops : 1500 m)
Standard tire (24.00 49)
Gross weigth (ks x 1000)
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 dump 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.
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 machine 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
care to prevent the tires from slipping or sticking
in mud.
The load should be dumped in accordance
with the instructions of the signal man.
HOW TO DRIVE MANUALLY IF TROUBLE OCCURS
IN THE ELECTRICAL SYSTEM OF THE
TRANSMISSION CONTROL
a) Even if electrical circuit fail during travel, the
transmission will hold the current speed range
while the engine is running. If you cannot control
the speed with the gear shift 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 have detected before the start of operate
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.
Be sure to firmly screw in hold plug after repair.
To check for troubles in the automatic transmission,
special checkers, etc. are required. Contact your
Beml when necessary to check the automatic
transmission.
HANDLING THE TIRES
Ton km per hour Rating
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 the 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.
 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- per- E = Tire load on the loaded machine
hour rating, troubles will occur frequently.
F = Turnaround distance
In such cases, take the following measures:
G = Turnaround frequencies for one day
1) Ease the working conditions : reduce the ton-km-
per-hour rating of the work. H = Total operation hour for one day

A = BxC
2) Replace the tires with those having a higher ton-
km-per-hour rating. B = D+E
2
CALCULATION METHODS OF ACTUAL T.K.M.P.H.
VALUE :
C = FxG
A = Actual T.km.P.H.
H
B = Average load per tire
The total operation hour for one day includes the
C = Average traveling speed per day operators break time and the time and the time during
which the machine is not in operation.

Ton-km-per-hour fire rating and maximum continuous traveling speed.

Tire ton-km-per-hour
rating with ambient Maximum continuous traveling speed
Tire temperature (km/h) with ambient temperature
0 0 0 0 0 0 0 0
16 C 27 C 38 C 49 C 16 C 27 C 38 C 49 C
Without load
Standard (front-wheel 37 35 32 30
Size : 24.00-49-42PR basis)
495 465 430 400
Structure : GP With load
Cord No. (TRA) :E3 (rear-wheel 22 21 19 181
basis)
Without load
If equipped (front-wheel 33 31 28 26
Size : 24.00-49-48PR basis)
445 416 387 358
Structure : GP With load
Cord No. (TRA) :E3 (rear-wheel 19 18 17 16
basis)

If equipped Without load

Size : 27.00-49-42PR (front-wheel 44 42 39 36
605 565 525 485 basis)
Structure : GP With load
Cord No. (TRA) :E3 (rear-wheel 27 25 23 22
basis)
Without load
If equipped (front-wheel 36 34 32 29
Size : 27.00-49-48PR basis)
495 463 431 399
Structure : GP With load
Cord No. (TRA) :E4 (rear-wheel 22 20 18 18
basis)
The values ton- km-per-hour rating given above vary somewhat with tire makers.
If you must
travel near the maximum speeds given, consult your
Kom\atsu distributor.
3) Tires whose carcass damaged more than 1/3 the
Defective tires as shown 1) to 6) below tire width.
should be replaced with new tires for safe
operations. 4) Tires with ply separation.
1) Tires with cuts, broken, or excessively deformed 5) Tires with radial cracks which reach the carcass.
bead wire.
6) Aged, deformed or abnormally damaged tires.
2) Excessively worn tires in which the carcass ply
(Excluding breaker) is exposed along the
circumference. 27
INSTRUCTIONS WHEN TRAVELING OVER A LONG
DISTANCE
When the machine travels continuously over a long
distance at high speed, the tires produce extreme heat,
this may cause the tires to be worn. To prevent this, the
following instructions should be observed :
Without load or with the minimum load.
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 reduced
during operation
The machine should be operated in either one of
the following two traveling conditions :
1) Continuous travel can be performed at shown to
previous page.
2) When the maximum traveling speed is 40 km/h,
and the machine should be stopped for at least
one hour after every 60 km at 38%C.
The machine should not be operated with the tires
filled with water or dry ballast.
TOWING
If towing is the sole means to convey a machine,
it must be made, giving full attention to the following.
1) When the engine is in operation :
Be sure to keep the engine running and be ready
for steering and braking. (Take full care that the
brake never work in the case of the defective air
circuit).
2) When the engine is out of operation :
Never haul the machine over 800 in. if the towing
28
distance surpasses that limit, be sure to remove the
drive shaft between the transmission and the differential
case.
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 air pressure in air reservoir abnormally drops
due to leakage from air circuit, parking brake and
emergency brake operate. When towing machine,
release both brakes.
EMERGENCY STEERING
The emergency steering system is operated by
electricity. It is used when the engine stops when
traveling, or there is an abnormality in the steering pump.
The emergency steering system becomes
operable when the emergency steering switch makes
steering possible.
Placing the switch in ON starts the electric pump with
the current from the battery, and thereby makes steering
possible.
Cautions for operation
1) Do not use continuously for more than 3 minutes.
(It is not designed for continuous operation)
2) The travel speed shall be 5 km/h or less.
3) Turn off the switch immediately after stopping 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 emergency steering continuously
for more than 3 minutes

RELEASE OF PARKING 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. Remove air change socket (1) from the front
reservoir.
2. Install air charge socket (1) in position after
removing the air hose connected to parking brake
chamber (2).
3. Connect one end of wheel air Charge hose (3) to
air Charge socket (1). (The hose can be connected
to the socket in one touch).
4. Press other hose (3) end to wheels valve (4) and
the brake will be released as air is supplied to the
brake chamber.
5. When the parking brake is released, remove 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.
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 the tires.
29
EMERGENCY BRAKE
Function of Emergency brake
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 drops 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.
Handling Cautions
Be careful not to start the machine traveling when
air pressure in the main reservoir drops 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
Rear
After preparing for towing the machine, open drain
valves of rear emergency brake to bleed air pressure.
Stop machine completely and bleed air
from emergency system.
When releasing the emergency brake on slope, To prevent impact load to the hydraulic circuit and
put chocks against the tires. hoist cylinders when tilting the dump body, reduce
the engine revolutions as the body is about to reach
Check before starting its maximum incline.
Start engine and drain water from emergency air To inspect the dump body in the raised
reservoir and main air reservoir. position, be sure to use the safety wire and
During cold weather, Drain water after the days depress the HOLD button.
work has ended to prevent freezing. When check the machine, be sure to use
the dump control switch button cover (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 the gear shift lever to neutral and the parking

valve lever to BRAKE.

2. The dump body rises when the dump control
switch button RAISE is pressed.
Once the RAISE button is pressed, the dump body
keeps rising even after the button is released.
3. The tilting speed varies proportionally with the
speed of engine revolution.
4. As the dump body reaches a predetermined kick
out position, it returns to HOLD automatically and
the dump body remains stationary there.
During travel, make sure that the
FLOAT lamp (green) is on. TO protect the
hydraulic devices and main frame from
needless load.
Reduce the dumping speed when dumping
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 button, and check the machine.
When checking the machine with dump
body kept raised, always lock the dump
lever at HOLD position with safety lock
and lay the safety air between dump body
and rear axle housing.

5. To stop the rising of the dump body halfway, press

the HOLD button.

6. The dump body goes down when dump control

switch button LOWER is pressed. When the
dump body is lowered to a certain degree (beyond
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 the
above operation.

30
HANDLING OF BATTERY
PRECAUTIONS FOR CHARGING
BATTERY
1. Before charging, disconnecting 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.
0 negative (-) terminal of the engine which is
3. If the electrolyte temperature exceeds 45 C stop
charging for a while.
4. Turn off the charger as soon as the battery is
charged.
Overcharging the battery may cause followings:
1 : Overheating the battery
2 : Decreasing the quantity of electrolyte.
3 : Damaging the electrode plate
5. If the electrolyte gets on your skin or clothes,
immediately wash with plenty of clean water.
6. Do not mix up cables (positive (+) to negative (-)
or negative (-) to positive (+), as it will damage
the alternator.
7. When inspecting or servicing a battery, be sure to
stop the engine and turn the starting switch to
(OFF) position.
8. When performing any service to battery, besides
checking the electrolyte level or measuring the
specific gravity, disconnect cables from the
battery.
REMOVAL AND INSTALLATION OF BATTERY
When removing battery, first disconnect the cable
from the ground (normally, from the negative (-)
terminal). If a tool touches a cable connecting the
positive terminal and the chassis, there is danger
of sparks being emitted.
When installing battery, the ground cable should
be connected to the ground terminal as the last
step.
STARTING ENGINE WITH A BOOSTER CABLE
When starting up the engine with a booster
cable, do as follows:
1. Before connecting the booster cable
1) Size of booster cable and clip should be
suitable for the battery size.
2) Check cable and clips for breaks, corroded
surfaces, etc.
31
3) Make sure cables and clips are firmly secured.
4) Keep the starting switch in OFF position.
5) The battery of the running engine must be the
same capacity as that of engine to be started.
2. Connect the booster cable in the following manner.
1) Connect on clip of booster cable a to the
positive (+) terminal of the engine to be started.
2) Connect the other clip to the positive (+)
terminal to engine which is running.
3) Connect one clip of booster cable B to the
running.
4) Connect the other clip to the body of the
machine to be started.
Make sure the clips are firmly connected to
battery terminals. Then, start the engine.
When connecting the cables, never contact
the positive (+) terminals and negative (-)
terminals.
Make sure that the booster cable
connections are correct. Connect the
booster cable to the body as far as possible
from the battery.
3. Starting the engine
1) Turn the starting switch to START position and
start up the engine.
2) If the engine doesnt start at first, try again after 2
minutes or so.
After the engine has started, the booster cables
should be disconnected in the reverse order in
which they were connected.
1. Disconnecting the booster cables.
1) Disconnect the clip of booster cable B from
the body of the machine which was started.
2) Disconnect the other clip form the negative
(-) terminal of the running engine.
3) Disconnect the clip of booster cable A from
the positive (+) terminal of the running
engine.
4) Disconnect the ether clip from the positive (+)
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 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 mare convenient. Under rough
job site or operating conditions, it is necessary to
somewhat shorten the maintenance intervals stated in
this manual.
PRECAUTIONS FOR
MAINTENANCE
For safety when carrying out
maintenance
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, 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 operators seat
and the other one performing the maintenance.
Both should confirm the operation is safe.
The body should always be lowered before carrying
32
out any maintenance. However, if the nature of the
maintenance requires the dump body to be raised
for inspection or maintenance, always use the
safety pin, and lock the dump lever in the HOLD
position.
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 leaders 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 stop the engine before washing 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.
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.
Never inspect the fan belt or attempt any
maintenance when the engine is running.
Always stop the engine before carrying out
maintenance on this or other moving parts, or near
any moving parts.
When working under the machine, hang a caution
sign in the operators compartment, and if
necessary, also put signs around 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 carrying out maintenance, pay careful
attention to other workers and persons in the
vicinity. Care is particularly needed 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 operators 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 when 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 extremely
dangerous to loosen anything carelessly. In
particular, repair of tires should be left to the tire
manufactures dealer.
GENERAL POINTS TO BE BORNE IN MIND WHEN
CARRYING OUT MAINTENANCE
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.
33
When replacing parts, always use the genuine
BEML parts specified in the part Book.
Always use the grades of grease and oil
recommended by BEML. Choose the viscosity
specified for the ambient temperature.
Always use pure oil or grease, and be 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 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.
If there is air in the hydraulic brake line, the braking
effect will be poor.
If this happens, bleed the air fully from the circuit.
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, since it is somewhat
difficult to determine accurately the progress of change
in quality, wear of fatigue of them, waver will exist in
judgment whether some 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.

No. Unit composed of Interval Remarks

replacement parts
1. Service brake valve parts Every 2000 hours Replace as a
or one year 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. Item Service Page
CHECK BEFORE STARTING EVERY 50 HOUSE SERVICE
a. Oil, water and air Check leakage 14 a. Lubricating 37
b. Nuts and bolts Check and retighten 14 -1 Dump body Lubricate 2 points 37
c. Electric wirings Check and retighten 14 hinge pin

d. Exhaust gas Check colour and 15 -2 Rear suspension Lubricate 4 points 37

noise -3 Front suspension Lubricate 4 points 37
e. Cooling water Check and supply 15 -4 Hoist Cylinder pin Lubricate 4 points 37
f. Fuel Check and supply 15 -5 Differential support Lubricate 8 points 37
g. Engine oil pan Check and supply 15 -6 Steering cylinder Lubricate 13 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 INITIAL 250 HOURS SERVICE 38
k Fuel tank Drain water and 16 a. Hydraulic tank Change oil 38
sediments b Transmission case Change oil 38
l Air reservoir Drain water 16 c Differential case Change oil 38
m Emergency brake Drain water 16 d Final drive case Change oil 38
tank
e Hydraulic filter Replace element 38
n Hub nuts Check and retighten 16
EVERY 250 HOURS SERVICE
o Tires Check air pressure 17
a. Lubricating 38
and damage
-1 Output shaft Lubricate 2 point 38
q Machine warning Check 17
device -2 Drive shaft Lubricate 5 point 38

r Foot brake Check function 18 b Transmission oil Replace element 38

filter
s Retarder control Check function 18
lever c Belt tension 39

t Parking brake Check function 18 -1 Alternator belt Check tension 39

valve lever -2 Compressor belt Check tension 39
u Steering Check function 18 (if equipped)

v Rear view and Check 18 d Breathers 40

under mirrors -1 Differential case Clean 40
w Lamps Check 18 breather

x Horn and turn Check 18 -2 Hydraulic tank Clean 40

signal lamps breather

y Instrument Check 18 -3 Transmission case Clean 40

breather
z Water separator Check 18
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

* For engine side PM details refer engine maintenance manual

35
No. Item Service Page No. Item Service
Page
EVERY 300 HOURS SERVICE
EVERY 50 HOURS SERVICE
a. Lube Oil Filter Change 41
a. Turbocharger Clean blower 45
b By-pass filter Change impeller
c Crank case oil Change b Turbocharger rotor Check play 45
d Fuel filter and strainer Change c Vibration damper Check 45
EVERY 500 HOURS SERVICE d Emergency relay Clean 45
a Lubricating 41 valve
-1 Fan pully assy Lubricate 1 point 41 e Brake disc Check 45
-2 Tension pully assy Lubricate 2 point 41 f Alternator and Check 45
starting motor
d Rediator fins Check & clean 42
g Engine breather Check and 45
e Front Brake Check liner / disc
pipe replace
d Radiator fins Check and clean 42
EVERY 4000 HOURS SERVICE
EVERY 1000 HOURS SERVICE
a. Water pump Check 45
a. Lubricating 42
b After-cooler Clean element 45
-1 Steering column Lubricate 3 points 42 (if equipped) and deflector
-2 Transmission Lubricate 1 points 42 c Fan pulley and Check 45
mount tension pulley
-3 Parking brake Lubricate 2 points 42 d Air compressor Check 46
linkage
WHEN REQUIRED
b Transmission case Change oil 42
a. Air cleaner Check, clean 46
c Hydraulic tank Change oil 43 element or replace when
required
d Differential case Change oil 43
b Coolant Change twice a 47
e Final drive case Change oil 43
year or every
f Transmission oil Clean 43 1000 hours
strainer
g Hydraulic filter Replace element 44
h Rear brake Check wear 44 d Water separator Drain water 48
i. Turbocharger Check and 44
various fasteners retighten

36
 4. Hoist cylinder (4 points)

EVERY 50 HOURS SERVICE

a. LUBRICATING
Apply grease to the grease fittings show by arrows:
1. Dump body hinge pin (2 points)

2. Rear suspension (4 points)

5. Differential support (8 points)

3. Front suspension (4 points)

6. Steering cylinder pin and linkage (13 points)

37
 d. FINAL DRIVE CASE, CHANGE OIL
e. HYDRAULIC FILTER, REPLACE ELEMENT
For details of method of replacing or maintaining,
see the section on EVERY 1000 HOURS SERVICE

EVERY 250 HOURS SERVICE

a. LUBRICATING
Apply grease to the grease fittings show by arrows:
b. BATTERY ELECTROLYTE 1. Out put shaft (2 point)
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.

Maintenance for every 50 hours should be

At the same time, clean the battery cap breather carried out at the same time.
openings and check the terminal connections.
2. Drive shaft (5 points)
Use a non-metallic funnel to handle distilled water
or electrolyte.

INITIAL 250 HOURS SERVICE

Perform the following maintenance after
running the machine for the first 250 hours.
a. HYDRAULIC TANK, CHANGE OIL
b. TRANSMISSION CASE, CHANGE OIL
c. DIFFERENTIAL CASE, CHANGE OIL
b. TRANSMISSION OIL FILTER

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. Compressor belt for car cooler (if equipped) sagging

of about 10 mm in the middle of the compressor
pulley for cooler (1) and accessory pulley (2) when
After installing the cover, run the engine with air-
depressed with your thumb (at about 6 kg)
bleed bolt (4) kept loose ad tighten it when oil overflows.
indicates the tension is proper.
When the element has been replaced, check the
transmission oil level.
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. BELT TENSION

1. Alternator 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)

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.

Adjustment Replace the belt if it has stretched beyond the

point of adjustment or if it has cuts or fissures.
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
 The type of lubricant used depends on the ambient
d. BREATHERS
temperature. Select according to the table FUEL,
1. Differential cases breather COOLANT AND LUBRICANTS.

Remove the differential case breather and wash

out dirt form the inside with clean diesel fuel.

2. Final drive case

1) Stop the machine so that cast line (1) comes into

2. Hydraulic tank breather horizontal.

Remove snap ring (1) of the breather and cover (2) 2) Remove plug (G) and check for the oil level. If the
and clean element (3). 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.

1
3. Transmission case breather

Remove the breather and wash out dirt from the

inside with clean diesel fuel. f. DRIVE SHAFT

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 THE OIL LEVEL

1. Differential case

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

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

If the parking brake fails to work properly, adjust it Take care not to stain the brake pad and
in the following manner. the disc surface with oil or grease.

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. Confirm that the indication of the air pressure
gauge is in the green range and then release the a. LUBRICATING
parking brake.

2. Turn bolt (1) clockwise and lot pads (2) on both

sides come to lose contact with disc (3).

3. Back off bolt (1) a half turn counterclockwise.

Apply grease to the grease fittings shown by

arrows.

1. Fan pulley assy

2. Tension pulley assy

When adjusting the parking brake, 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 automatically while adjusting 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. RADIATOR FINS
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. If they
have cracks or become fragile, replace with a new
one. In addition, check hose clamp for loosening
2
Air pressure should be less than 10kg / cm
2
and steam pressure is less than 4 kg/ cm
3. Parking brake linkage (2 points)
Never touch the nozzle of the air or steam to the
radiator fins
When washing the radiator, always direct air or
0
steam at 90 C to the radiator.

b TRANSMISSION CASE
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.
Refill capacity: 110 litres
The type of lubricant used depend on the ambient
EVERY 1000 HOURS SERVICE temperature. Select according to the FUEL,
Maintenance for every 50, 250 and 500 hours COOLANT AND LUBRICANTS.
should be carried out at the same time.
a. LUBRICATING
Apply grease to the grease fittings shown by
arrows:

1. Steering columns (3 points)

Loosen Bolts, remove cover and apply grease.

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.

42
c. HYDRAULIC TANK Change oil every 1000 hours or 1000 km which
ever comes earlier.
Lower the dump body, stop the engine and wait for
lowering of oil temperature. Remove drain plug (1) e. FINAL DRIVE CASE
and loosen plug (2) to drain the oil. Then, refill the
rank with engine oil through oil filler (F) 1. Stop the machine so that case line (1) becomes
horizontal.
Refill capacity : 490 litres.
The type of lubricant used depends on the ambient 2. Remove drain plug to drain the oil.
temperature. Select according to the table FUEL
3. Refill the case with fresh oil through oil filler (G).
COOLANT AND LUBRICANTS
When removing the cap, turn it slowly to Refill Capacity: 90 litres (Each side)
relieve inner pressure. The type of lubricant used depends on the ambient
For the method of checking the oil level. Refer to temperature. Select according to the table FUEL,
section CHECK BEFORE STARTING. COOLANT AND LUBRICANTS.
Change oil every 1000 hours or 1000 km
whichever comes earlier.

For the method of checking the oil level, refer to

section EVERY 250 HOUSE SERVICE.

Change oil every 1000 hours or 1000 km

d. DIFFERENTIAL CASE whichever comes earlier.
Remove the drain plug (P), then drain oil through
f. TRANSMISSION OIL STRAINER
the plug hole. Fill the differential case with the specified
oil through the oil filler (F). 1. The strainer should be cleaned when the element
Refill capacity : 100 litres. is replaced after changing oil. Remove bolt (1) at
the lift side of transmission case. Remove cover
The type of lubricant used depends on the ambient (2), then remove the strainer and spring. Upon
temperature. Select according to table FUEL, completion of cleaning the strainer and magnet,
COOLANT AND LUBRICANTS. reinstall them.

Fir the method of checking the oil level, refer to 2. Loosen two bolts (1) for transmission oil strainer
section EVERY 250 HOURS SERVICE. (pilot) take out stainer (2) and clean it.

43
g. HYDRAULIC FILTER
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 the tank cap
slowly to release inner pressure.
* Use a genuine Beml filter element.
2
1 (Refer to section ADJUSTMENT).
* When oil fitter caution lamp lights, replace filter.
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. REAR BRAKE WEAR
Carry out inspection when the engine oil
temperature is below 60%C.
1. Shift parking brake valve lever to BRAKE and
secure foot brake does not work.
2. Remove air bleeding valve of rear brake and insert
disc wear gauge in to the air bleeding valve
44
3. Turn starting switch to ON, check air pressure
gauge pointer indicates in green range. When air
pressure is low, turn the engine as to keep 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 mark (A) shown on the gauge passes
through in the valve case, this means wear of disc
is in the limit of wear.
In such a case, contact Beml for maintenance.
5. The above procedures should be done to the
another rear brake.
After finish the wear check, bleed air out
completely.
i. TURBO CHARGER VARIOUS FASTENERS
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.
If any fault is detected, ask BEML to disassemble
and repair or replace.
Tightening torque torque as follows.
1. Clamp bolt for tubine housing:
0.8 0.1 kgm
2. Clamp bolt for blower housing:
O.55- 1.0 kgm
3. Connecting bolt for turbocharger exhaust manifold
and turbine housing:
10.0 12.5 kgm
4. Mounting bolt for turbocharger oil pipe (inlet):
2.0-3.5 kgm
5. Mounting bolt for turbo charge oil pipe (outlet):
6.0 7.5 kgm
EVERY 2000 HOURS SERVICE c. VIBRATION DAMPER

Maintenance for every 50, 250, 500 and 1000 Check decrease of damper fluid, dent or out of
hours should be carried out at the same time. flat. If there is any abnormality, contact Beml for repair.

a. TURBOCHARGER d. EMERGENCY RELAY VALVE

Excessive carbon or oil sludge adhering to Refer to section EMERGENCY BRAKE.

turbocharger blower impeller may deteriorate normal
Request service to BEML because special tools
performance of turbo charger and may sometimes
are required for removing parts and adjustments.
damage it.
e. BRAKEDISC
Contact BEML.
Ask BEML to check and repair brake disc.
1. Remove the turbocharger oil supply tube and the
drain tube. Then, remove the connection area of f. ALTERNATOR AND STARTING MOTOR
the intake manifold and the blower housing so
that the blower impeller can be seen. As the hours of engine employment indicate that
the brushes are already worn out, you should request
2. Using light oil, wash the impeller to eliminate repair from BEML.
carbon adhered on the surface.
They should be repaired every 1000 hours, if the
a. Do not use wire brushes or the like to prevent machine is frequently operated at night.
damage to the impeller surface.
g. ENGINE BREATHER PIPE
3. Pour light oil through the turbocharger oil filler.
Turn the blower impeller several turns so that 1. Remove breather pipe from cylinder blocks of right
foreign materials such as sludge can be washed and left banks.
away.
2. Check there is no adherence of oil sludge inside
4. Using your fingers, turn the impeller vigorously of the pipe.
for one revolution or more. If there is no sigh of
interfering with or being caught in somewhere, 3. When oil sludge adheres, replace with new pipe.
the impeller is normal.
EVERY 4000 HOURS SERVICE
If the impeller seems to turn heavily, contact BEML
to ask to repair or replace it. a. WATER PUMP

5. If the impeller is found normal after this check, Maintenance for every 50, 350, 1000 and 2000
supply engine oil to the turbocharger. hours should be carried out at the same time.

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).
Rotor axial play
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.
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.
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
b. AFTER COOLER (if equipped)
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).
c. FAN PULLEY AND TENSION PULLEY
Check the pulley to see if there is any leaking
grease. If any abnormality is found ask Bmle to repair
as replace it.

45
d. CHECK AIR COMPRESSOR 4. Push the dust indicator reset button (2) to return
the red piston to the original position.
Ask BEML to check and repair it.
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.
WHEN REQUIRED
Check inner element mounting nuts for loose ness
a. AIR CLEANER ELEMENT and if, necessary, retighten.

Checking Replacing inner element

Whenever the red piston in dust indicator (1) 1. First remove the outer element, and then remove
appears, clean the air cleaner element. Stop the engine the inner element.
when cleaning the element.
2. Cover the air inlet port.

3. Clean the air cleaner body interior. Remove the

cover from the air inlet port.

4. Fit a new inner element to the connector and

tighten it with nuts.

5. Install the outer element.

NOTE: Do not attempt to reinstall a cleaned inner

element.
Cleaning or replacing outer element
Do not clean or replace the air cleaner
1. Loosen bolt and remove band and remove cover element with the engine running.
and remove the outer element.
Cleaning outer element
2. Clean the air cleaner body interior and the
removed cover. With compressed air

3. Clean and inspect the element: (See 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
With water level surface.
2
Dash city water (less than 3 kg/ cm ) on element from WATER FILLER
inside along folds, then from outside and again from
inside. Dry and check it.

With cleaning agent

For removing oils and fats as well as carbon etc.,

attached on the element, the element may be cleaned
in lukewarm solution of mild detergent, then rinsed in
clean water and left to drip dry.

Drying can be speeded up by blowing dried 5. When the water reaches the vicinity of the water
2
compressed air (less than 7 kg/ cm ) from the filler, put the engine at low idling, open the drain
inside to the outside of the element. valves, then pass water through the cooling system
until clean water comes out from the drain valves
Never attempt to heat the element.
for 10 minutes.
0
Using warm water (about 40 C) instead of soapy
When doing this, adjust the amount of water
water may also be effective.
supplied and drained to keep the radiator full at all
If small holes or thinner parts are found on element time.
when it is checked with an electric bulb after
DRAIN VALVE (RADIATOR)
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.

6. When the water becomes completely clean, stop

the engine and close valves (2) and (3).

7. After draining off the cooling water, wash out the

cooling system using commercially available
detergent. Follow the instructions on the detergent
container.

8. After washing the cooling system, 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.

47
DRAIN VALVE (Cylinder block)

When float is at or above red line, drain the water

according to the following procedures

1. Loosen drain plug and drain the accumulated

water until the float reaches the bottom.

9. When the water reaches the vicinity of the water 2. Tighten drain plug
filter, put the engine at low idling, open the drain
valves, then pass water through the cooling 3. If air is sucked into fuel line when drain the water,
system until clean water comes out from the drain be sure to bleed air in the same manner as for the
valves. fuel filter.

When doing this, adjust the amount of water (See Fuel Filter Cartridge in Every 500 hours Service
supplied and drained to keep the radiator full at section).
all times.
ADJUSTMENT
10. When the water becomes completely clean, stop
the engine and close the all drain valves. FAN BELT

11. Replace the corrosion resister cartridge and open Adjustment

valve (1).
As this machine is provide with a device which
12. Supply water until, it overflows from water filler. keeps a constant fan belt tension without regard to
elongation of the V- belt, no adjustment is required until
13. Run the engine 5 minutes at low idling and hen the belt is broken.
for another 5 minutes at high idling to eliminate
air trapped in the cooling system (leave radiator
cap off during this operation). Check the size a to see that it is maintained within
50 5mm.
14. Stop the engine and wait for about 3 minutes.
Supply cooling water up to the specified level (up If not, adjust the fan belt as follows:
to the lower end of the water supply tube). Tighten
Tighten adjusting bolt (2) until size a becomes 50
the cap.
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 raising the cap lever
to relieve internal pressure.

c. WATER SEPARATOR (if equipped) Replacement

1. Loosen lock nut (1) and completely release the

spring.

2. Press tension pulley (3) in the direction indicated

by the arrow in the figure to remove the V- belt.
Then install a replacement.

Replace three V belts at the same time.

48
 Front

2) Rear brake

Rear

1. Pull the retarder control lever, and loosen air bleed

plug (1) to bleed the air from the circuit. After closing
plug (1), release the retarder control lever.

2. Repeat this procedure until no more bubbles come

out from air bleed plug (1). After bleeding the air,
tighten plug (1) securely.

When bleeding the air from the system, raise the

oil temperature to make the bleeding of air easier.

SUSPENSION CYLINDER

During operation, the following abnormalities may

be noticed the machine bounces greatly, 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, and unload.

Check the cylinder length in the before operation

inspection.

1. Check for cylinder length

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. Rear

2. Check for cylinder oil amount If oil is short, signs of being hit are found on differential
case and stopper.
a. Front

If any abnormality is found by checking contact

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

TROUBLESHOOTING GUIDE

This guide is not intended to cover every conditions, Loose fan belt.
however many of the more common possibilities are
listed. Accumulated dust or fur in the cooling system.

ENGINE Clogged rediator fins or fins out of place.

Oil pressure gauge pointer will not return to red Defective water temperature gauge.
(left side) when the engine is shut down. Defective thermostat or its seal.
Defective oil pressure gauge. Leaky thermostat seal.
Oil pressure gauge pointer fluctuates abnormally. Loose radiator filler cap.
Insufficient oil in pan (when operating at high altitude)
Oil pressure gauge pointer stays within the red Water temperature gauge pointer stays in the red
range (left) on dial. range (left on dial during engine running.

Insufficient oil in oil pan. Defective thermostat.

Oil leakage due to damaged piping, loose piping Defective water temperature gauge.
joints or connections.
Too cooled engine
Defective oil pressure gauge Engine fails to start
Oil leakage from full-flow filter. Insufficient fuel in fuel tank
Stem spurts out the pressure valve on the radiator. Air in fuel line.
Water temperature gauge pointer stays within the
red range (right) on dial, Insufficient torque of starting motor to crank up
engine.
Insufficient coolant or coolant leakage.
No fuel in fuel filler.

50
Engine emits white or blue-white exhaust gas. Starting motor 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 emits black exhaust smoke.
Wiring is defective.
Clooged air cleaner elements
Batteries are discharged.
Engine runs but operates erratically (Hunting)
CHASSIS
Air leakage in fuel supply line.
Torque converter malfunction
Engine creates knocking
* Torque converter oil pressure remains low
Use of improper fuel. 0 0
oil temperature: 70 - 90 C.
Over heat.
oil temperature at torque converter inlet :
2
Fuel sometimes stops flowing. 8.0 1.0 kg/cm
Small hole in fuel tank cap clogged. Oil pressure at toque converter outlet
Breather tube of fuel tank clogged. a) Engine idling slow: 2.5 0.5 kg /cm
2

2
ELECTRICAL CIRCUITS b) Engine at full throttle : 40 1.0 kg / cm
Ammeter deflects widely when engine runs Torque converter overheats.
constantly.
Air or oil leaking from loose joints of oil pipe or
Head lamps are dark when engine speed is at broke pipe.
maximum. Head lamps flicker when engine is
running. Ger pump worn or sticking.

Wiring is defective Lack of transmission oil.

Improper belt tension. Transmission oil filter element is clogged.

Ammeter doesnt deflect when engine is running. Fan belt is loose.

Ammeter is defective Water temperature is high.

Wiring is defective Oil cooler is clogging.

Alternator is noisy. Oil pressure is low.

Alternator is defective. Lack of oil circulation due to worn gear pump.

Starting motor doesnt operate when turning on Long use of automatic drive.
starting switch.
Steering is hard.
Wiring is defective.
Gear pump is defective
Starting switch is defective.
Demand valve is misadjusted.
Batteries are discharged.
Oil pressure valve is defective.
Battery switch is defective.
Internal leakage occurs in steering cylinder.

Brake operates poorly.

Brake shoes improperly adjusted.

51
Brake is unbalance. If any abnormality occurs as listed on the left, stop
the machine, Parking brake valve lever should be
Brake shoe adjustment is improper. placed in BRAKE position, check the LED display
Dumping speed is slow. of the controller, and then contact BEMl for repair.

Dumping time should be 13.0 2.0seconds when Please contact BEML for repair of any
0 0
oil temperature is 70 - 90 C. abnormalities other then those listed on the left.
Response of dump body to operation is slow. If the starting procedure of the engine is wrong the
display will show STARTING SAFETY and the
Gear pump is defective.
engine will not start.
Oil is lacking
(refer to section OPERATING YOUR MACHINE).
Demand valve is defective.
TM / OVERRUN does not mean the failure of the
Suspension is rough. machine. Please try again to start the engine.
Gas is leaking from broken U packing
Gas is leaking from valve core.

TRANSMISSION SHIFT CONTROLLER

LED display
No. Failure mode Contents of failure
Red Green
1. Lighting Lighting MODEL SELECTION Defect of input side harness
SAFETY
2. Flashing alternately STARTING SAFETY Engine starts at other than N
3. Lighting Fast SOLENOID VALVE Defect of solenoid valve and
flashing SAFETY / of output side harness
4. Lighting Slow T/M SOLENOID VALVE Defect of solenoid valve and /
flashing SAFETY or output side harness
5. Lighting Off T/M FAST ROTATION
T/M overrun
SAFETY

6. Fast Off T/M OUTPUT SENSOR Failure of T/M output side

flashing SAFETY sensor system
7. Slow Off SHIFTPOSITION Failure of shift position
flashing SAFETY sensor system
8. Slow Lighting THROTTLE SAFETY Failure of throttle switch
flashing system
9. Fast Lighting T/M INPUT SENSOR Failure of T /M input side
flashing SAFETY sensor system
10. Simultaneous flashing PROGRAM SAFETY Failure of AESC
11. Off Off POWER SOURCE OFF Failure of power circuit
12. Off Lighting NORMAL In operation

T/M: Transmission

52
 STORAGE Remove the rocker housing and fully lubricate the
valves and rocker levers. Also, check the valves
BEFORE STORAGE for correct operation.

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.
After every part is washed and dried, the machine
should be housed in a dried building. Never leave
it out doors.
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.
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.
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).
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.
Loosen the oil pipe flange at the turbocharger 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.
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 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 STORAGE The machine serial number is stamped on the front

Carefully observe the following procedure when part of the left side bumper.
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
Location of the engine serial number.

The engine serial number is stamped on the upper

left side of the cylinder block.

NOTE:

(1) When fuel sulphur content is less than 0.5% 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) When starting the engine in an atmospheric
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.
(3) Use Api classification CD as engine oil and if API
classification CD as engine oil and if API
clasification CC, reduce the engine oil change
interval to half.
Specified capacity : Total amount of oil for components
and oil in piping
Refill capacity : Amount oil needed to refill system
during inspection and maintenance.

54
55