BG825
MOTOR GRADER
OPERATION & MAINTENANCE
MANUAL

BEML LIMITED
INDIA
 
OPERATION & MAINTENANCE
MANUAL

BG825 MOTOR GRADER

EQPT.SL.NO.25044 & UP

BEML LIMITED
INDIA
 
        

  
 
 

BG825 OPERATION & MAINTENANCE

MANUAL

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

The Company reserves the right to make changes or add improvements at any time without incurring
any obligation to install such changes on products sold previously. Because of continuous research
and development, periodic revisions may be made to this publication. Customers should contact their
local BEML Service Manager for information on the latest revision.
 FOREWORD
This Operation & maintenance manual is written for use by the operator and/or the service
technician and is designed to help these persons to become fully knowledgeable of the Motor
Grader and all its systems in order to keep it operating safely and efficiently. All operators and
maintenance personnel should read and understand the materials in this manual before
operating the Motor grader or performing maintenance and/or operational checks on the Motor
grader. All safety notices, warnings and cautions should be understood and followed when
operating or accomplishing repairs on the Motor grader.

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

Please read this manual carefully BEFORE operating the machine.

Please continue studying this manual until proper operation is completely reinforced into
personal habit.

This manual describes the basic techniques. Skill is performed as the operator or anyone
get the correct knowledge and performance of the machine.

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

The safety information contained in this manual is intended only to supplement safety
cords, insurance requirements, local laws, rules and regulations.

Some photographs and illustration pictures are different from your machine as technical
improvement is continuously reflected on it. Revision to up-to-date manual's content is
performed in later editions.

NOTE: The specification contained in this manual is subject to change at any time
without notice. Contact your BEML Representative for the latest Information.
 
 

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

!
“ DANGER ”,“ WARNING ” and “ IMPORTANT ” in this manual
to alert the reader to hazards arising from improper operating
  and maintenance practices.
 

 
Indicates the potential hazard which may result in personal injury or
 
death if proper precautions are not taken.
 

Indicates the potential for equipment damage. This is a general

reminder of proper safety practices.

Indicates a specific potential hazard which will result in either personal

injury or death if proper precautions are not taken.
 BREAKING IN YOUR NEW MACHINE

Each machine is carefully adjusted and tested before shipment. However, a new machine
requires careful operation during the first 100 hours to break in the various parts.

If a machine is subjected to unreasonably hard use at the initial operation stage, the potential of
performance will prematurely deteriorate and the service life will be reduced. A new machine
must be operated with care, particularly with regard to the following items.

 After starting let the engine idle for 5 minutes to allow proper engine warm-up prior to
actual operation.

 Avoid operation with heavy loads or at high speeds.

 Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning should
be avoided.

 With increase in ambient temperature, Change lubricating oil and fuel to that of
recommendation and add ACF ( Anti Corrosion Fluid ) in premixed condition to the
coolant.

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

1 Changing all oil, filter elements and cartridges.

2 Checking and adjustment of engine valve clearance.

For replacement procedure and details, see maintenance table in the maintenance section.

 When replacing oil filter elements (cartridges), check their interiors for dirt and dust. If
heavily collected, check for possible cause before starting operation.

 Hours of operation are indicated by the service meter.

 
 

TABLE OF CONTENTS

Sl.no. Subject Section

1 OPERATIONS A

2 MAINTENANCE B

3 SPECIFICATION C

4 FUEL AND LUBRICANTS D

 
 SECTION - A

OPERATION
 
 
 

Section A
OPERATION
INDEX

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

1. 1. SAFETY HINTS A5
1.1. General A5
1.2. Safety Rules A7
1.3. Safety features A7
1.4. Unauthorized modification A7
1.5. Before starting operation A7
1.6. After starting engine A8
1.7. During operation A9
1.8. Parking A12
2. 2. GENERAL LOCATIONS A13
3. 3. DASH BOARD SYSTEM A14
3.1. Introduction A14
3.2. Power supply A14
3.3. PV750 Murphy display A14
3.4. Transmission controller A18
3.5. Inspection chart for transmission control module (Table-I) A19
3.6. Solenoid combination – Check as per table -II A20
3.7. Trouble shooting A21
3.8. Precautions for welding on machines with electronic
A23
controls
3.9. Steps for improving the reliability of Murphy dash board
A26
System
3.10. Emergency steering system on motor grader A33
3.11. Starting motor trouble Shooting A36
3.12. Alternator wiring test A37
3.13. Batteries A37
3.14. Care of the battery A38
3.15. Battery and charging System A40
3.16. Servicing battery A40
3.17. Recharging batteries A41
3.18. Starter motor A43
4. 4. INSTRUMENTS AND CONTROLS A53
4.1. Work equipment control lever A53
4.2. Steering wheel tilt lever A53
4.3. Steering post tilt pedal A53
4.4. Work equipment control lever safety lock A54
4.5. Fuel control lever A54
4.6. Gear shift lever (& parking brake) A54
4.7. Inching pedal A55
4.8. Brake pedal A55

BG825 A1
 
 
 
Sl. no. Section reference no. and Description Page no.
4.9. Accelerator pedal A56
4.10. Dust indicator A56
4.11. Articulate lock pin A56
4.12. Operator’s seat A57
4.13. MCB A58
5. 5. CHECK BEFORE STARTING A59
5.1. Check and refill coolant A59
5.2. Check and refill fuel tank A59
5.3. Drain water and sediment In fuel tank A60
5.4. Drain water from air tank A60
5.5. Check oil level in engine oil pan A60
5.6. Check electrical wiring A61
5.7. Check dust indicator A61
5.8. Check and adjust tire Pressure A61
5.9. Check and adjust Steering wheel A61
5.10. Is rise in air pressure Normal? A62
5.11. Other check points A62
5.12. Check the windshield Wiper, window washer and
Defroster for normal Function. Check for Sufficient washer A62
fluid Level.
5.13. Check for sediment and Water in the Water Separator A62
6. 6. OPERATING YOUR MACHINE A63
6.1. Before starting the Engine A63
6.2. To start the engine A63
6.2.1 Special starting A64
6.3. Check after starting A64
6.4. To stop the engine A64
6.5. To move the Machine off A65
6.6. Changing gear speed A65
6.7. Forward-reverse shifting A66
6.8. Turning A66
6.9. To stop the machine A67
6.10. Cautions for operating hills A67
6.11. Slopes, steep hills A67
6.12. Precautions when stopping or parking Machine A67
7. 7. COLD WEATHER OPERATION A68
7.1. Preparation for low temperature A68
7.2. Fuel and lubrication A68
7.3. Coolant A68
7.4. Battery A68
7.5. Starting in cold weather A69
7.5.1 To start the engine A69
8. 8. CAUTIONS AFTER COMPLETION OF WORK A70
9. 9. AFTER COLD WEATHER A70
10. 10. WORKS TO BE CARRIED OUT BY A MOTOR GRADER A70
11. 11. JOBS EFFECTUATED WITH ARTICULATED FRONTFRAME A73

BG825 A2
 
 Sl. no. Section reference no. and Description Page no.
12. 12. OPERATING OF WORK EQUIPMENT A73
12.1 Operation method of the work equipment control lever A73
12.2 Cautions in operation of work equipment A74
13. 13. ADJUSTMENT IN SHIFTING OF WORK ATTACHMENT A74
13.1 Blade projection A74
13.2 Propulsion angle of blade A75
13.3 Adjustment of blade cutting angle A75
13.4 Bank-cutting posture (right side) A75
13.5 Shoulder reach posture (right side) A76
13.6 Operation of the blade accumulator A77
13.7 Features of the blade accumulator A77
14. REVERSING AND REPLACEMENT OF CUTTING EDGE
14. A78
AND END BIT
14.1 Turning and replacing A78
14.2 Replacing ripper point A78
15. 15. CHANGING TIRES A79
15.1 How to changes tires A79
16. 16. HOW TO USE LEANING STOPPER A79
17. 17. DRIVING ALONG ROAD A80
17.1 Position of blade when traveling A80
17.2 Way to insert shack when transporting A80
17.3 Articulated operations A80
17.4 Precautions when travelling on road A81
18. 18. HANDLING OF BATTERY A81
18.1 Precautions for charging battery A81
18.2 Removal and installation of battery A82
18.3 Starting engine with a booster cable A82
19. 19. TOWING A83
19.1 Towing the machine A83
19.2 Releasing parking brake A83
20. 20. TRANSPORTATION A84
21. 21. EMERGENCY STEERING SYSTEM A85
21.1 Function A85
21.2 Checks A85

BG825 A3
 
 

NOTES:

BG825 A4
 
 
 
OPERATION

1. SAFETY HINTS:

1.1. GENERAL

Safety records of most organizations will

show that the greatest percentage of
accidents is caused by unsafe acts of the
persons.

The remainders are caused by unsafe

mechanical or physical conditions. Report
all unsafe conditions to the proper
authority.

FIGURE 1-2. OPERATOR’S SAFETY

Take care of your health. Do not drive

Read and follow all safety precautions.
Failure to do so may result in serious
injury or death.
Wear well-fitting helmet, safety shoes and
working clothes. If the nature of the work
requires safety, wear protective goggles or
mask, thick gloves, ear plugs or other
protection as shown in the Figure 1-1.
when tired, or after drinking.
Learn the prohibitions, cautions, and rules
about work procedures in the work site.
When there is a leader, fix standard
signals and always follow these signals
when operating.
If there should be an accident or fire or
any other such unexpected mishap, deal
with it quickly, using the nearest apparatus
as shown in the Figure 1-3.

FIGURE 1-1. SAFETY ACCESSORIES

Trained and authorized personnel should

operate and maintain the machine.

Accidents or injuries are liable to occur FIGURE 1-3. SAFETY APPARATUS

when the operator is careless or slack. It
is most important to bear safe operation in Be sure fire extinguishers have been
mind at all times as shown in Figure 1-2. provided and know how to use them.

When working with another operator or a
person on worksite traffic duty, be sure all
personnel understand all hand signals that
are to be used.
BG825
Provide a first aid kit at the storage point
as shown in the Figure 1-4. Be sure you
know the phone numbers of persons you
should contact in case of an emergency.
A5
 
 

FIGURE 1-4. SAFETY FROM

FIRE HAZARD

Learn before and the locations of the first

aid boxes and fire extinguishers and how
to use them. It is also important to know FIGURE 1-5. FLAME RESTRICTED
the emergency contact system.
Exhaust gas dangerous. When running
Learn about the safety devices on your
the engine for long periods in a poorly
own machine and about how to use them.
ventilated area, there is a danger of gas
Confirm that they are correctly attached in
poisoning, so open the windows or doors
the prescribed position.
to ensure a good supply of fresh air as
shown in the Figure 1-6.
Such safety devices include:

 Guards
 Canopies
 Protective Devices
 Roll-Over Protective Structures
 Seat Belts, etc.

Take care not to get caught by protruding

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

Keep fire away from stored fuel, lubricants FIGURE 1-6. AVIOD FUMES
and anti-freeze.
Read Operation and Maintenance Manual
Thoroughly remove wood chips, leaves, carefully as shown in the Figure 1-7.
paper and other flammable things
accumulated in the engine compartment.
These could cause a fire.

Check fuel, lubrication, and hydraulic

systems for leaks. Have any leaks
repaired. Wipe up any excess oil, fuel or
other flammable fluids.

Be sure a fire extinguisher is present and

working.

Do not operate the machine near any

flame as shown in Figure 1-5.
FIGURE 1-7. READ MANUAL
CAREFULLY
BG825 A6
 

Learn how to use the control devices,
gauges and warning devices. Be sure you
understand the meaning of the Caution
plates. Remember the check points and
checking method for engine oil, fuel,
cooling water and hydraulic oil levels.
When working on a road, pay attention to
the safety of passing vehicles and
pedestrians. If necessary, assign a
signalman or provide temporary
barricades.
Before starting the machine, perform all
necessary checks as stated in the
Operation and Maintenance Manual.
1.2. SAFETY RULES
Trained and authorized personnel should
operate and maintain the machine.
Follow all safety rules, precautions and
instructions when operating or performing
maintenance on the machine.
When working with another operator or a
person on worksite traffic duty, be sure all
personnel understand all hand signals that
are to be used.
Check the Machine - Before you begin
your workday, you should inspect your
machine and ensure that all systems in
good operating condition. Do not operate
the machine until all deficiencies are
corrected.
1.3. SAFETY FEATURES
Be sure all guards and covers are in their
proper position. Have guards and covers
repaired if damaged.
Learn the proper use of safety features and
use it properly.
NEVER remove any safety features.
ALWAYS keep them in good operating
condition.
Improper use of safety features could
result in serious bodily injury or death.
BG825
1.4. UNAUTHORIZED
MODIFICATION
Any modification made to this vehicle
without authorization can possibly create
hazards.
Before making any modification, consult
the authorized BEML service personnel.
1.5. BEFORE STARTING
OPERATION
Examine the lay of the land and the kind
of soil at the work site to determine the
dangerous points and the best method of
operation.
Proceed with the work only after making
safety arrangements about the dangerous
points else it may be threat to operator as
shown in the Figure 1-8.
FIGURE 1-8. ENSURE SAFETY
ARRANGEMENTS
Inspect leakages from the fuel, lubricating
and hydraulic systems. Check that tire
inflation pressure is standard, that hub
nuts are not loose, and that no other parts
are damaged or missing. Machines having
such failures should not be operated.
When getting on or off the machine, use
the handrail and step provided. Do not
jump or down from the machine.
Do not leave parts or tools lying around in
the vicinity of or on the floor of the
operator's compartment. Keep everything
in its proper place. If the tools are
scattered here and there it can be a
problem for the operator while moving as
shown in the Figure 1-9.
A7
 
 
Inspect the inside of the engine room and
remove any dead leaves or paper. Dead
leaves or paper are highly inflammable
and can cause fires as shown in the
Figure 1-11.

Before starting the engine, confirm that all

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

FIGURE 1-9. TOOLS TO BE IN

PROPER LOCATION

Wipe off thoroughly any grease, oil or mud

on the step, handrail, floor or control
levers. Failure to do this may cause you to
slip.

Check the level of the fuel, lubricants and

cooling water. Extinguish cigarettes before FIGURE 1-11. INSPECT THE M/C
checking or replenishing. Check that the
radiator cap and each oil filler caps or 1.6. AFTER STARTING ENGINE
plugs are firmly tightened.
Confirm that all gauges and warning
Adjust the operator's seat until it is in the devices are functioning correctly, and that
most comfortable position for operating. the gauge readings are within the
prescribed range.
If the belt is damaged or worm, replace it
with a new one. Check the play and travel of each lever
and pedal before giving the clearance for
To ensure the safety of the workers near operation as shown in the Figure 1-12.
the machine, always sound the horn to
warn them before starting the engine and
moving the machine. Be particularly
careful to check that the road is clear
before backing the machine as shown in
the Figure 1-10.

FIGURE 1-12. CHECK FOR

CLEARANCE BEFORE OPERATION

Operate the blade to confirm that they are

FIGURE 1-10. HORN BEFORE MOVING functioning normally.
BG825 A8
 

Move the machine slowly and listen
carefully to the engine or gears to confirm
that they are not making any unusual
noises.
Operate the gear shift lever to confirm that
the travel speeds for forward and reverse
are functioning normally. Also carry out a
brake test at each travel speed.
Choosing a safe place, turn the machine
to the left and right to confirm that the
steering devices are functioning normally
as shown in the Figure 1-13.
FIGURE 1-13. TAKE TURN
CAREFULLY
If these tests reveal anything wrong,
however slight it may be, contact the man
in charge of the machine and operate the
machine only after obtaining his
permission.
1.7. DURING OPERATION
Always concentrate. It is extremely
dangerous to allow yourself to be
distracted or to think of other things when
operating a machine.
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.
The work area should be made as flat as
possible. If the work area is flat operation
is made much easier and this reduces
operation fatigue.
The machine should always be operated
at the speed where it can be controlled.
BG825
Never do the following.
 Speeding
 Sudden starting, sudden braking,
sudden turning.
 Snaking
 Coasting
Before, careful of those around you, and
always confirm that there is no person or
obstacle in the way before driving or
turning the machine as shown in the
Figure 1-14.
FIGURE 1-14. AVOID OBSTACLES
Always operate slowly in crowded places.
On haul roads or in narrow places, give
way to loaded vehicles.
Raise each work piece of equipment as
high as possible and keep the blade within
the machine width while traveling.
Maintain the specified traveling posture.
Do not control the vehicle speed by
pressing the brake as it will overheat the
brake lining.
Do not allow unauthorized persons into
the work area as shown in Figure 1-15.
FIGURE 1-15. DON’T ALLOW
UNAUTHORISED ENTRY
A9

Always be aware of the operating capacity
of the machine. Using the machine to do
work beyond its capacity will not only
damage the machine, but may even cause
unexpected accidents.
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 to take
appropriate action. Be especially careful in
the case of a fuel leak as there is danger
of fire.
If the machine breaks down and needs to
be towed, first confirm that the brakes are
working properly, and then tow, using a
wire rope or any other suitable towing
equipment as shown in Figure 1-16.
FIGURE 1-16. USE SUITABLE
APPARATUS FOR TOWING THE M/C
When parking the machine after
discontinuing work, put the gear shift lever
into "Neutral" apply the brake lock, lower
the blade and scarifier (option) to the
ground, and put all safety levers into the
"LOCK" position.
FIGURE 1-17. PROPER PARKING OF
THE M/C
BG825
Never leave the operator's seat without
switching the engine off as shown in
Figure 1-17.
When continuing operations after rain,
remember that conditions will have
changed from those before the rain
started, so proceed with caution. Be
particularly careful when approaching the
shoulder of the road or cliffs, as they may
have been loosened by the rain.
Check the load limits of bridges before
crossing otherwise it will lead to accidents
as shown in Figure 1-18.
FIGURE 1-18. CHECK LOAD LIMIT OF
THE BRIDGES BEFORE CROSSING
When operating on uneven ground, drive
at as low speed as possible and avoid
sudden changes in direction.
When operating at the edge of a cliff or at
the shoulder of a road, remember the
following points:
When operating in a place where there is
danger of the machine falling over the
side, be doubly careful. Do not approach
the edge of the cliff or road shoulder by
mistake.
 When working on river embankments
or other places made of piled soil,
there is danger that the weight or
vibration of the machine may cause
the machine to sink into the piled soil,
so be extremely careful when
operating in such places.
A10
 
 
 When operating on slopes, remember
the following points :

 When driving on a slope, always drive

directly up or down it. Never drive
horizontally or diagonally across the
slope, as this may cause the machine
to roll over or slip sideways.

 When going down a slope, use the

engine as a brake. If this is not enough
to control the speed of the machine,
use the service brake as well. Never
coast down a slope with gear shift
lever in "Neutral" or with clutch
disengaged.

 As far as possible, avoid turning the

machine on a slope. It may cause the
machine to roll over or slip sideways.

 Before going up or down a slope,

select a travel speed most suited to
the slope. Do not change gear on the
slope.
 If the engine stalls on a slope, first use
the brake to stop the machine, and
then return the gear shift lever to
"Neutral" before staring the engine
again. See the Figure 1-19. While
operating in the slope.
FIGURE 1-19. OPERATING IN SLOPE
When using the articulation system, be
particularly careful not to let the blade
damage the rear tire. (In articulate frame
model):
Operating articulation system when
traveling at high speed may cause the
machine to overturn. Always perform this
operation at the speed below 10 km/hr. (In
articulate frame model).

Always observe the traffic regulations and

leave margin for emergencies.

When operating in a city area, be sure to

locate underground pipes and cables
before starting the machine to prevent
them from being broken.

When operating inside a building always

be sure of the clearance of the ceiling,
entrances, aisles, etc. and the load limit of
the floor else it will lead to accidents as
shown in the Figure 1-20.

BG825 A11
 

FIGURE 1-20. OPERATING INSIDE
BUILDING
Never allow other person than the
operator to ride on the machine during
operation.
When passing through a narrow space, be
careful of the side and overhead
clearances. Take special care not to touch
any obstacles on either side or overhead.
If necessary, have someone outside the
machine call out instructions.
When operating at night, remember the
following points:
 Be sure to arrange an adequate
lighting system.
 At night it is very easy to make
mistakes in assuming the distance and
height of objects and land.
When operating in fog, mist or smoke,
where visibility is bad, be careful to
confirm first whether operation is safe.
When visibility drops below safety level,
stop work and wait for the visibility to
improve.
When operating in snow, or cleaning
snow, remember the following points:
 Even sight slopes can cause expected
side slipping, so in such places,
operate with extreme caution.
 Never use the service brake to stop
suddenly on slopes. Lowering the
BG825
working equipment is a far more
effective way of stopping.
Operating in snow should be done
carefully as shown in the Figure 1-21.
FIGURE 1-21. OPERATING IN SNOW
During operation, use seat belt .
1.8. PARKING
When parking the machine, park it in a
safe place outside the working area, or in
the specified place as shown in the Figure
1-22. The following factors should be
considered when choosing a parking
place: it should be on flat, firm ground
where there is no danger of rock falls,
landslides or floods. If the machine has to
be parked on the slope, it should be
parked facing directly up or down the
slope and chocks should be placed under
the tires. When the machine is facing
downhill, lower the blade so that it cuts
slightly into the ground to further increase
the safety.
When parking the machine, return the
gear shift lever to "Neutral", apply the
brake lock, lower the blade the scarifier
(option) to the ground, and put all safety
levers in the "LOCK" position. Switch off
the engine and remove the key.
FIGURE 1-22. PARKING THE VEHICLE
A12
 
 
2. GENERAL LOCATIONS

1. Head lamp
2. Turn signal lamp
3. Blade lift cylinder
4. Ripper
5. Rear tire
6. Blade
7. Front tire

BG825 A13
 

3. DASH BOARD SYSTEM
The Equipment vital parameters are
monitored using Murphy PV750 Display
mounted on front console as shown in
figure 3-0.
FIGURE 3.0. MURPHY DISPLAY
SCREEN
3.1. INTRODUCTION
The BG825 Dash board instrumentation
consists of I/O module and LCD (Liquid
Crystal Display) PV750Murphy display for
real time monitoring of vehicle critical
parameters and also to provide audio and
visual warnings to alert the operator about
impending breakdown. In addition to this,
various switches are mounted on the dash
board for system controls.
The Murphy Controller accepts On/off and
analogue signals from electro-mechanical
switches and sensors fitted on the
equipment sub systems and send the
information to the LCD display via CAN
and also provide audio & visual alarm
whenever any vehicle critical parameter
crosses its safe operating point.
BG825
LCD Murphy Display consists of following
gauges, pilot indicators & warning
messages.
 Engine oil pressure gauge : 0-10 bar
 Engine Water temp gauge: 40-120 º C.
 Fuel level gauge
 Voltmeter
 Tachometer
 Air Pressure gauge (2 nos.)
 Engine Oil temp Gauge 40 -120 ºC
 Transmission oil temp gauge
40-160ºC
 Speedometer
3.2. POWER SUPPLY
The unit will work on the alternator –
battery supply of 18 –32 VDC, available
on the equipment and it is protected
against reverse polarity, and electrical
noise caused by switching of starting
motor, horn, wiper, solenoids, etc.
3.3. PV750 MURPHY DISPLAY
LCD Murphy Display accepts the analog
and digital signals from I/O Module
through CAN and displays the real time
value of critical parameter on Murphy
screen and also gives the warning
messages if vehicle critical parameter
crosses its safe operating point.
Murphy PV750 Display screen front panel
first screen is shown in the Figure 3.3a
Murphy PV750 Display screen second
panel first screen is shown in the Figure
3.3b
A14

FIGURE 3.3a MURPHY PV750
DISPLAY-FRONT PANEL
(FIRSTSCREEN)
FIGURE 3.3b MURPHY PV750
DISPLAY-FRONT PANEL
(SECOND SCREEN)
Type of Sensors using for the various
parameter are as follows:
Fuel Level: Fuel level is sensed using
resistive type sensors.
Temperature gauges: Temperature
sensors are thermistor type.
Pressure gauges: Pressure sensors are
current output type .
Warning indicators
Check before starting
The following parameters are to be
checked before the Engine start.
 Radiator water level
 Engine oil level
 Hydraulic oil level
BG825
All indicator will be switched ON once the
key switch is turned ON and goes OFF
after few seconds (System check). If any
one of the above parameter is abnormal,
then the particular warning symbol
indication on Murphy display along with
text message and buzzer is displayed.
Battery charge and other parameters
All indicator will be ON once the key
switch is turned ON and goes OFF after
few seconds (System check). The battery
charging indication will go OFF when
engine is started and 24V received from
alternator ’I/WL’ point. If 24V is not
received, battery charging indication will
indicate on Murphy display along with
buzzer.
Pilot indicators
The following indicators are only for giving
pilot indication when operated.
 Differential lock
 Lift arm lock
 Absorber(optional)
 Preheat(optional)
 High beam
 Turn signal (Right, Left)
 Engine oil level(optional)
 Final drive oil temperature
 Coolant level
All indicators will be switched ON once the
key switch is turned ON and goes OFF
after few seconds (System cheek). If any
one of the parameter is operated
/abnormal then the indicator will be ON as
long as the parameter is operated /
abnormality present.
PV750 Murphy Navigation buttons
To see all the parameters press the button
and navigate to the next screen as shown
in the Figure 3.3c
A15
 
 
 Wiper Motor Switch(Front & Rear)
 Wind Shield Washer Switch (Front
& Rear)
 Rear/Reverse lamp switch

LH Panel

LH panel assy. consists of Emergency

FIGURE 3.3c MURPHY PV750
NAVIGATION BUTTONS
Once Warning Symbol is appears on the
screen, immediately stop the vehicle and
press the Button (shown in fig.) to see the
warning messages and read the warning
messages on Murphy display
pressing the key as show below.
Steering switch, Rops lamp switch (front
& rear) and roof lamp switch and fan
switch. Emergency Steering switch can
be actuated in case of regular steering
pump fail. When this push bottom switch
is actuated emergency steering motor will
be “ON” and the lamp in the steering
switch goes ON when pressed. Details as
shown in the Figure 3.3e.
by

RH Panel

RH panel assy. consists of following

switches and key-switch as shown in the
Figure 3.3d.

FIGURE 3.3e LH PANEL

FIGURE 3.3d RH PANEL

 Lifter arm lock switch

 Starter switch
 Head lamp switch
 Differential lock & unlock switch
 Dust indicator
 Work lamp front and rear
 Engine shut off switch

BG825 A16
 

3.4. TRANSMISSION CONTROLLER
BG825 Transmission consists of
electrically operated solenoids for gear
shifting. The shift tower is used to select
the required gear position manually to
operate the equipment at appropriate
speed. The shift tower consists of 8
forward, 8 reverse, neutral and parking
brake position.
Engine start: The equipment will start
only when shift lever is in parking brake
position. Other than parking brake
position, the Engine will not start.
FIGURE 3.4. TRANSMISSION CONTROL
BG825
Forward and reverse gear position :
The forward and reverse gear position will
be sensed by two proximity switches
mounted on the shift tower. Based on the
actuation of proximity switch,
forward/reverse gears will be engaged.
Shift lever position sensing :
Non contact type Hall Effect sensors are
used to sense the shift lever position.
Details as shown in the figure 3.4. below
A18
 
 

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

SL.
CONDITION ACTION REMARKS
NO.
01 Power supply Should operate between 18-32v DC

Reverse polarity
02
protection
Should not affect the controller

Gear shift lever 2-4 kg

03 Centre of knob and graduation on FRP
a) Operating force console should coincide for every range.
b) Lever position

Put shift lever in ‘P’ position. Check for Engine should not
Engine start actuation of start relay coil (CNRST) and start other than
04
ground signal from this relay to starting ‘P’ position &
circuit check the same.

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

following Check power to
a) Proximity switch (CNSWR) get ‘on’ backup alarm in
(red LED on) reverse gear
05 Reverse alarm b) Relay (CNRTR) coil to be position (N to 8)
energized and provides ground
signal to backup alarm relay.
c) Backup relay (CNRBB) coil get
energized and provides 24v power
to buzzer to drive alarm.

i) Proximity (F) switch get ‘on’ (red

Shift lever position LED on)
Relay (F) coil will be energized and Check the
i) Neutral forward
provides ground to forward solenoid forward solenoid
energized in all
ii) Proximity (R) switch get ‘on’ (red LED
j) Neutral reverse gear position
on)
(F1-8 )
06 Relay (R) coil will be energized and
provides ground to reverse solenoid

When shift lever position is between 1 to 4

07 Both in forward &
Differential relay gear the differential relay (CNRD1) coil is
energized and provides ‘NC’ contact reverse direction

Check shifting of shift lever by pressing

knob

Shifting from ‘n’ to ‘p’ position Both in forward &

08 Mechanical lock for (N P) reverse direction
gear shifting
a) Shifting from ‘5’ to ‘6’ gear during both
forward & reverse position.
b) Shifting from ‘7’ to ‘6’ gear during down
shifting in both forward & reverse position.

BG825 A19
 
 
 

3.6. SOLENOID COMBINATION – CHECK AS PER TABLE-II

SHIFT LEVER SOLENOID COMBINATION

POSITION F R L H 1 2 3 4
P
N- *
FORWARD
N-REVERSE *
1 * * *
2 * * *
3 * * *
F 4 * * *
5 * * *
6 * * *
7 * * *
8 * * *
1 * * *
2 * * *
3 * * *
R 4 * * *
5 * * *
6 * * *
7 * * *
8 * * *

NOTE: 1. (*) Indicates solenoids are energized

2. All solenoid will be driving in sinking mode

Shift lever
Ground details @ CNT 02 connector
position

P Pin 2

Pin 4&6 1. The ground signal is same for

1
both forward & reverse range.
Pin 4&7
2
2. Check ground points with
Pin 4&8 respect to +24v using multimeter.
3
Pin 4&9 3. In neutral position both reverse
4
& forward solenoids get ground
Pin 5&6 signal through respective relays.
5
Pin 5&7
6
Pin 5&8
7
Pin 5&9
8

BG825 A20
 
 
 

3.7. TROUBLE SHOOTING

Supporting tools required D) Parking brake not working

 Multimeter & circuit diagram Probable fault

 Shift tower - The shift selector is a
range selector, which is used to select
the range of maximum permitted gear.
The sensing is based on the non-
contact sensor to ensure long life and
trouble free operation. Mechanical lock
is provided to avoid accidental shift to
'p' position, up shifting from 5 to 6 gear
and down shifting from 7 to 6 gear.
A) Shift tower position check as per
table - II
B) Functional checking as per
table - I
C) Engine not starting
Probable fault
 Shift tower @ 'P’ position no ground
signal
 Parking brake not working
Remedy
 Check shift tower ground signal at pin2
of CNT 02 connector (no ground signal
w.r.to +24v replace the controller)
 * Check parking brake relay (CNRPB)
function & wiring replace relay if found
Faulty.
 Measure the parking brake solenoid
resistance (if found open circuit
replace Parking brake solenoid).
 

 Shift tower @ 'P" position no ground

signal

 Starting relay (CNRST) not

functioning

Remedy

 Check shift tower ground signal at

pin-2 of cnt 02 connector. (no round
signal w.r.to +24v replace the
controller).

 Check starter relay function &

wiring(replace relay if found faulty)

BG825 A21
 

3.8. PRECAUTIONS FOR WELDING ON MACHINES WITH ELECTRONIC CONTROLS
As with all machines with Electronic
Controls, special care should be taken
when welding on the machine. Here are
some tips to keep in mind when
performing welding on the Dump truck and
Motor Graders. For additional details,
review the Operation and Maintenance
Manual.
General Warnings & Tips
 Always wear proper personal
protective equipment
. the welder to the ECM. Welding on
 Before welding around electronics,
Remove the electronics in that area to
reduce or eliminate heat damage
caused by the welding process.
Remove the controller unit if welding is
to be done within 10” of it.
 Lock-out and Tag-out the machine.
 Clamp the ground cable from the
welder to the component that will be
welded and place the clamp as close
to the weld as possible. Attach the
welder ground cable no more than 2
feet from the part being welded. If
grounding cable is connected near
instruments, connectors, etc., the
instruments may malfunction.
 Do not use electrical components
(ECM or ECM Sensors) or electrical
component grounding points for
grounding the welder.
BG825
 Do not weld in wet areas or in the
rain.
 Always weld in a well ventilated
area.
 Keep your work area clear of
anything flammable
 Do not use cables that are frayed,
cracked or have bare spots in the
insulation
 Never connect the ground cable of
the engine or engine mounted
components is not recommended.
 Do not apply more than 200 V
continuously.
 Always avoid laying welding cables
over or near the vehicle electrical
harnesses. Welding voltage could
be induced into the electrical
harness and possibly cause
damage to components.
 Always fasten the welding machine
ground (-) lead to the piece being
welded.
A23

Welding instructions:
a) Turn off the Ignition switch.
b) Turn –off Battery disconnect switch
c) Remove Both positive(+) and the
negative (-) terminal of the battery to
stop the flow of current when carrying
out electrical welding.
d) Before welding on truck, be certain
that each of these components are
completely disconnected:
• Transmission and brake controllers
• Engine ECM
• Batteries
e) Cover all electronic controllers for
protection from sparks.
f) Engine must never be used as a
grounding point.
g) Ensure the connection of automatic
CAN grounding circuits for protection
of CAN bus lines. If it is not
connected/provided, all CAN bus lines
are to be disconnected from the
controller (Engine, transmission, Brake
and Murphy modules) and Murphy
display units.
Jump Starting and Battery Charging
 Do not connect the jumper starting or
battery charging cables to any part of
the Engine / Transmission / other
ECMS.
 When using jumper cables to start the
engine, make sure to connect the
cables in parallel: Positive (+) to
positive (+) and negative (-) to
negative (-).
 When using an external electrical
source to start the engine, turn the
disconnect switch to the “OFF”
position before connecting the cables
to the battery.
BG825
 Do not exceed 36 volts. Remove
the key from the key switch before
attaching jumper cables to the
battery.
 When jump starting, make sure
you choose the right size of cable
for vehicle. Always connect
positive cable first and negative
cable last. Disconnect the negative
cable first and reconnect it last.
Handling controller
1) The controller contains a
microcomputer and electronic
control circuits. These control all of
the electronic circuits on the
machine, so be extremely careful
when handling the controller.
2) Do not place objects on top of the
controller.
3) Cover the control connectors with
tape or a vinyl bag. Never touch
the connector contacts with your
hand.
4) During rainy weather, do not leave
the controller in a place where it is
exposed to rain.
5) Do not place the controller on oil,
water, or soil, or in any hot place,
even for a short time. (Place it on a
suitable dry stand).
6) Precautions when carrying out arc
welding when carrying out arc
welding on the body disconnect all
wiring harness connectors
connected to the controller. Fit an
arc welding ground close to the
welding point.
A24
 
 
Points to remember when
troubleshooting electric circuits

1) Always turn the power OFF before

disconnecting or connecting
connectors.

2) Before carrying out troubleshooting,

check that all the related connectors
are properly inserted. Disconnect and
connect the related connectors several
times to check

3) Always connect any disconnected

connectors before going on to the next
step. If the power is turned ON with
the connectors still disconnected,
unnecessary abnormality
displays/error codes will be generated.

4) When carrying out troubleshooting of

circuits (measuring the voltage,
resistance, continuity, or current),
move the related wiring and
connectors several times and check
that there is no change in the reading
of the tester. If there is any change,
there is probably defective contact in
that circuit.

BG825 A25
 
 
 
3.9. STEPS FOR IMPROVING THE RELIABILITY OF MURPHY DASH BOARD
SYSTEM

BG825 A26
 
 
 

Shield: Braided
Silver Plated Wire
Jacket:: ETFE
Noise Source Fluropolymer

Insulation: PTFE
The total Effect
over e PTFE Conductor: Silver
is 14-14-0
Plated Copper or
Alloy

Effect of Noise on twisted pair

BG825 A27
 
 
 

BG825 A28
 
 
 

BG825 A29
 
 
 

Single point Grounds

Once all the major components are fitted with their own return wire, by collecting all the
return wires at a common point, the single point ground(SPG) works to get the entire
electrical system” singing of the same sheet of music”. It does this by simply making sure
that every electron has a clear path back to its source, whether it’s the alternator or the
battery.

BG825 A30
 
 
 

BG825 A31
 
 
 

BG825 A32
 

3.10. EMERGENCY STEERING SYSTEM ON MOTOR GRADER
The emergency steering system is
supplementary steering system, to operate
the steering system in case of failure /
malfunctioning of steering pump / Engine
while equipment is in moving condition.
The emergency steering system is
consists of electrically operated DC motor
to drive the pump to provide the required
flow to steering system.
Manually operated Emergency steering
system :
The operator has to press the switch to
operate Motor and pump incase of failure
of steering system.
A switch mounted on the console next to
the operator can be used to activate the
emergency steering system if necessary
to steer the equipment when the engine is
not operable.
Note: Use of the emergency steering
system should be limited to a
maximum of 90 seconds.
Emergency steering system of BG825 Motor grader is shown in the Figure 3.10.a below.
FIGURE 3.10.a. EMERGENCY STEERING SYSTEM
BG825
The manual steering system intent to use
in case of failure of main steering system
to move the equipment to safer side. The
system should not be operated more than
90 seconds. The continuous operation of
emergency steering Motor leads to failure
of Motor and Pump.
In order to avoid the Motor failure due to
inadvertent operations, ON-Delay timer is
being provided to cut-off power to Motor
after 90 seconds, details are as follows.
On-Delay Timer: The On-Delay timer is
allows the Motor to operate for 90
Seconds and switch off the motor after
specified time. If operator wants to operate
the Motor for More than 90 seconds, the
Steering switch mounted on the dash
board to be operated once again.
The emergency steering system is a
safety system. The system should be
checked daily to ensure the proper
functioning of system. The procedure for
checking emergency steering system is
explained below.
A33
 
 

Manual Emergency steering system

Check:

1. Turn the starting switch key to the ON

position.

2. Start engine and run for one minute.

3. Switch off the engine and switch ‘ON’

emergency steering switch, and check
that the steering wheel can be
operated for 10 seconds.

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

FIGURE 3.10.b CIRCUIT FOR MANUAL EMERGENCY SYSTEM

Emergency
Steering Switch

From Circuit
Breaker
Emergency
Steering Relay Buzzer

Battery
Emergency
Steering Motor

BG825 A34
 
Preventive Maintenance Procedures: Corrosion, dirt, and dust:

The object of preventive maintenance is to The Motor operates less efficiently when
identify and correct potential problems corrosion forms or dirt particles build up
before they occur. around wire and cable connection points.
Corroded and dirty connection points
Wires and cables: impair the flow of electrical current. Clean
For any type of vehicle electrical system, all connections on a periodic basis.
it‘s important to keep all connection Points
clean. Road dirt and grease create Timely preventive maintenance of the
resistance that interferes with electrical system provides smoother operation and
current flow. In order to get the necessary long life for Motor and pump components.
power from a unit , there must be little or  
no resistance between the batteries and
the motor. In the same vein, you need to
make sure that wires and cables are
clean, properly tightened, and of the
proper size. Any loss of current due to
poor connections will reduce power to
motor.

Clean all connections on a periodic basis.

Also check for tension on terminals due to
improper routing.

Battery :

A battery having a low / poor state of

charge will place abnormal stresses on
the system. When measuring battery
voltage, make sure voltage is 24 V or
greater.

Excessive heat:

A motor can become damaged if it

operates too long at high temperatures.
Excessive heat is generally due to
continuous engagement of the Motor.
Damage to Motor system components can
occur when the motor is operated for long
periods. Motor should not be operated for
more than 90 seconds and allow Motor to
cool down for 3 minutes after operation.
 

BG825 A35

 

3.11. STARTING MOTOR TROUBLE SHOOTING
SYSTEM
The heavy-duty electrical system is made
up of the starting system and the charging
system. These systems are, in turn,
comprised of batteries, the starter, the
alternator, the interconnecting wiring and
electrical and mechanical switches. For
maximum operating efficiency, all parts of
the system must be functioning properly.
DIAGNOSIS:
Diagnosis is the three part process that
begins when a problem is perceived and
ends when the equipment is confirmed as
serviceable. The process can be
described by using three questions that
must be answered to assure completion.
FIGURE 3.11 STARTING MOTOR TROUBLE SHOOTING
BG825
 What are the symptoms? This is what
has been observed (seen, heard, felt
or smelled) that indicates a problem.
 What caused the symptoms? This
involves using diagnostic procedures
to identify the root cause of the
problem.
 How do we fix it? Usually this involves
the adjustment, repair or replacement
of some part or parts.
The Circuit connection for starting motor
with Alternator is shown in the Figure 3.11
below.
A36

3.12. ALTERNATOR WIRING TEST
This procedure is the first step in checking
out the charging system. The output of the
alternator, the batteries and the accessory
loads with a minimum of voltage loss. Any
loss slows the rate of charge to the
batteries and could cause the batteries to
be partially discharged. Discharged
batteries can result in starter damage. Low
output voltage can cause improper
performance of other vehicle electrical
components.
MAGNETIC SWITCH CONTACTOR
TEST
The figure for Magnetic Switch Contactor
test is shown below.(Figure 3.12.)
FIGURE 3.12. MAGNETIC SWITCH
CONTACTOR
With carbon pile connected as for previous
Starter Solenoid Circuit Test, proceed as
follows:
Connect
1. Digital voltmeter set on low scale
across large terminals of magnetic
switch. Battery voltage will show
immediately.
BG825
Test
1. Push starter button with key on. Voltage
will read zero.
2. Turn on and adjust carbon pile to 100
amp load (60 amp if 24 volt system).
3. Read and record voltage (V11) across
magnetic switch on voltmeter then release
starter button.
4. Magnetic switch contactor voltage loss
(V11) shall not exceed 0.2 volts for 12 or
24 volt system.
5. Replace magnetic switch if contactor
voltage loss is excessive.
3.13. BATTERIES
Batteries are perishable devices that wear
out at some point in time. With use they
deteriorate and eventually become
incapable of performing their important
job. In addition, new, good batteries may
become discharged for various reasons.
Neither worn out nor discharged batteries
can supply the power necessary for
cranking. Thus the battery check becomes
the starting point for diagnosing electrical
system problems.
Because of vibration, corrosion,
temperature changes or damage, the
performance of wiring, connections, and
secondary components as well as the
function of the starter and alternator can
deteriorate. This in turn can cause
malfunctions within the starting and
charging systems. For the purpose of
testing, wiring and components are broken
down into four circuits that must be tested.
A37

Cranking Circuit
This consists of the large cables that carry
the high starter current. Excessive loss
here causes slow cranking speeds,
especially in cold weather. Inability to start
from slow cranking can lead to starter
burn-up if the starter is cranked over 30
seconds. Deeply discharged or worn-out
batteries can also cause the same
problem.
Solenoid Circuit.
This consists of the wiring from the battery,
through a push button or magnetic switch,
to the “S” terminal of the starter solenoid,
and back to the battery. Excessive loss
here can cause the solenoid to shift in and
out (chatter) resulting in a no start
condition. This can cause a burned
contact disc and terminals of the starter
solenoid. Deeply discharged batteries can
also cause this problem.
Magnetic Switch Circuit
(When Magnetic Switch Used). This is
made up of the wiring from the battery
through a key switch and/or start button to
the coil of the magnetic switch and back to
the battery. Excessive loss here can
cause a “no start” complaint.
Charging Circuit.
This consists of the wiring between the
alternator and the battery and back to the
alternator. Excessive loss here can cause
the batteries to not charge properly. As
noted above, discharged batteries will
cause other problems.
BG825
3.14. CARE OF THE BATTERY
When handling a battery, the following
safety precautions should be followed
Hydrogen gas is produced by the
battery.
A flame or spark near the battery may
cause the gas to ignite.
Battery fluid is highly acidic.
Avoid spilling on clothing or other fabric.
Any spilled electrolyte should be flushed
with large quantity of water and cleaned
immediately.
To remove or replace a battery, always
disconnect the cable first, then the positive
cable. After installing battery, connect
battery cables and make sure to properly
tighten all terminals.
Keep the battery cable connections
clean.
The cable connections, particularly at the
positive (+) terminal post, tend to become
corroded. The product of corrosion, or
rust, on the mating faces of conductors
resists the flow of current. The inability of
the starter motor to crank the engine is
often due to the rust formation in the
battery cable connection. Clean the
terminals and fittings periodically to ensure
good metal-to-metal contact, and grease
the connections after each cleaning to
protect them against rusting.
Be always in the know as to state of
charge of the battery.
The simplest way to tell the state of
charge is to carry out a hydrometer test.
The hydrometer is an inexpensive
instrument for measuring the specific
gravity (S.G.) of the battery electrolyte.
A38

Why measure the S.G.?
Because the S.G. of the electrolyte is
indicative of the state of the charge. The
direct method of checking the battery for
state of charge is to carry out a high rate
discharged test, which involves a special
precise voltmeter, an expensive
instrument used generally in the service
shops but no recommendable to the user
of the machine. At 20 degree centigrade of
battery temperature (electrolyte
temperature).
 The battery is in FULLY CHARGED
STATE
if the electrolyte S.G. is 1.280.
 The battery is in HALF CHARGED
STATE
if the S.G. is 1.220.
 The battery is in NEARLY
DISCHARGED STATE
if the S.G. is 1.150 and is in danger of
freezing.
The following information is basic in nature
and is nothing new; it is merely a
reiteration of what every service shop
personnel knows about the automotive
storage battery. The information is
intended to serve as a reminder to the
reader, with a hope that he will, in turn,
reminded each final user of the important
basic facts about the battery whenever
opportunity permits him to engage in a
conversation with the final user in the shop
or out of the shop.
 The battery is a very reliable
component, but needs periodical
attentions. Keep the battery container
clean; prevent rust formation on the
terminal posts; keep the electrolyte up
to the upper level uniformly in all cells;
and try to keep the battery fully
charged at all times.
BG825
 Preserve the capacity of the battery.
There is a limit to the ability of the
battery to hold electricity is store. This
limit is called “capacity”.
WAYS FOR THE BATTERY TO LOWER
IT'S CAPACITY
Loss of electrolyte, or fall in electrolyte
level.
When this happens, the battery cannot
hold so much electricity as it originally
could. Handle the battery with care when
you take it down. Barring the loss of
electrolyte by careless spilling or
otherwise, the electrolyte level goes down
gradually in the battery at work because
the water content of it evaporates.
Periodically refill distilled water to each
cell, as necessary, so that the electrolyte
is always up to the specified level. Never
allow its surface to fall so much as to
expose the cell plates.
Overcharging the battery in place or off
the machine.
In recharging the battery off the machine,
caution must be exercised so as not to
overcharge it. Over charging give rise to
several complexities. For one thing, it
heats up the battery to deform the battery
container to result in a destroyed battery.
Overcharging could occur in a battery in
place if the voltage regulator is in mal
condition to allow the alternator (or
dynamo in other machines) to develop too
high an output voltage. For another thing,
“gassing” occurs in a battery being
overcharged to result in a loss of water
content. One of the most serious
consequences of overcharging is the
swelling of positive-plate grids, causing
the grids to crumble and the plates to
buckle.
A39

Undercharging the battery in place.
Regulator malfunctioning is usually the
cause of the battery remaining in a state of
charge far below its capacity. This
condition is very undesirable in freezing
weather, for the electrolyte in such a
battery can easily freeze up to result in a
destroyed battery. Moreover, an
undercharged battery is an easy prey to a
greater evil sulfation.
Sulfation
Let us recall the electrochemical reactions
that take place in the battery during
charging and discharging. As the battery
gives out its energy (discharging), the
active materials in its cell plates are
converted into lead sulfate.
During recharging, this lead sulfate is
reconverted into active material. If the
battery is allowed to stand for a long
period in discharged condition, the lead
sulphate becomes converted into a hard,
crystalline substance, which will not easily
turn back to the active material again
during the subsequent recharging.
“Sulfation” means the result as well as the
process of that reaction. Such a battery
can be revived by very slow charging and
may be restored to usable condition but it
is a damaged battery and its capacity is
lower than before.
3.15. BATTERY AND CHARGING
SYSTEM
Located on the battery box, this warning
decal (WA 3101) stresses the need to
keep all spark producing materials away
from the battery. When another battery or
24V DC power source is used for a jump
start, all switches must be off prior to
making any connections. When
connecting jumper cables, maintain
correct polarity, connect positive posts
together and then connect the negative
lead of the jumper cable to a good frame
ground.
BG825
Do not connect the negative posts of
the vehicle batteries.
This hook up completes the circuit but
minimizes the danger of sparks near the
batteries.
Sulphuric acid is toxic and corrosive, use
proper safety gear - goggles, rubber glove
and rubber gloves when handling and
servicing batteries.
If sulphuric acid is spilled on the skin,
immediately flush the area with large
amount of running water for at least 15
minutes, and get medical attention at
once.
Counteract swallowing of acid by drinking
large amount of water or milk, followed
with mild of magnesia, beaten eggs or
vegetable oil. Get medical care promptly.
3.16. SERVICING BATTERY
Proper servicing will increase the life of
the batteries. Checking electrolyte level
and cleaning are the two most important
items in servicing.
Service the electrolyte level with distilled
water or water approved by the
manufacturer. Hard water will cause
mineral deposits on the cell plates and
decrease battery life. Add water until the
top of the plates are covered. Over filling
will weaken the battery electrolyte and
cause corrosion of battery connections.
Batteries can be cleaned by using soda
solution or ammonia, and rinsing with
clear water.
The decal for battery is pasted on the
vehicle as follows:
When washing batteries, make sure
that cell caps are tight to prevent
cleaning solution from entering the
cells.
A40

When installing the batteries, check all the
connections for corrosion. If corrosion is
present, clean the terminal or clamp and
apply coating of petroleum jelly to prevent
further corrosion.
3.17. RECHARGING BATTERIES
LEAD ACID BATTERIES
(RE-CHARGING)
1. Prior to operating battery charger,
make sure that leads are connected to
the corresponding terminals.
2. In case if the voltage is low or shelf life
is more than 60 day, then subject the
battery for refresh charging with the
help of battery charger @ 16
Volt/battery and 10% (1/10) rated
capacity of battery (AH) Charging
current . Example: for 100 Ah battery
charging voltage will be 16 Volts and
charging current will be 10% of AH- 10
Amps.
NOTE: During charging process
vent caps should be kept open for
venting and premises should be
properly ventilated.
3. A battery is consider fully charge when
its CCV (Closed circuit voltage)
reached 15.6 to 16.00 Volts and
Specific gravity of electrolyte
measuring 1.250 (±0.005).
4. All the cells of battery should gas
freely and three hourly consequently
reading shows constant reading of
voltage and specific gravity.
5. Make sure the charging system of the
equipment to which battery is fitted
deliver required charging voltage (15
Volts-CCV) and charging current of
10% rated capacity of battery AH.
BG825
6. Continue charging till
a) The battery voltage reaches about
15.8 to 16.6 volts.
b) All the cells are gassing freely.
c) The voltage and specific gravity
readings remain constant for 3
consecutive hours.
Once the battery has been fully
recharged, the specific gravity of the
electrolyte should be 1.250 + 0.005 @
27 Deg. C.
7. If the specific gravity is lower than that
specified above, adjustment should be
made by removing the requisite
quantity of acid form the cell and
replacing with acid of 1.300 specific
gravity. If the specific gravity is higher
that the specified value, requisite
quantity of acid should be removed
and replaced with distilled water. The
battery should then be given a charge
of 2 to 3 hours to allow the electrolyte
to mix thoroughly. This adjustment
should be done only in a cell which
gasses freely on charge.
8. Once the battery is fully recharged and
the specific gravity adjusted, switch off
the charger. Fix the vent plugs tight
and wash the battery with plenty of tap
water. Wipe the battery with clean
cotton waste and smear the terminals
with petroleum jelly/Vaseline.
9. In case the battery has been subject to
a very deep discharge (specific gravity
absolutely zero), then the battery
should be drained completely and
filled with electrolyte of 1.150 specific
gravity it should then be charged at
50% of the recommended charging
current for 3 to 4 days and then
increased to 100% charging should be
continued till the conditions as per
point no. 2 above are met. The specific
A41

gravity will be above 1.250 and this
should be adjusted to 1.250.
10. It should be ensured that the
electrolyte temperature does not
exceed 50 Deg C during charging at
which time charging should be
discontinued and temperature allowed
to drop to 40 Deg C.
NOTE : The time of recharge
is solely dependent on State of Charge
and State of Health of battery.
DO Not Smoke or allow open flame
around a battery or during re-charging!
DO Not attempt to charge a frozen
battery, Serious Injuries may occur!
BG825
Precaution during Charging
1. Use Rubber gloves while handling
sulphuric acid.
2. On body contact with acid, use water
generously and contact a physician if
necessary.
3. Keep constant watch on the
temperature of electrolyte and reduce
charging current if temperature
crosses 50⁰C.
Prior to operating battery charger, make
sure that leads are connected to the
corresponding terminals, and remove cell
caps to dissipate any gas accumulation.
The battery charging system process can
be monitored by checking specific gravity.
To check specific gravity level of a cell,
use Hydrometer.
Specific gravity reading of 1.270 to 1.215
@ 27 degree centigrade indicates that
battery is fully charged. A reading below
1.215 @ 27 degree centigrade is
considered as uncharged and is
unsatisfactory for use.
Note: The specific gravity reading will vary
with ambient temperature, and may need
correction. Correction can be made by
adding 4 gravity points for every 3.4
degree centigrade or by subtracting 4
gravity for every 3.4 degree centigrade
below 27 degree centigrade.
A voltage reading may also be taken
across each of the individual cells. The
voltage reading across each individual cell
should be approximately 24 V DC.
SEQUENCE OF PROCEDURES
It is important that the procedures in the
manual be followed in the exact sequence
specified. Batteries, wiring and
connections should be checked and
corrected to the specifications given. If
cranking problems still occur, then
connecting cables should be checked
A42

before replacing the starter with a known
good unit. Similarly, in the charging circuit,
batteries wiring and connections should be
thoroughly checked and corrected to the
specifications given. Only then should the
alternator be checked and replaced if
necessary.
NOTES :
The use of digital voltmeters is highly
recommended for the following reasons:
 Digital voltmeters are generally more
accurate than analog (needle
movement) instruments.
 Digital readings need no interpretation;
everyone sees the same number.
 Digital instruments are generally auto
ranging; they automatically select the
proper range for the value of the
reading
 Reversing polarity with a digital
instrument will simply result in a
negative reading (minus sign) whereas
with an analog voltmeter, reversing
polarity could damage the meter.
 If analog meters are not read directly
facing the meter, inaccuracies may
result.
3.18. STARTER MOTOR
Diagnostic - Fault finding chart
Chart - 1 @ STARTER MOTOR
INACTIVE
The solenoid valve cannot be heard
clicking.
NOTES :
Check
– The condition and voltage of the
battery
BG825
– The condition of the battery
wiring and terminals
– The condition of the earth straps
– The condition of the power fuse (if
fitted).
Repair or replace the faulty
components, if necessary.
– Check the presence and the condition
of the fuses.
Replace if necessary.
– Check, on the starter motor, the
connection and the condition of the
control terminal.
Repair if necessary.
– Check, with the ignition on, that the
immobilizer is inactive.
In the event of a problem, use the
immobilizer fault finding procedure.
– Check, using an ammeter that the
vehicle's consumers have not short-
circuited.
If there is a problem, carry out a fault
search (damaged wiring, relays
sticking, etc.).
– Check, with the ignition on and with
the starter motor operational, for the
presence +24 Volts on the starter
motor control line.
If not correct:
If the vehicle is fitted with a circuit
breaker or additional alarm:
– Check if it is acting on the starter
motor control line.
– Check the insulation and condition of
the connections with the circuit
breaker or the alarm.
– Ensure that these are both operating
correctly.
A43
 
 

– Check if 12 Volts is present before the
ignition is switched off; replace the
circuit breaker or alarm.
 If the model is controlled by the starter
motor switch:
– Check the line between the switch and
the control terminal.
– Check that the rotary switch is
operating correctly.
– Check the supply to the rotary switch.
 If the model is controlled by the
immobilizer:
Check for the presence of + 24 volts at the
starter motor power terminal.
Repair or replace the faulty
components, if necessary.
If not correct,
– Check the insulation and the continuity
of the power line between the battery
and starter motor.
Repair if necessary.
 Put the vehicle in neutral (also neutral
on automatic gearboxes) and try to
turn the starter motor by hand.

– Check the line between the switch and
the control terminal.
– Carry out a fault finding procedure on
the immobilizer.
If not correct, check
– If there is oil in the engine (seizure),
– The timing adjustment,

Repair or replace the faulty – That no auxiliary is slowing down the

components, if necessary. motor,

If everything is correct, replace the – That the gearbox and its control are
starter motor. not faulty,

AFTER REPAIR – That there are no objects which could

be blocking the free movement of the
– Check that the starter motor is motor at the flywheel end,
operating correctly.
– That the engine is not flooded and that
CHART - 2 @ STARTER MOTOR there is no object (dropped valve...) in
BLOCKED the cylinders.

The solenoid clicks, but the starter motor Repair if necessary.

does not run.
Check, using an ammeter that the
NOTES : vehicle's consumers have not short-
circuited.
Check
If there is a problem, carry out a fault
– The condition, the voltage and
search (damaged wiring, sticking relays,
conformity of the battery,
etc.).
– The condition of the battery wiring and
If everything is correct, replace the starter
terminals,
motor.
– The condition of the earth straps,
AFTER REPAIR
– The condition of the power fuse (if – Check that the starter motor is
fitted). operating correctly.
BG825 A44
 
 
 
CHART - 3 @ UNDERPOWERED – That there are no objects which could
STARTER MOTOR be blocking the free movement of the
motor at the flywheel end,
The starter motor is not turning the engine
over quickly enough. – That the engine is not flooded and that
there is no object in the in the intakes,
NOTES
– The valve clearances.
Check
Repair if necessary.
– The condition, the voltage and
conformity of the battery, If everything is correct, remove the starter
motor and check for signs of wear.
– The condition of the battery wiring and
terminals, Repair if necessary.

– The condition of the earth straps, If everything is correct, replace the starter
motor.
– The condition of the power fuse (if
fitted). CHART - 4 @ INTERMITTENT
OPERATION
Repair or replace the faulty components, if
necessary. The starter motor does not operate during
all the starting sequences.
Check, using an ammeter that the
vehicle's consumers have not short- NOTES
circuited.
Check
If there is a problem, carry out a fault
search (stripped wiring, sticking relays, – The condition, the conformity and the
voltage of the battery,
etc.).
– The condition of the battery wiring and
Check the insulation and continuity of the
terminals,
starter motor power wiring to the battery.
– The condition of the earth straps,
Repair if necessary.
– The condition of the power fuse (if
Put the vehicle in neutral (also neutral on
fitted).
automatic gearboxes) and try to turn the
starter motor by hand. Repair or replace the faulty components, if
necessary.
If not correct, check
Check that the immobilizer is not faulty
– If there is oil and water in the engine
and that it becomes inactive each time the
(seizure),
ignition is switched on.
– That no other auxiliary is slowing down
the motor (coolant pump, air Perform a fault finding procedure on the
conditioning compressor, etc.), engine immobilizer system if necessary.

– The adjustment and condition (tension Check the condition and the connection of
wheel sticking...) of the timing system, starter motor control circuit terminal.

– That the gearbox and its control are Repair if necessary.

not faulty,

BG825 A45
 

Check if the vehicle is fitted with circuit
breaker or an additional alarm.
Check they are working correctly.
Check the condition and insulation of
starter motor control circuit line.
Repair if necessary.
Check that the starter motor switch is
operating correctly.
Repair or replace it, if necessary.
Connect the diagnostic tool and check
that the immobilizer is operating correctly
(vehicles with immobilizer controlling the
starter motor).
Perform a fault finding procedure on the
engine immobilizer system if necessary.
Remove the starter motor and check that
there are no bad contacts (contact brush).
Repair if necessary.
If everything is correct, replace the starter
motor.
CHART - 5 @ NOISY STARTER MOTOR
The noise is only present during the
starting phase and afterwards.
NOTES
Check
– The condition and voltage of the
battery,
– The condition of the battery wiring and
terminals,
– The condition of the earth straps,
– The condition of the power fuse (if
fitted).
Repair or replace the faulty components, if
necessary.
BG825
Check the mountings securing the starter
motor to the engine.
Reaffix if necessary.
Check the condition of the flywheel ring
gear.
Repair or replace it, if necessary.
Check the condition of the starter motor
drive pinion.
Check that the centering pin is present.
Replace the starter motor if necessary.
If the noise persists after starting:
– Check that the control circuit is no
longer being supplied.
If necessary, check the insulation of the
control line (short circuit to + 12 volts), the
operation of the rotary switch and the
immobilizer (if the starter motor is
controlled by the engine immobilizer).
Repair the faulty components.
– Check that the solenoid is operating
correctly and the starter motor fork is
returning.
Replace the starter motor if necessary.
AFTER REPAIR
– Check that the starter motor is
operating correctly.
CHART - 6 @ STARTER MOTOR
OVERHEATING
Odour / smoke coming from under the
bonnet during the starting sequence.
NOTES
Check
– The condition and voltage of the
battery,
A46

– The condition of the battery wiring and
terminals,
– The condition of the earth straps,
– The condition of the power fuse (if
fitted).
Repair or replace the faulty components, if
necessary.
Check the condition of the starter motor:
– Label showing signs of peeling,
– Blue annealing at terminals,
– Wiring has melted,
– Paint melting / or odour of paint
melting.
Before replacing the starter motor, check
that there is no external cause for this
fault (water or oil leak from above, motor
seized or abnormally difficult to turn, short
circuit, etc.).
AFTER REPAIR
– Check that the starter motor
operating correctly.
The Primary Causes of Starting System
Malfunction:
Before discussing the preventive
maintenance and diagnostic procedures
for the starting system, we are going to
cover certain environmental and product
application factors that can cause the
starting system to malfunction.
Battery charge
A battery having a low / poor state of
charge will place abnormal stresses on
the starting system. When measuring
battery voltage, make sure voltage is 24 V
or greater.
BG825
Excessive heat
A starter motor can become damaged if it
operates too long at high temperatures.
Excessive heat is generally due to
continuous engagement of the starter.
Damage to starting system components
can occur when the starter motor is
cranked for long periods (often due to cold
weather starts etc.). Starter should
operate for 30 seconds maximum then let
to cool down for 2 minutes.
Excessive vibration.
If starting system components are poorly
or loosely mounted to the vehicle’s
engine, the resulting vibration can
damage sensitive internal components.
Corrosion, dirt, and dust.
Starting system components operate less
efficiently when corrosion forms or dirt
particles build up around wire and cable
connection points. Corroded and dirty
connection points impair the flow of
electrical current.
is
Defective solenoid.
If the starter fails to engage or fails to stay
engaged, the pull-in or holding coil may be
defective, or the wiring to the solenoid is
bad. You need to check the wiring to the
solenoid. If the wiring is ok then the coil is
defective and you will have to replace the
solenoid.
Commutator Problems
Starter motors rely on commutators, or
switches that reverse the direction of
current between the external circuit and
rotor, to contact the motor's brushes and
generate electrical power. Commutators
can wear down over time, or accumulate
dirt or other sediment that can impede
operation. Cleaning or replacing the
commutator typically corrects the problem.
A47

Worn Bearings
Motor bearings, or devices in a motor that
allow rotational movement between parts,
can also fail due to normal wear and tear.
Worn bearings can cause the armature, or
coil that generates electrical energy via a
magnetic field, to drag on the stator, or
stationary component of the motor,
resulting in a short circuit and starter
motor failure. Replacing the bearings
typically restores normal motor function.
Jammed Gear
A jammed Bendix gear, or gear used to
press into the flywheel ring gear to crank
the engine, often results in a "clunking"
noise when attempting to start the engine.
The jammed Bendix gear, along with the
ring gear and, if damaged, the starter
motor, may need replacement to start the
engine.
Battery cable and its routing :
The battery cable connected to Starter
motor solenoid “B” point should be flexible
and tension should not be there on
terminal. If Battery cable connected with
heavy tension on the terminal leads to
short circuit of terminal, since the terminal
comes out and touches to the solenoid
body. Also it leads to burnt of solenoid
terminal.
Preventive Maintenance Procedures:
The object of preventive maintenance is to
identify and correct potential problems
before they occur.
There are two preventive maintenance
procedures that can greatly enhance the
efficiency of the starting system’s
functions.
These two procedures also represent the
initial steps one should take when fully
BG825
diagnosing (i.e. troubleshooting) a
problem in the vehicle’s starting system.
Engine operating condition.
Keeping the engine in good running
condition is essential to ensure efficient
operation of the starting system. Simply
put, an engine in poor condition is harder
to start, and this shortens the life of the
starter motor. An engine that starts easily
results in fewer turns of the starter motor,
and therefore, a longer life for the starter.
Wires and cables.
For any type of vehicle electrical system,
it‘s important to keep all connection points
clean. Road dirt and grease create
resistance that interferes with electrical
current flow. In order to get the necessary
power from a unit the size of a starter
motor, there must be little or no
resistance between the batteries and the
starter motor. In the same vein, one need
to make sure that wires and cables are
clean, properly tightened, and of the
proper size. Any loss of current due to
poor connections will reduce power of the
starter motor.
Clean all connections on a periodic basis.
Also check for tension on terminals due to
improper routing.
Employing the preventive maintenance
steps we've outlined will be extremely
beneficial to the starting system. There's
also another way to save oneself a lot of
time and wrench work:
Visually inspecting the starting system’s
components for signs of damage.
Diagnostic / Troubleshooting
Procedures
Timely preventive maintenance of the
starting system should keep it running
smoothly.
A48

However, if the starter motor is cranking
slowly, or not at all, it’s time to diagnose
(i.e. Troubleshooting) the starting system.
Any discussion about the electrical system
must begin with the batteries. Before one
begin analyzing, the starting system, one
must be sure the batteries have been
properly tested and are at least 75%
charged. Otherwise, any electrical tests
conducting on the starting system will be
inaccurate.
One must also be aware that if the
batteries aren't being recharged, there
may be a problem in the charging system,
which will lead to starting system
problems Once verified that the batteries
and charging system are working, one can
begin testing the starting system.
When troubleshooting, you always want to
strive for the most easily obtainable
solution and progress toward the most
difficult problems to address.
And remember, when replacing
electrical equipment, always
disconnect all battery ground cables at
the batteries.
Ignition / Run switch test
Begin by determining whether the problem
is in the ignition switch, Safety relay and
associated wiring or if it’s in the solenoid
and starter motor.
We will begin with the ignition switch
circuit. Connect a voltmeter between the
4ST switch terminal of the starter solenoid
and ground see Figure below.
Have someone attempt to crank the
engine and record the voltage. You'll get
either no voltage, low voltage, or normal
voltage, with slow cranking or no cranking
at all.
BG825
IGNITION TEST
First, troubleshoot the switch circuit. You
can test it by connecting a remote start
switch between the battery positive and
the switch terminal on the starter solenoid.
When you close the switch, the starter
should engage and start the engine.
Again, record the voltage while cranking
and compare it to your first reading. A
difference of less than one volt is not
enough to indicate a problem. If there is a
difference of more than one volt, however,
then there is a problem in the switch
circuit.
Use the voltmeter to check each
connection, moving backward through the
switch circuit. If your first test of the
ignition switch had shown low voltage,
that may indicate a shorted starter motor,
which would have to repaired or replaced.
If the voltage in your first test was normal,
but there was slow cranking or no
cranking at all, that would indicate a
problem related to the batteries, battery
cables, or a damaged starter.
4ST Relay / Magnetic switch
The magnetic switch is a sealed unit and
not repairable. For testing of 4ST relay
Disconnect cables from the switch
terminals and wires from coil terminals.
A49

Coil Test
Using an ohmmeter, measure the coil
resistance across the coil terminals.
 The coil should read approximately
10-15 Ohms at 72°F (22.2° C).
 If the ohm meter reads Infinity (∞), the
coil is open and the switch must be
replaced.
 If the ohmmeter reads 0 Ohms, the
coil is shorted and the switch must be
replaced.
Place one of the ohmmeter probes on a
coil terminal and another on the switch
Mounting bracket. If the meter displays
any resistance reading, the coil is
grounded and the switch must be
replaced.
 The ohmmeter should display ¥ when
the probes are placed across the
switch terminals.
NOTE
The switch terminals should show
continuity when 24 VDC is applied to the
coil terminals, however high resistance
across the internal switch contacts due to
arcing etc. could prevent the switch from
delivering adequate current to the
cranking motor. If the coil tests are
satisfactory but the switch is still suspect,
it should be replaced with a new part.
Solenoid test
Although the reasons for low voltage or
normal voltage with slow cranking are
different, the procedures for locating the
problem area are the same. If the solenoid
clicks but the motor won’t turn, it means
current is flowing through the solenoid
coils but not through the main contacts.
Connect the voltmeter to the motor
terminal of the solenoid as per the figure
below .
BG825
If there's no voltage from the motor
terminal to ground (when the solenoid is
activated), that indicates the disc isn't
making contact with the terminals. The
solution is to repair or replace the
solenoid.
Starter motor test
If voltage is present at the solenoid motor
terminal, then the problem is the starter
motor or its cabling.
SOLENOID TEST
If your original test of the ignition (or run)
switch indicated normal voltage, but slow
or no cranking, your next step is to check
the motor system and its connections.
If the drive pinion keeps shifting out of
mesh with the flywheel, then check for a
broken or a loose external ground wire on
the solenoid. Replace a broken wire or
reattach a loose one.
Measure the amp draw with ammeter in
either the positive, see figure below , or
ground cable, see figure below , of the
starter motor while pressing the start
switch. If the amp draw is excessive,
according to the manufactures
specifications, then the starter motor is
faulty. Slow cranking or high current draw
can also indicate that bushings are worn
because of an off-center armature.
A50

Worn bushings and / or and off-center
armature cause poling and throw off the
alignment of the magnetic fields. But,
before you replace the starter, check the
condition of the engine to make sure it
turns freely. An engine in poor condition
could cause the starter to work harder or
longer. In other words, the starter may not
be the problem. It may be damaged by the
engine’s poor condition.
STARTER MOTOR TEST, POSITIVE
CABLE
STARTER MOTOR TEST, NEGATIVE
CABLE
Voltage drop test
Sluggish cranking may be caused by a
very small amount of extra resistance in
the circuit. This may come from dirty
connections or bad or broken cables. With
the voltage drop test, you first must check
BG825
the starter’s positive terminals, then the
negative terminals.
Positive cable test
Connect voltmeter, ammeter, and carbon
pile tester as per figure below . Adjust a
carbon pile load tester until ammeter
reads 500 amps through to the meter.
Note the voltage reading. On 12-volt
system, voltage drop should not exceed0
.4 volts. On a 24 volt system, voltage drop
should not exceed 1 volt. Turn off carbon
pile tester when test is complete. 
POSITIVE CABLE TEST
Negative cable test
Connect voltmeter, ammeter, and carbon
pile load tester as per figure below. Adjust
carbon pile load tester until ammeter
reads 500 amps. Note the voltage
reading. On 12- volt system, voltage drop
should not exceed .4 volts. On a 24 volt
system, voltage drop should not exceed 1
volt. Turn off carbon pile tester when test
is complete.
A51

NEGATIVE CABLE TEST
Solenoid voltage drop test
The final check takes place at the
solenoid terminal. And for this test, you
must crank the engine. Disconnect the
carbon pile load tester, voltmeter (if
applicable), and ammeter so that none of
the testing equipment will be damaged by
the test procedure. An auto ranging digital
voltmeter is useful in this case, as full
battery voltage appears across the
solenoid terminals before they close.
Connect voltmeter as per figure below.
Crank the engine and note the voltage
reading. No more than two-tenths voltage
drop should exist between the solenoid
contacts.
SOLENOID VOLTAGE DROP TEST
BG825
The voltage readings from the three tests
(Positive and Negative cable tests and
Solenoid voltage drop test) must not add
up to more than one volt for a 12 volt
system or 2.5 volts for a 24 volt system.
If the voltage drop is more than allowable,
check the cables and connections. To be
sure the problem is actually a bad cable,
do the voltage drop test over again using
a jumper cable to parallel the original
cable. If the voltage drop is acceptable,
then you know the cable is the problem.
One final note: There are many variations
of grounding the starter circuit. Some
vehicles have a ground cable for the
battery and another ground cable for the
starter motor. Both attach to the frame.
When doing a voltage drop test, you must
check all cables regardless of the circuit.
Starter Replacement
In the event that all of the diagnostic /
troubleshooting procedures point to a
faulty starter, you'll need to replace your
unit with a new starter.
A52
 
 
4. INSTRUMENTS AND 4. Power tilt control lever
CONTROLS 5. Blade rotation control lever

 CONTROL LEVERS AND 6. Drawbar side shift lever

PEDALS 7. Articulation control lever
8. Leaning lever
4.1 WORK EQUIPMENT CONTROL
LEVER 9. Scarified life lever
10. Right blade lift lever
Control levers operate the work
equipment.
4.2 STEERING WHEEL TILT LEVER

This lever is used to tilt the steering wheel

and instrument panel forward or
backward.

Turn the lever to the left to release the

lock, move the steering wheel to eh
desired position, then tighten the lever to
lock in position.

The steering wheel can be adjusted freely

to 20 degrees.

Details are as shown in the Figure 4.1. as

follows:
Always stop the machine before
adjusting the angle of the steering
wheel.

4.3 STEERING POST TILT PEDAL

Depress the pedal and the steering post

can be tilted.

Adjust to give a suitable operating position

for your physique.

Details are as shown in the Figure 4.3. as

follows:

FIGURE 4.1. CONTROL LEVERS

1. Left blade lift lever

2. Ripper lift lever
FIGURE 4.3. STEERING POST TILT
3. Blade side shift lever PEDAL
BG825 A53
 
 
 
4.4 WORK EQUIPMENT CONTROL Fuel control lever (1) is shown in the
LEVER SAFETY LOCK Figure 4.5. as follows.

This is locking mechanism for control

levers.

Mechanical lever lock is shown in the

Figure 4.4. as follows.

FIGURE 4.5. FUEL CONTROL LEVER

4.6 GEAR SHIFT LEVER (&

PARKING BRAKE)

This lever is used to change the

transmission gear.

There are eight gears forward and

reverse, so place the gear shift lever in
the desired position to shift gear.

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

the parking brake applied.

The button on the lever need only be

pressed when shifting the following
positions:


P N N  P 


FIGURE 4.4. CONTROL LEVER SAFETY

LOCK 5 6 6 7 

4.5 FUEL CONTROL LEVER

(BOTH FORWARD AND REVERSE).
This adjusts the engine speed and output.
When starting the engine, the engine will
Engine stop: not start if the gear shift lever is not in the
Lever at S position P position.

Low idling: The parking brake does not work unless

Pull lever from S position to position the staring switch at ON.
where operating force changes.
Gear shift lever (1) is shown in the Figure
High idling: 4.6. as follows
Lever at F position
BG825 A54
 

FIGURE 4.6. GEAR SHIFT LEVER
4.7 INCHING PEDAL
This pedal connects and disconnects the
motive force from the engine, and is used
when stopping or starting the machine, or
when switching between FORWARD and
REVERSE.
Details are as shown in the Figure 4.7. as
follows:
FIGURE 4.7. INCHING PEDAL
When the pedal is depressed, the motive
force is cut off.
In 1st, 2nd, and 3rd speeds, fine control of
the machine is possible using this pedal.
 
BG825
The inching pedal can be used in
Forward and Reverse, but should not
be used for starting in 4th speed or
above.
Continuous use of the inching pedal to
give a partially engaged clutch
condition should be limited to 10
seconds.
 
Never use the inching pedal in this way
continuously for more than 10
seconds. If the inching pedal is used in
this way for more than 10 seconds, the
life of the machine will be markedly
reduced.
4.8 BRAKE PEDAL
The brakes are applied on the four rear
wheels when this pedal is depressed.
Details are as shown in the Figure 4.8. as
follows:
FIGURE 4.8. BRAKE PEDAL
A55
 
 
Details are as shown in the Figure 4.10.
as follows:

Do not put your foot on this pedal

unnecessarily.

4.9 ACCELERATOR PEDAL

This pedal is interconnected with the fuel

control lever. Therefore, the engine is
easily controlled from low idling to full
running by means of the accelerator
pedal, with the fuel control lever held at
low idling position. If the pedal is raised
from low idling position, the engine will
stop.

FIGURE 4.10. DUST INDICATOR

4.11 ARTICULATE LOCK PIN

This pin is used to lock the front frame

and rear frame to prevent the machine
from bending when servicing or
Details are as shown in the Figure 4.9. as transporting the machine.
follows:
Details are as shown in the Figure 4.11.
as follows:

FIGURE 4.9. ACCELERATOR PEDAL

4.10 DUST INDICATOR

This device indicates clogging of the air

cleaner element. When red piston (1) FIGURE 4.11. ARTICULATE LOCK PIN
appears in the transparent part of this  
indicator, the element is clogged.
Immediately clean element.
 
After cleaning, push indicator button (2) to When servicing or transporting the
return red piston to original position. machine always use this lock pin.

BG825 A56
 
For normal traveling, always remove
the lock pin.
4.12 OPERATOR’S SEAT
Adjust the seat position at the beginning
of each shift or when operators change.
C: Seat cushion adjustment
Turn knob (3) to make the seat
comfortable and match your weight.
For LIGHT weight, turn to RIGHT.
For HEAVY weight, turn to LEFT.
D: Seat angle adjustment

Adjust the seat so that the brake pedal Move lever (4) up and push back to adjust
can be depressed all the way with the seat angle (2 stages).
operator's back against the back rest.
E: Backrest adjustment

Pull lever (5), set backrest to desired

position, then release lever.

Adjustment range: 4 stages

Details are as shown in the Figure 4.12.

as follows:

A: Seat height adjustment

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

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

Range of adjustment: 75 mm

B: Forward-backward adjustment
FIGURE 4.12. OPERATOR'S SEAT
Move lever (2) to the left set the seat in
the desired position, then release the
lever.

Range of adjustment:

140 mm (7stages)

BG825 A57
 
 
 
4.13 MCB

The MCB protect the electric devices and The Circuit breaker decal with rating is
wiring from burning out. shown below Figure 4.13.a

Details are as shown in the Figure 4.13.

as follows:

FIGURE 4.13. MCB FIGURE 4.13. CIRCUIT BRAKER

DECAL
Replace a fuse with another of the same
capacity.

Before replacing a fuse, be sure to turn

off the starting switch.

BG825 A58
 
 
 
5. CHECK BEFORE STARTING

The check before starting shall never

be neglected as troubles are prevented
before hand by the check.

 Walk around the machine body and

check whether there is any trace of
leakage of oil or water. In particular,
the joint of high pressure hose and
hydraulic cylinder should be paid
special attention.

 In case leakage is found, inspect the FIGURE 5.1. REFILL COOLANT

leaking location and stop the leakage.
When leakage is not stopped, you are
request to contact BEML service
personnel.

 Inspect the tightening of bolts and nuts

on every section. When loosened
ones are found, apply increased
tightening. In particular, attachment
positions of air cleaner and muffler
should be paid special attention. Do not remove the cap while cooling
water is hot, hot water may spout out.
5.1 CHECK AND REFILL
COOLANT When removing the radiator cap, lift
the lever to relieve inner pressure
Remove radiator cap (1) at the top rear of 5.2 CHECK AND REFILL FUEL
the machine and check that the cooling TANK
water reaches the area marked by shaded
lines. Add water if necessary.  Use fuel gauge to check the fuel
level.
If volume of coolant added is more than
usual, check for possible water leakage.  Top up the tank through the filler after
the day’s work is over.
Details are as shown in the Figure 5.1. as
 A clogged cap breather hole may stop
follows:
the fuel flow to the engine.

 Check it from time to time and clean.

 Fuel capacity : 500 lts

Details are as shown in the Figure 5.2. as

follows:

BG825 A59
 
 
 

FIGURE 5.4. DRAIN WATER FROM AIR

TANK

5.5 CHECK OIL LEVEL IN ENGINE

OIL PAN

 Use dipstick to check the oil level.

 The oil level should be between mark

L and H. If necessary, add oil at oil
FIGURE 5.2. REFILL FUEL TANK
filler (F) .

Details are as shown in the Figure 5.5. as

When adding fuel, never let the fuel
overflow. This may cause a fire. follows:

5.3 DRAIN WATER AND SEDIMENT F

IN FUEL TANK

Loosen fuel tank drain valve and drain

sediment and water accumulated at the
bottom, together with fuel.

5.4 DRAIN WATER FROM AIR TANK

Open drain plugs to drain water after

stopping the engine.

For machines with auto drain valve

Depress the brake pedal several times
and the water in the drain valve will be
drained.

Details are as shown in the Figure 5.4. as FIGURE 5.5. OIL LEVEL IN ENGINE OIL
follows: PAN

BG825 A60
 
 
 
 The type of lubricant used depends on In that case, clean element referring to the
the ambient temperature. Select section “WHEN REQUIRED”.
according to table “FUEL, COOLANT
AND LUBRICANTS". After cleaning element, push button to
return red piston.
 When checking the oil level, park the
machine on a level surface, stop the 5.8 CHECK AND ADJUST TIRE
engine and waits for 15 minutes PRESSURE
before checking. Standard pressure
5.6 CHECK ELECTRICAL WIRING Front wheel : 40 PSI ( 2.81 kg/cm2 )
Rear wheel : 40 PSI ( 2.81 kg/cm2 )
Check for damage of the fuse and any
sign of disconnection of short circuit in the Make sure that tire and rim is free from
electric wiring. Check also for loose wear and damage, and that hub nuts are
terminals and tighten any loose parts. not loose.
Check the following points carefully. 5.9 CHECK AND ADJUST
STEERING WHEEL
 Battery
 Starting motor When checking steering wheel play, start
 Alternator engine and raise front wheels off ground.
The standard steering wheel play is 10 to
12 mm. If the play is beyond standard or
steering is abnormal, contact your BEML
service personnel.
If the fuse is damaged or there is any
sign of short circuiting in the electric
wiring, always, investigate the cause
and correct it.

Contact your BEML service personnel for

investigation and correction of the cause.

5.7 CHECK DUST INDICATOR

When air cleaner element is clogged, the

red piston of dust indicator (1) reaches
service level and gets locked.

Details are as shown in the Figure 5.7. as

follows:

FIGURE 5.9. CHECK AND ADJUST

FIGURE 5.7. CHECK DUST INDICATOR STEERING WHEEL
BG825 A61
 
 
 
5.10 IS RISE IN AIR PRESSURE
NORMAL?

When the pressure inside the air tank is 0,

and air is charged, the time taken for the
air pressure indicator to reach the green
range should be as follows.

Engine low idling: Approx. 3 minutes

Engine full: Within 1.5 minutes

5.11 OTHER CHECK POINTS

 CHECK LAMPS FOR SWITCHING,

DIRT AND DAMAGE.

 CHECK REAR VIEW MIRROR FOR

POSITIONING, DIRT AND DAMAGE.
FIGURE 5.12. WINDSHIELD WASHER
 CHECK FOR DIRT AND DAMAGE
ON REFLECTOR
5.13 CHECK FOR SEDIMENT AND
 CHECK HORN WATER IN THE WATER
SEPARATOR
 IS THE COLOR OF EXHAUST
GAS NORMAL The water separator separates water
mixed in the fuel. If float (2) is at or above
 DO THE INSTRUMENTS red line (1), drain the water.
FUNCTION NORMALLY?

 HAVE ANY DEFECTS WHICH WERE

FOUND DURING THE PREVIOUS
DAY’S OPERATION BEEN
CORRECTED?

 CHECK THE DOOR LOCK FOR

NORMAL FUNCTION.

5.12 CHECK THE WINDSHIELD

WIPER, WINDOW WASHER AND
DEFROSTER FOR NORMAL
FUNCTION. CHECK FOR
SUFFICIENT WASHER FLUID
LEVEL.

FIGURE 5.12. WATER SEPARATOR

If the windshield washer fluid level is
low, add fluid through cap (1). For the draining procedure, see section
“WHEN REQUIRED”

 Check the fuel tank to remove water

and sediment in the fuel.

BG825 A62
 
6. OPERATING YOUR MACHINE 6.2 TO START THE ENGINE

6.1 BEFORE STARTING THE • Set fuel control lever (1) at the HALF
ENGINE OPEN position.

• Before starting the engine, check the

position of all levers.

• Carry out an initial inspection.(For

details of the inspection see CHECK
BEFORE STARING.)

• Is gear shift lever (parking brake) (1)

In the PARKING position and locked?
• Engine will not start unless gear shift
Lever is in PARKING.
• Are work equipment control levers (2)
at the neutral (HOLD) position and
locked with the safety lock?
• To start the engine, put the key (2) to
the START position and turn over the
starting motor.
• As soon as the engine starts. Release
the starting switch key (2) to allow it to
return automatically to ON position.

Details are as shown in the Figure 6.1. as

follows:

Details are as shown in the Figure 6.1. as

follows:

FIGURE 6.1. CHECKS BEFORE

STARTING ENGINE
FIGURE 6.2. TO START ENGINE
BG825 A63
 
 
 Do not leave key in START for more  Avoid sudden acceleration of the
than 20 seconds. engine until the warming up operation
is completed.
 If engine will not start, repeat the
starting procedure after about 2
minutes.  Do not run the engine at low idling or
high idling for more than 20 minutes. If
 To start engine in cold weather refer to it is necessary to run the engine at
COLD WEATHER OPERATION. idling, apply a load from time to time or
raise the engine speed to a midrange
6.2.1 SPECIAL STARTING
speed.
When starting after running out of fuel, fill
6.4 TO STOP THE ENGINE
with fuel, then bleed the air from the fuel
system before starting.
 Idle the engine at low speed for about
5 minutes to cool it.
6.3 CHECK AFTER STARTING

After starting the engine, do not operate
the machine immediately. First carry out
the following operations and checks.
 Pull the fuel control lever (1) and run
the engine at mid range speed for
about 5 minutes with no load.
Details shown in the Figure 6.3. below
 Set fuel control lever (1) to the STOP
position to stop the engine.
It is also possible to release the
accelerator pedal to “STOP” position and
stop the engine.
 Return the starting switch (2) to the
OFF position, and withdraw the key.

Details shown in the Figure 6.4. below

FIGURE 6.3. CHECK AFTER STARTING

 After warm-up run is completed, check

engine water temperature gauge,
engine oil pressure gauge and air
pressure gauge for proper operation.

 Run engine with light load until engine

water temperature gauge indicator
moves into green range.

 Check for normal coloration of

exhaust, any abnormal sound or
vibration.

FIGURE 6.4. TO STOP THE ENGINE

BG825 A64
 
 
 

 Do not attempt to stop a hot engine

immediately unless it is necessary.
Such unreasonable operation will
reduce the life span of the various
engine parts.

 Specially when stopping an

overheated engine, be sure to cool the
engine gradually by idling it at a
middle idling speed.

6.5 TO MOVE THE MACHINE OFF

 Free safety lock of work equipment

levers and bring the work equipment in
the traveling posture.

FIGURE 6.5. TO MOVE THE M/C OFF

 Depress inching pedal (1) and set
gear shift lever (2) to 1st, 2nd and 3rd 6.6 CHANGING GEAR SPEED
speed.
 Acceleration

Partially release the accelerator pedal

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

 Release inching pedal (1), depress

accelerator pedal (3), and the machine
will start.

 Deceleration

Release accelerator pedal (1) to

decrease traveling speed and shift
gear shift lever (2) to the next stepped-
 When starting the machine, check that down position. When shifting gear,
the air pressure monitor is OFF. always shift one speed at a time.

Details shown in the Figure 6.5. below

BG825 A65
 
 
 
Details shown in the Figure 6.7. below

Details shown in the Figure 6.6. below

FIGURE 6.7. FORWARD REVERSE

SHIFTING

6.8 TURNING

The grader turns to the desired side by

turning the steering wheel (1) to that side.

Details shown in the Figure 6.8. below

FIGURE 6.6. CHANGING GEAR SPEED

6.7 FORWARD-REVERSE SHIFTING

Always stop the machine when switching

between FORWARD and REVERSE.

 Depress brake pedal (1) to reduce the

travel speed, then depress inching
pedal (2) to stop the machine.

 Set gear shift lever (3) to the desired

position, then depress accelerator
pedal (4) while slowly releasing
inching pedal (2) to start the machine.
FIGURE 6.8. TURNING
Leaning to the turning side will minimize
the turning radius. In case the grader
turns while reversing, leaning to the
opposite of the turning side will minimize
the turning radius.

BG825 A66
 
6.9 TO STOP THE MACHINE ( IN
EQPT RUNNING CONDITION )
• Release the accelerator pedal (1)
• Depress the brake pedal (2). Before
the machine come to a stop, depress
the inching pedal (3).
Details shown in the Figure 6.9. below
FIGURE 6.9. STOPPING THE M/C
• Place gear shift (parking brake) lever
at the P position to apply the parking
brake.
• Lock safety lock for work equipment
levers.
• Stop the machine on hard and even
ground to prevent it from falling down
or slipping.
BG825
6.10 CAUTIONS FOR OPERATING
HILLS
When traveling downhill, use the same
gear as when going up the hill, and use
the engine as a brake. If the travel speed
is still too fast, use the foot brake as
necessary.
6.11 SLOPES, STEEP HILLS
When the engine comes to a stop during
uphill or downhill traveling.
Depress the brake pedal to stop the
machine.
Return the gear shift lever (parking brake)
to the parking P position and start the
engine.

This machine has two brake control
systems. If one breaks down the other
is still effective. However because
braking capacity is reduced drive
slowly when traveling.

Use the parking brake as necessary to
compensate insufficient effect of the
wheel brake.
Do not shift gear or place the
transmission in neutral when going
downhill. The braking effect of the
engine cannot be used, so this is
dangerous. Always keep the gear shift
lever in a travel position when going
downhill. Failure to do this may result
in engine overrun and damage to the
engine or transmission. To prevent
engine overrun, always shift down one
gear at a time.
6.12 PRECAUTIONS WHEN
STOPPING OR PARKING
MACHINE
When stopping or parking, pay attention to
the following points.
Stop the machine on firm level ground in a
safe place where there is no danger from
falling rocks, landslips or floods. Lower the
A67
 
 
work equipment to the ground, place all  Never use methanol, ethanol or
control levers in NEUTRAL or HOLD and propanol based antifreeze.
lock in place.
 Where no permanent antifreeze is
7. COLD WEATHER available, an ethylene glycol antifreeze
OPERATION without corrosion inhibitor may be
used only for the cold season. In this
7.1 PREPARATION FOR LOW case, clean the cooling system twice a
TEMPERATURE year (in spring and autumn). When
refilling the cooling system, add
If the temperature becomes low, it antifreeze in autumn, but do not add
becomes difficult to start the engine, and any in spring.
the coolant may freeze, so do as follows.
 Absolutely avoid using any water leak
7.2 FUEL AND LUBRICANTS preventing agent irrespective of
whether it is used independently or
Change fuel and oil with low viscosity for mixed with antifreeze.
all systems.
 Do not mix one antifreeze with a
For details of the specified viscosity, see different brand.
the

TABLE OF FUEL, COOLANT AND

LUBRICANTS.
Antifreeze is flammable, so keep it
7.3 COOLANT away from any flame.
After cleaning inside of the cooling 7.4 BATTERY
system, add antifreeze to the coolant to
prevent the coolant from freezing when As ambient temperature drops, battery
the machine is not being used. capacity will drop, and electrolyte may
sometimes freeze if battery charge is low.
 For details of the antifreeze mixture
when changing the coolant, see when Maintain battery at a charge level of
REQUIRED. approx. 100% and insulate it against cold
temperature so that machine can be
Care in using Antifreeze readily started the next morning.
Use a permanent Anti freeze (ethylene Measure specific gravity of fluid and
glycol mixed with corrosion inhibitor, obtain rate of charge from the following
antifoam agent, etc.) meeting the standard conversion table:
requirements as shown below.
Temp of
With permanent antifreeze, no change of Fluid / 200C 00C -100C - 200C
coolant is required for a year. If it is Rate of
Charge
doubtful that available antifreeze meets
the standard requirements, ask the 100% 1.28 1.29 1.30 1.31
supplier of that antifreeze for information. 90% 1.26 1.27 1.28 1.29
Standard requirements for permanent 1.24 1.25 1.26 1.27
80%
antifreeze
75% 1.23 1.24 1.25 1.26
SAE……………………………......….J1034
When electrolyte level is low, add distilled
FEDERAL STANDARD…………………… water in the morning before work instead
O-A-548D of after the day’s work. This is to prevent
fluid from freezing at night.
BG825 A68
 
 
 

To avoid gas explosions, do not bring

fire or sparks near the battery.

If the electrolyte gets on your skin or Necessary preheating time is as follows.

clothes, immediately wash with plenty
of clean water.

7.5 STARTING IN COLD WEATHER

For attention of engine starting, refer to

section “OPERATING YOUR MACHINE”

7.5.1 TO START THE ENGINE

 Set fuel control lever (1) at the HALF Ambient temperature Preheat time
OPEN position.
Above 0 deg cent -
0 deg cent to -10 deg cent 20 seconds
 Place starting key (2) in HEAT position -10 deg cent to -20 deg cent 30 seconds
to flash preheating monitor (3).
 If the preheating time is too short or
Details shown in the Figure 7.5.1 below too long, the engine will be difficult to
start, so always keep to the correct
preheating time.

 When preheating monitor (3) goes off,

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

 When the engine starts, turn key (2) to

the ON position. (When releasing key,
the key will return automatically to
ON.)

FIGURE 7.5.1 STARTING THE M/C IN

COLD WEATHER

BG825 A69
 

 Put the fuel control lever (1) in LOW
IDLING position.
 If the engine does not start up despite
carrying out the above operations,
leave it for about 2 minutes and then
repeat the above procedure 2 and 3.
 Once the engine starts up, thoroughly
warm up the engine before putting the
machine into operation. Initially, put
the gear shift lever in the lowest
position, and then gradually apply the
load.
Never use starting aid fluids as they
may cause explosions.
8. CAUTIONS AFTER
COMPLETION OF WORK
 Mud and water attached on the
machine.
 Mud can easily be removed soon after
it has adhered to the machine Dried or
frozen mud will not only become
difficult to remove, but also cause
various defects.
 In particular, water drops collected on
the surface of the piston rod of the
hydraulic cylinder shall be fully wiped
out. When water drops is frozen on the
surface of the piston rod, the seal may
be broken.
 When washing the machine, be
careful not to throw water on the
alternator and breathers.
BG825
 Drain water collected in fuel system so
that such water may be frozen at
night.
 As battery capacity drops at low
ambient temperature, cover the
battery or remove it from the machine
to be kept warm at night.
(In a machine equipped with auto
drain)
 Depress the brake pedal to purge the
air out of the air system. The brake
pedal may be depressed and released
several times to completely purge the
air.
9. AFTER COLD WEATHER
When weather becomes warm, perform
the following without fail :
Replace lubricating oils for various units
with the ones specified for warm-weather
use.
If for any reason permanent antifreeze
can't be used, and an ethyl glycol base
antifreeze (winter, one season type) is
used instead, or if no antifreeze is used,
drain the cooling system completely, then
clean the inside of the cooling system
thoroughly, and fill with ACF.
10. WORKS TO BE CARRIED
OUT BY A MOTOR GRADER
 Land Grading (Figure 10.1.)
 To level-finish the scraped or turned
up ground, drive the machine in 1st to
2nd with the blade kept at a given
level approx. to the ground. The
scraping angle is set at the standard
angle of 36deg. Take care not to run
over the banking to avoid the machine
pitching, otherwise uneven scraping of
the road face occurs and traction
power will be decreased.
A70
 
 

Take enough caution to obstacles

covered under the snow.

FIGURE 10.1.

 Repairing of Gravel Road (Figure

10.2.)

 When repairing a gravel road, lower

the blade so that it can just touches
the surface of the road and drives the
grader in 1st to 2nd speed range.
Although it is desirable that the
repairing operation should be finished
by a minimum cycle times of travel,
travelling too fast speed may cause
rough finishing of the road.
FIGURE 10.2.
FIGURE 10.3.
 Scarifying (With Scarifier - Option-
Attached) (Figure 10.4.)
 The scarifier (OP) is attached to break
up ground surfaces too hard to be
penetrated with the blade. In this
operation, the scarifier is usually
driven in 1st and 2nd speed range. It
is necessary for the teeth of the
scarifier to penetrate deep into the
ground. If the number of the scarifier
teeth is not adequate to penetrate the
teeth deep into the ground, reduce the
teeth in number so as to allow proper
scarifying. (The number of the scarifier
teeth must be 5 or more).

 Snow removing (Figure 10.3.)

 In the case of fresh snow, set the

blade at the appropriate propulsion
angle and drive the machine with
enough high speed (3rd or 4th gear) as
a throw aside the snow.

 In case of heavy or a thick layer of

snow, drive the machine in 1st or 2nd
gear. The scarifier can also be used
for turning up the snow. The snow in
thrown to one side of the machine

 In cases of extremely heavy snow, the

snow plow attachment (optional) is
more effective

FIGURE 10.4.
BG825 A71
 

 Mixing (Figure 10.5.)
 The blade of the grader is available for
mixing up road construction materials
by its rolling function. In this operation,
the grader should be driven in the 2nd
and 3rd speed range with the blade
forward tilted and slightly angled. Too
great a volume of mixing materials
may prevent sufficient rolling of them.
FIGURE 10.5.
 Spreading (Figure 10.6.)
 The traveling speed of the grader is
most suitable in the 2nd to 3rd speed
range, with the blade sliding, as in the
spreading operation. Avoid changing
its traveling direction unnecessarily
lest the newly flattened surface will be
disturbed by the rear wheels of the
grader. Be careful that the materials
are spread to an adequate thickness.
FIGURE 10.6.
BG825
 Ditching (Figure 10.7.)
 Ditching should be in the 1st to 2nd
speed operation. The blade must
positioned in such a manner that dug
soil is inside the rear wheels. In
addition, be sure to remove the earth
heaped up under the chassis before it
reaches the bottom of the machine,
Lean the front wheels, correspondingly
to the tilt of the machine.
FIGURE 10.7.
 Bank Cutting (Figure 10.8.)
 Adjust the blade to the bank cutting
position at the first speed range.
 To allow the grader to run straight,
lean the front wheels adequately for
the tilt.
FIGURE 10.8.
A72
 
 
11. JOBS EFFECTUATED WITH leaned front wheels and articulated
THE ARTICULATED FRONT front frame). (Figure 11.3.)
FRAME

The motor grader can be effectively

applied to the following jobs with the
articulated front frame.

 When performing land leveling,

repairing of gravel road or snow
removing operation on a narrow and
sharply curved road, the 7.9 m
reduced turning radius of the machine
equipped with the articulated front
frame allows the operator to travel the
machine easily.(Figure 11.1.) FIGURE 11.3.

12. OPERATING OF WORK

EQUIPMENT

12.1 OPERATION METHOD OF THE

WORK EQUIPMENT CONTROL
LEVER

There are provided ten work equipment

control levers, which are operated as are
indicated in the following figures. (Figure
12.1.a. & 12.1.b.)

FIGURE 11.1.

 During land leveling, allowing the front

wheels to run on the previously
leveled track adjacent to the trank
being leveled is effective in minimizing
the vertical. Vibration of the machine,
thus increasing the smoothness of the
finished ground surface. (Figure 11.2.)

FIGURE 11.2.
 By concurrent use of blade side shift
and front wheel offset, road corners
are made easy for operations(with
FIGURE 12.1.a.
When operating the work equipment
control lever, sufficient attention is
required for the movement of the work
equipment and its movement range must
be limited, as the work equipment or the

BG825 A73
 
 
 
hydraulic cylinder possibly hit against  Blade and step (Figure 12.2.c)
parts, damaging them.

FIGURE 12.2.b
12.2 CAUTIONS IN OPERATION OF
WORK EQUIPMENT
When the work equipment is operated,
special attention should be given to
contacts at the following parts.
 Front wheel and blade (Figure 12.2.a.)
FIGURE 12.2.c.
13. ADJUSTMENT IN SHIFTING
OF WORK ATTACHMENT
It is essential to shift the work attachment
to an optimum position for each work, to
allow high job efficiency.
13.1 BLADE PROJECTION
The degree of projection is controllable by
the control lever during operation. If
further projection is needed, stop the
grader for a while and change the
installing position of the blade horizontal
shifting cylinder piston rod, as follows.
(Figure 13.1.)

Projection to right Position (1)

FIGURE 12.2.a.

 Rear wheel and blade (Figure 12.2.b.)

FIGURE 13.1.

FIGURE 12.2.b.
BG825 A74
 

13.2 PROPULSION ANGLE OF
BLADE
Angle of blade and body center line is
called the blade propulsion angle.
In the normal scraping work, set the angle
at 600 more or less. Set at a lesser angle
when the scraping resistance is great, or
when the soil is hard, or when the soil in
front of the blade is difficult to carry or
throw to the side.
13.3 ADJUSTMENT OF BLADE
CUTTING ANGLE
This machine is equipped with a power tilt
blade, so the blade cutting angle can be
varied freely in the following range.
Installation of this power tilt blade gives
the following advantages.
 Optimum blade cutting angle can be
obtained by operating the control lever
for soil quality.
 Since the cutting edge can be set to
the desirable angle, a powerful
BG825
breaking is available to cut the frozen
surface during snow removal.
 If the blade is operated with the
hydraulic tip control, the distance
between the cutting edge and the
excavation surface changes. This
means that fine adjustment of the
excavation surface is possible.
 In the low-banking position when
raising the dirt and snow, the optimum
blade cutting angle can be selected to
increase operating efficiency.
13.4 BANK-CUTTING POSTURE
(RIGHT SIDE)
 Fully protrude the blade drawbar to the
right.
 Place lifter lock switch in RETRACT
position on the operator’s
compartment to remove pin .
 If the pin cannot be removed
because of interference with lifter ,
operate the blade lift cylinders as
necessary.
 Extend the right hand blade cylinder
and retract the left hand cylinder,
rotate lifter, and move the bracket hole
and pin apart.
 Place lifter lock switch at the INDEX
position, turn lifter further and insert
pin into the bracket hole.
 When the pin has entered the hole, set
lifter lock switch to the LOCK position.
A75
 
 
 Retract the right hand lift cylinder and Drawbar and lifter (Figure 13.4.a.)
extend the left hand cylinder. Repeat
this several times so that the circle is
rotated with the blade raised on the
right hand side, and desired bank-cut
posture can be attained.

 When bringing the blade into bank

cut posture on the left-side of the
machine, change every “left-hand”
and “right-hand” in the above
mentioned description with each
other.

 When bringing the blade into bank-

cut posture, be careful not to clash
the blade against various portions FIGURE 13.4.a.
of the machine.
Drawbar and frame (Figure 13.4.b.)
Details shown in the Figure 13.4. below

FIGURE 13.4.b.

13.5 SHOULDER REACH POSTURE

(RIGHT SIDE)

 Rotate the lifter in a similar manner to

the bank cutting posture, and lock it
using the bank control lock pin.

 Rotate the circle to the desired

position.

 Put the machine in the left hand side

FIGURE 13.4. shoulder reach posture using the
same procedure as the above.

 When increasing the size of the

Always lower the blade to the ground
before removing the bank control lock
pin. If the blade is raised, it may rotate
and fall.
BG825
shoulder reach, change the mounting
position of the piston rod of blade
horizontal feed cylinder.
(Refer to the section on blade thrust.)
A76

 The banking performance is improved,
if the mounting position for the piston
rod of the blade horizontal feed
cylinder is changed as follows:
 When banking to right, to a position
where the blade is thrusted left.
 When banking to left, to a position
where the blade is thrusted to right.
13.6 OPERATION OF THE BLADE
ACCUMULATOR (OPTIONAL)
 Lower the blade to the ground and
stop the engine. Turn the starting
switch to the ON position to supply
power to the electric circuits, then turn
on the accumulator switch. Next, move
the R.H. and L.H. blade lift levers
forward and backward to release the
residual pressure in the accumulator
and the hydraulic circuits.
 Turn off the accumulator switch, and
then start the engine.
 Next, extend the R.H. and L.H. blade
lift cylinders about 50 mm. (At this
time, holding pressure is produced at
the bottom of the blade lift cylinders.)
 Turn on the accumulator switch to
operate the accumulator. The oil in the
bottom of the R.H. and L.H. blade lift
cylinders will flow into the
accumulator, both blade lift cylinders
will shorten, and the front wheels will
lower to the ground.
At this time, a pressure is maintained
at the bottom of the blade lift cylinders,
that is, a pressure acts on the blade.
When the machine is operated under
this condition, the blade can follow a
difference in ground level of about
50mm, which is the standard operation
when an accumulator is in use.
BG825
In actual operation, the blade lift
cylinder levers will move properly so
that the blade can follow the required
difference in ground level with the
proper pressing force.
Once the accumulator is set and the
machine is started, the blade lift levers
do not need to be operated. When
stopping the work for a time, the
accumulator can be reset to the same
Condition as before stopping the work
by turning off the switch, lifting the
blade, lowering it to the ground again,
and turning on the switch again.
13.7 FEATURES OF THE BLADE
ACCUMULATOR (OPTIONAL)
Ease of work
 The blade does not need to be
operated.
 This work does not require a lot of
skill.
Safety and protection
 Shocks are reduced.
 The machine is protected from buried
objects. (The machine runs over
projecting objects.)
Improved steering performance
 Steering performance on curves is
improved.
 Side slips on curves are reduced.
 Steering performance with the leaning
system is improved.
 Side slips made while using the
leaning system are reduced.
 Trouble with front wheels (floating or
unstable wheels) is eliminated.
A77
 
 
Improved workability

 The pressing force of the blade is

improved.

 The relief of the blade is improved.

14. REVERSING AND

REPLACEMENT OF CUTTING
EDGE AND END BIT

Replace cutting edges and end bits

before their blade’s end faces wear out.
When wear is extended to the
mounting faces, their repair must be
done prior to replacing.

14.1 TURNING AND REPLACING
 Lift the blade to a suitable height and
put a block underneath the blade rail
to prevent its falling.
 Mount the cutting edges after inverting
it, or replacing it with a new one.
 The tightening torque for the mounting
nuts is 40 to 54 kgm.

 Tighten the nuts again after several

hours’ operation.

 If both ends of the cutting edge and

side edges are worn out, replace them
with new ones.

14.2 REPLACING RIPPER POINT

 Drive out the pin with a bar and

hammer, and remove the point

 Fit a new point to the shank and drive

in the pin. The pin can be reused.

Do not raise the blade unnecessarily

high. Be sure not to put your body
underneath the blade when blocking it

 Clean the mounting face after

detaching the cutting edge and the
end bit.

BG825 A78
 

15. CHANGING TIRES
15.1 HOW TO CHANGE TIRES
 Front wheel
 Lower the work equipment to the
ground set the gear shift parking brake
lever to the P Position to apply the
parking brake.
 Then, attach the socket wrench
(accessory machine tool) to the hub
nuts and loosen all the hub nuts by 3/4
to 1 turn.
 Depress the lift cylinder. If the front
tires are lifted, lock the control lever,
remove the hub nuts and change all
the tires.
Details shown in the Figure 15.1.
FIGURE 15.1.
BG825
 In installing new tires, tighten lightly
with the tires lifted and tighten the tires
to the specified torque in the order
shown in the photos, after placing the
tires on the ground.
 Tightening torque :
225+25 kgm
Whenever the front tires are raised off
the ground, support the front axle
center frame on the block to assure
safety.
 Rear wheel
 Repeat the front wheel change
procedures 1) and 2).
 Depress fully the right and left lift
cylinders and the front tires are lifted
about 50 cm off ground. Retract the lift
cylinder on the side where the tire is
not removed, to lift rear wheels.
Install new tires according to the
procedure 4) of the wheel tire change.
 Tightening torque:
225+ 25 kgm
Whenever the rear wheels are raised
off the ground, stably support the
tandem on the block to assure safety.
16. HOW TO USE LEANING
STOPPER
When a front tire punctures, do not
attempt to travel the machine by
temporarily applying a pad to the swing
stopper. If it is necessary, travel the
machine slowly only within the minimum
necessary distance. In this case, be sure
to securely keep the punctured tire off the
ground with chains, etc.
A79
 
 
When the leaning pipe is damaged,
temporarily prevent the front wheels from
leaning so that the machine can be
successfully self-propelled to the nearest
repair shop.

How to apply the leaning stopper

FIGURE 17.1.

 Be careful to keep a clearance

between the blade and front tires.

 If the machine is articulated with the

blade at the minimum propulsion
angle, the blade will damage step.
Fix the leaning rod (2) to the front axle
17.2 WAY TO INSERT SHACK WHEN
using the bolts (1) provided in the tool
TRANSPORTING
box.
The way to insert the shank when
transporting is as shown in the diagram
below.

If the machine is traveled with the Install the shank that comes in the center
leaning cylinder piston rod fluctuating of the ripper body with the point facing to
or the front wheels leaning on one the rear, or install it in a position other
side, because of damaged leaning than the center.
piping, dangerously unstable steering
and excessively worn tires will result.
Have the faulty leaning pipe repaired
by mechanics quickly.

17. DRIVING ALONG ROAD

In addition to strict observance of traffic

laws and rules concerned, keep the
following in mind:

17.1 POSITION OF BLADE WHEN

TRAVELING

When travelling, raise the blade fully and Do not install the shank in the center of
set it so that it does not extend outside the the ripper body with the point facing
machine. (Figure 17.1.) forward. The shank may damage the
ripper cylinder.

17.3 ARTICULATED OPERATIONS

When performing operations with the

machine articulated, remove the lock link
on the left side of the machine.
BG825 A80
 
 
 
The machine can be articulated 250 to
both right and left, giving a minimum
turning radius of 7.9m.

 Remove the snap pin (1), then pull out

pin (2).

 Put the removed lock pin (1) in the pin

case under the operator’s cab and fix
the lock pin to the case with the
removed pin and snap pin (2).
(Figure 17.3.)
FIGURE 18.1.a

 If the electrolyte temperature exceeds

45 degree Cent, stop charging for a
while.

 Turn off the charger as soon as the

battery is charged.

Overcharging the battery may cause

followings:
FIGURE 17.3.
a) Over heating the battery
17.4 PRECAUTIONS WHEN
TRAVELING ON ROADS b) Decreasing the quantity of
electrolyte.
To relieve operator’s fatigue, take a rest
by 30 minutes – 1 hour – 30 minutes c) Damaging the electrode plate.
mode, every 80 kilometers or every 2
hours of traveling (whichever term expires  If the electrolyte gets on your skin or
earlier). clothes, immediately wash with plenty
of clean water.
18. HANDLING OF BATTERY  Do not mix up cables (positive (+) to
negative (-) or negative (-) to positive
18.1 PRECAUTIONS FOR CHARGING (+), as it will damage the alternator as
BATTERY shown in the Figure 18.1.b.
 Before charging, disconnect the cable
from the negative (-) terminal of the
battery. Otherwise, an unusually high
voltage will damage the alternator.

 While charging the battery, remove all

battery plugs for satisfactory
ventilation.

 To avoid gas explosions, do not bring

fire or sparks near the battery as
shown in the Figure 18.1.a. FIGURE 18.1.b

 When inspecting or servicing a

battery, be sure to stop the engine and

BG825 A81
 

turn. The starting switch key to “OFF”
position.
 When performing any service to
battery besides checking the
electrolyte level or measuring the
specific gravity, disconnect cables
from the battery.
18.2 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. Details shown in the
Figure 18.2.
 When installing battery, the ground
cable should be connected to the
ground terminal as the last step.
FIGURE 18.2.
18.3 STARTING ENGINE WITH A
BOOSTER CABLE
When starting up the engine with a
booster cable do as follows:
Before connecting the booster cable
a) Size of booster cable and clip
should be suitable for the battery
size.
b) Check cables and clips for breaks,
corroded surfaces, etc.
BG825
c) Make sure cables and clips are
firmly secured.
d) Keep the starting switch key in
OFF position.
e) The battery of the running engine
must be the same capacity as that
of engine to be started.
Connect the booster cables in the
following manner.
a) Connect one clip of booster cable
A to the positive (+) terminal of the
engine to be started.
b) Connect the other clip to the
positive (+) terminal to the engine
which is running.
c) Connect one clip of booster cable
B to the negative (-) terminal of the
engine which is running.
d) Connect the other clip to the body
of the machine to be started.
 Make sure the clips are firmly
connected to battery terminals.
Then, start the engine.
Mark sure that the booster cable
connections are correct. Connect the
booster cable to the body as far as
possible from the battery.
Details are shown below in Figure 18.3.a.
FIGURE 18.3.a.
A82

When connecting the cables, never
contact the positive (+) and negative (-)
terminals.
Starting the engine
 Turn the starting switch key to START
position and start up the engine.
 If the engine doesn’t 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.
Disconnecting the booster cables
a) Disconnect the clip of booster cable B
from the body of the machine which
was started.
b) Disconnect the other clip from the
negative (-) terminal of the running
engine.
c) Disconnect the clip of booster cable A
from the positive (+) terminal of the
running engine.
d) Disconnect the other clip from the
positive (+) terminal of the engine
which was started.
Details are shown below in Figure 18.3.b.
FIGURE 18.3.b.
BG825
19. TOWING
19.1 TOWING THE MACHINE
This machine must not be towed except in
emergencies. When towing the machine,
take the following precautions.
If there is a failure in the air circuit, the
brakes cannot be used, so be
extremely careful when towing.
 When engine can be used.
 Always keeps the engine running
when towing the machine, so that the
steering and braking can be used.
 When engine cannot be used.
 When transporting a disabled machine
by towing, the transportation distance
should be within 600 m at a speed of 8
km/h or less. (When towing more than
600 m, remove the drive shaft.)
 If the distance is more than the above
mentioned, or if more than one day
has elapsed since the engine trouble,
be sure to use the trailer for
transportation.
 If the machine is towed without the
engine running, on lubrication oil will
be supplied to the transmission. The
gears and bearings are rotated, so this
may cause them to be damaged.
 If leakage in the air circuit has caused
the pressure inside the air tank to
drop, the parking brake will be applied.
When towing the machine, release the
parking brake.
19.2 RELEASING PARKING BRAKE
If the pressure in the air tank drops below
2.4 kg/cm2, the parking brake is applied
automatically. Therefore, when towing the
machine, release the parking brake as
follows.
A83

Turn bolt (1) and the parking brake will be
released.
Stop the machine on a flat surface when
releasing the parking brake, and check
that the surroundings are safe. In
emergencies or when the parking brake
must be released on a hill, block the tires
carefully before releasing the brake.
20. TRANSPORTATION
In addition to strict observance of traffic
laws and rules concerned, it is desirable
to provide a special platform for loading
and unloading of the motor grader. If it is
necessary to use a ramp when loading a
motor grader on a trailer or unloading it
from a trailer, observe the following
instructions to assure safety:
 Securely brake the trailer and chock
trailer tires. Securely fix the ramp
boards in place so that the center of
motor grader being loaded coincides
with the center line of the trailer.
 Width, length and thickness of ramp
boards must large enough to assure
safe loading and unloading of the
motor grader.
 Remove all the mud from the
undercarriage to prevent the machine
from slipping to the side on hilly roads.
 Slowly travel the motor grader on the
ramp straight.
BG825
Never attempt to change the direction
of travel on the ramp. If it is necessary
to change the direction of travel, once
return the machine to the original
position.
Remove the mud form the under
carriage to prevent the machine from
slipping to the side on slopes.
 Properly load the motor grader on the
trailer at the specified position. To
prevent the grader on the trailer from
moving back and forth during
transportation, apply a chock to front
and rear of each wheel and fix the
motor grader with chains and wire
ropes. Pay special care to prevent the
motor grader from slipping sideward.
 Rest the work equipment on the trailer
deck and observe the following:
Place the gear shift lever in the parking
position.
Place work equipment control lever in hold
position.
Apply safety locks.
Pull the staring switch key out.
 Determine the optimum transportation
route, taking width of road and
permissible overhead clearance and
weight limitation into consideration.
 Lock the articulation lock pin in the
same way as for normal travel.
 Lock the articulation lock pin in the
same way as for normal travel.
A84

Do not leave the front wheels raised off
the trailer deck using the brad as a
jack. The front wheels will fall gradually
during transportation.
When loading the machine, choose a
firm level road surface. Be sure that
you are well clear of the road shoulder.
 When transporting this machine,
check with your BEML service
personnel for advice.
21. EMERGENCY STEERING
SYSTEM
21.1 FUNCTION
This system acts to prevent steering
failure caused by a breakdown in the
engine or hydraulic pump when the
machine is being operated.
If the pressure in the steering hydraulic
circuit goes below 7 kg/cm2, the pressure
switch is turned ON, and the electric
motor is actuated to turn the hydraulic
pump and supply hydraulic pressure to
the steering circuit to make it possible to
operate the steering.
However, if the machine is traveling at
less than 1 km/h (0.62mph) (including
when the machine is stopped), the
steering is not automatically actuated.
The emergency steering motor must
not be operated continuously more
than 30 seconds.
BG825
21.2 CHECKS
 WHEN REQUIRED
 Check that AUTO/MANUAL selector
switch is at the AUTO position.
 Start the engine and raise the front
wheels of the ground with the blade.
 Normally keep the AUTO / manual
selector switch at the AUTO position.
 Stop the engine. Be sure to leave the
starting switch at the ON position.
 Turn the AUTO/MANUAL selector
switch to the “MANU” position.
 When the switch is operated, check
that the alarm buzzer sounds
continuously and that the electric
pump for the emergency steering is
operated.
 Turn the steering wheel and check
that the steering can be operated
without problem.
 When checking above points, do not
continue the check for more than 30
seconds.
 Turn the AUTO/MANUAL selector
switch to the AUTO position and check
that the monitor and warning lamps go
out, and that the electric pump for the
emergency steering stops working.
 If any abnormality occurs, turn the
starting switch to the OFF position to
stop the whole system.
A85
 
 

When checking the emergency

steering or when actuating the system
in emergencies, the level of the oil in
the auxiliary tank may go down. Check
the oil level in the auxiliary tank and
always keep the level in the auxiliary
tank above 2/3. When checking, fill the
tank.
 EVERY 500 HOURS SERVICE

 Start the engine, and drive the

machine with the engine at full throttle.

 Depress the inching pedal, and move

the fuel control lever to the ENGINE
STOP position to stop the engine.

 Check that the alarm buzzer sounds

continuously, that monitor lamp (1)
and central warning lamp flash, and
that the electric pump for the
emergency steering is operated when
the engine stops.

 Depress the brake to stop the

machine, and check that all the items
actuated in Step 3 stop.

 Do not continue the check in Step 3

for more than 30seconds.

BG825 A86
 
 SECTION - B

MAINTENANCE
 
 
 

Section B
MAINTENANCE
INDEX

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

1. 1. PERIODIC MAINTENANCE B3
2. 2. PRECAUTIONS FOR MAINTENANCE B3
2.1. General B3
3. 3. DURING MAINTENANCE B4
4. PERIODICAL REPLACEMENT OF SAFETY
4. B6
PARTS
5. 5. OIL FILLER AND LEVEL GAUGE POSITIONS B7
6. 6. LUBRICATION CHART B8
7. 7. MAINTENANCE TABLE B9
7.1.  Every 50 Hours Service B12
7.2. Every 250 Hours Service B19
7.3. Every 500 Hours Service B21
7.4. Every 1000 Hours Service B22
7.5. Every 2000 Hours Service B24
7.6. When Required B25
7.6.1 Clean inside of cooling system B25
7.6.2 Check, clean and replace Air cleaner B26
element
7.6.3 Electrical intake air heater B28
7.6.4 Clean condenser of Air Conditioner B29
7.6.5 Water separator B29
8. 8. ADJUSTMENT B29
8.1. Adjustment of Inch Pedal B29
9. 9. TROUBLE SHOOTING GUIDE B30
9.1. Engine B30
9.2. Chassis B31
9.3. Electrical system B32
9.3.1 Trouble shooting for Murphy B33
9.3.1.1 Overview B33
9.3.1.2 Power View 750 Display B34
9.3.1.3 I/O Module B37
9.3.1.4 Troubleshooting B39
10. 10. STORAGE B43
10.1.  Before storage B43
10.2. During storage B43
10.3.  After storage B43
11. 11. MACHINE AND ENGINE SERIAL NUMBERS B43

BG825 B1
 
 
 
NOTES:

BG825 B2
 
 
 
MAINTENANCE

1. PERIODIC MAINTENANCE

Proper lubrication and maintenance

assure trouble-free operation and long
machine life. Time and money spend for
scheduled periodic maintenance will be
amply compensated by prolonged
machine operation and reduced operating
cost. FIGURE 2-1. WORK AS PER
INSTRUCTION
All hourly figures given in the following
descriptions are based on service meter Do not handle electrical equipment while
readings. In practice, however, it is wearing wet gloves, or in wet places, as
recommended to review and convert this can cause electric shock as shown in
some / all of them into units of days, the Figure below 2-2.
weeks and months to make the
maintenance schedule more convenient
for day to day monitoring under hostile
operating conditions, it may be necessary
to review and shorten the maintenance
intervals.

2. PRECAUTIONS FOR
MAINTENANCE

2.1 GENERAL

Wear well-fitting helmet, safety shoes and

working clothes. When drilling, grinding or
FIGURE 2-2. HANDLE ELECTRICAL
hammering, always wear protective
EQUIPMENT CAREFULLY
goggles.
During maintenance do not allow any
Fuel or oil is dangerous substance. Never
unauthorized person to stand near the
handle fuel, oil grease or oily clothes in
machine.
places where there is any fire of flame. As
precaution in case of fire, always know the
Exhaust gas is dangerous. When working
location and directions for use of fire
inside, be particularly careful to have good
extinguishers and other fire-fighting
ventilation as shown in the Figure below
equipment.
2-3.
Always stop the engine before cleaning
the machine or adding fuel.

When working with other, choose a group

leader and work according to his
instruction. Do not perform any
maintenance beyond the agreed work as
shown in the Figure below 2-1.

FIGURE 2-3. PROPER VENTILATION

BG825 B3
 

Unless you have special instructions to
the contrary do not do maintenance,
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 as shown
in the Figure below 2-4.
FIGURE 2-4. PROPER PROCEDURE
FOR MAINTENANCE
While one person sitting in the operator's
seat and the other one performing the
maintenance never touch any moving
part.
Always remember that the hydraulic oil
circuit is under pressure. When feeding or
draining the oil or carrying out inspection
and maintenance release the pressure
first. The procedure for releasing the
hydraulic pressure is as follows: lower the
blade and scarifier (option) to the ground,
and stop the engine; move the control
levers to each position two or three times
and then slowly loosen the oil filter cap as
shown in the Figure below 2-5.
FIGURE 2-5. HYDRAULIC OIL UNDER
PRESSURE
BG825
Always use BEML genuine parts for
replacement.
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.
When checking or changing the oil, do it in
a place free of dust, and prevent any dirt
from getting into the oil.
3. DURING MAINTENANCE
Parking the machine on firm, flat ground.
Lower the blade and scarifier (option) to
the ground stop the engine. Return the
gear shift lever to "NEUTRAL", apply the
brake lock and set each control lever to
"LOCK" When maintenance has to be
carried out with the blade and scarifier
(option) raised, they must be securely
supported by blocks.
Thoroughly wash the machine. In
particular be careful to clean the filler caps
grease fittings and the area around the
dipsticks.
Be careful not to let any dirt or dust in to
the system.
Hang a caution sign in the operator's
compartment (for example "Do not start"
or "Maintenance in progress) this will
prevent anyone from starting or moving
the machine by mistake as shown in the
Figure below 3-1.
FIGURE 3-1. HANG CAUTION WHILE
DOING MAINTENANCE
Flame should never be used instead of
lamps. Never use a naked flame to check
B4
 
 
leaks or the level of oil, fuel, anti-freeze or When the strainer is located in the oil filter,
electrolyte as shown in the Figure below the strainer must not be removed while
3-2. adding oil.

When adding oil or checking the oil level,

check that the oil is at the correct level.
After greasing up, always wipe off the old
grease that was forced out.

When changing the oil or filter, check the

drained oil and filter for any signs of
excessive metal particles or other foreign
materials.

When removing parts containing O-rings,

FIGURE 3-2. AVOID FLAMES
gaskets or seals, clean the mounting
surface and replace with new sealing
Immediately remove any oil or grease on
parts.
the floor of the operator’s compartment, or
on the handrail. It is very dangerous if
When the work equipment is raised for
someone slips while on the machine.
inspection or repair, always place blocks
When check an open gear case there is a underneath to prevent falling as shown in
risk of dropping things in. Before removing the Figure 3-4.
the covers to inspect such cases, empty
everything from your pockets. Be
particularly careful to remove wrenches
and nuts as shown in the Figure 3-3.


FIGURE 3-4. PLACE BLOCKS
UNDERNEATH

When the machine is jacked up, always

put chocks against the wheels on the
opposite side. After jacking up, place
blocks to prevent the machine from falling
  as shown in the Figure 3-5.

FIGURE 3-3. KEEP TOOLS PROPERLY

Before draining the oil, warm up it to a
temperature 20 to 40 degree centigrade.

Be particularly careful when removing the

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

After replacing oil, filter, element or

strainer, bleed the air from the circuit. FIGURE 3-5. WHILE MACHINE IS
JACKED UP

Disassembly, repair and assembly of tires

require special equipment and high skill.
BG825 B5
 
 
 
Always consult a specialized tire repair 4. PERIODICAL REPLACEMENT
shop as shown in the Figure 2-11. OF SAFETY PARTS

Periodic replacement of safety parts

should be done to maintain the safety
standards.

Parts with passage of time have a greater

FIGURE 3-5. WHILE REPLACING TIRES
tendency to deteriorate in quality.
Furthermore their defective condition is
difficult to detect during periodic
maintenance. These parts must be
therefore replaced with the new ones after
a predefined interval even though there is
no abnormality. If any abnormality is found
parts must be replaced before the
predetermined period expires.

Always lock the front and rear frames
before inspecting and servicing the
machine. (Inarticulate frame model).
When handling the cutting edges always
wear gloves.
Periodical replacement is completely
different from the replacement due to the
claim against the guarantee by the
manufacturer so they must be treated
separately.

Special measuring apparatus is needed

for testing hydraulic pressure.

Remove the negative terminal from the

battery in maintaining the electrical
system.

The users of our machine should carry out

periodical maintenance in order to ensure
the working and operation safety as
shown in the Figure 3-6.

FIGURE 3-6. CARRY OUT PERIODIC

MAINTENANCE

When carrying out other difficult

maintenance works, carrying them out
carelessly can cause unexpected
accidents. If you consider the
maintenance is too difficult, always
request the BEML service personnel to
carry it out.
BG825 B6
 
 
 
5. OIL FILLER AND LEVEL
GAUGE POSITIONS

1. Cooling water inlet 4. Cooling water drain valve

2. Transmission case drain plug 5. Tandem drive case drain plug
3. Engine oil pan oil filler and level gauge 6. Circle reverse gear case oil filler and
drain plug.
BG825 B7
 
 
 
6. LUBRICATION CHART

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

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

ENGINE OIL SAE 15W40 SAE 15W40

C
TRANSMISSION OIL CD SAE 30W CD SAE 30W
A
HYDRAULIC OIL CD SAE 10W CD SAE 10W
B
LITHIUM BASE GREASE NLGI,GRADE#2 NLGI,GRADE#2
L
MULTI PURPOSE GEAR OIL GO SAE 90 GO SAE 140
F

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

NO. OF
SL. NO. DESCRIPTION LUBEKEY SERVICE
POINTS 250 500 1000 2000
50
1 CIRCLE GUIDE L 6 GREASE

2 BLADE GUIDE RAIL (SMEAR) L 2 GREASE

3 DRAW BAR BALL JOINT L 1 GREASE

4 BANK-CUT CONTROL BRACKET L 2 GREASE

5 BLADE LIFT CYLINDER BALL YOKE L 6 GREASE

6 BLADE LIFT CYLINDER BALL JOINT L 2 GREASE

7 DRAW BAR SIDESHIFT CYLINDER JOINT L 2 GREASE

8 POWER TILT CYLINDER PIN L 1 GREASE

9 RIPPER LINKAGE PIN (OP) L 8 GREASE

10 RIPPER CYLINDER PIN(OP) L 3 GREASE

11 LEANING CYLINDER PIN L 1 GREASE

12 TIE ROD L 2 GREASE

13 STEERING CYLINDER L 4 GREASE

14 LEANING PIN L 2 GREASE

15 LEANING ROD PIN L 2 GREASE

16 CENTER PIN L 1 GREASE

17 KING PIN L 6 GREASE

18 ARTICULATION CYLINDER PIN L 4 GREASE

19 PROPELLER SHAFT L 2 GREASE

19A HITCH PIN L 2 GREASE

19B CONSOLE TILT BRACKET L 2 GREASE

19C POWER TILT CYLINDER MTG. BRACKET L 2 GREASE

20 ENGINE OIL PAN C 1 CHECK CHANGE

21 OIL CASE TRANSMSSION A 1 CHECK CHANGE

22 OIL CASE FINAL DRIVE A 1 CHECK CHANGE

23 TANDEM DRIVE CASE A 2 CHECK CHANGE

24 HYDRAULIC OIL B 1 CHECK CHANGE

25 OIL CASE WORM GEAR F 1 CHECK CHANGE

26 FRONT WHEEL SPINDLE BEARING OIL A 2 CHECK CHANGE

27 ENGINE OIL FILTER CARTRIDGE 1 CHANGE

28 CENTRIFIGAL OIL FILTER 1 $

29 MAIN FUEL FILTER CARTRIDGE 1 CHANGE

30 PRE FUEL FILTER CARTRIDGE 1 CHANGE

31 TRANSMISSION FILTER ELEMENT 1 CHANGE

32 HYDRAULIC OIL FILTER ELEMENT 1 CHANGE

33 CRANK CASE BREATHER **

BG825 B8
 
 
 
7. MAINTENANCE TABLE

No. Item Service

CHECK BEFORE STARTING
a. Oil and water leak Check
b. Nuts and bolts Check and retighten
c. Electric wiring Check and retighten
d. Coolant Check and Supply
e. Fuel Check and Supply
f. Fuel tank Drain water and sediment
g. Air tank Drain water
h. Engine oil pan Check and Supply
I Dust indicator Check
j. Tire pressure Check and adjust
k. Steering wheel play Check
l. Air pressure Check
m. Lamps Check
n. Rear view mirror Check
o. Reflector Check
p. Horn Check
q. Exhaust gas cooler Check
r. Instruments Check
s. Previous day’s defects Check
t. Door lock Check
u. Wiper, window washer and defroster Check
v. Water separator Inspect float position
EVERY 50 HOURS SERVICE
a. Greasing
1. Circle Guide Greasing 6 points
2. Blade Guide Rail (Smear) Greasing 2 points
3. Draw Bar Ball Joint Greasing 1 point
4. Bank - Cut Control Bracket Greasing 2 points
5. Blade lift cylinder yoke Greasing 6 points
6. Blade lift cylinder ball joint Greasing 2 point
7. Draw bar side shift cylinder joint Greasing 2 points

BG825 B9
 
 
 
No. Item Service
8. Power tilt cylinder pin Greasing 01 point
9. Ripper linkage pin (op) Greasing 8 points
10. Ripper cylinder pin (op) Greasing 3 points
11. Leaning cylinder pin Greasing 1 point
12. Tie rod Greasing 2 points
13. Steering cylinder Greasing 4 points
14. Leaning pin Greasing 2 points
15. Leaning rod pin Greasing 2 points
16. Centre pin Greasing 1 point
17. King pin Greasing 6 point
18. Articulation cylinder pin Greasing 4 points
19. Propeller shaft Greasing 2 points
19a. Hitch pin Greasing 2 points
19b. Console tilt bracket Greasing 2 points
19c. Power tilt cylinder mtg. Bracket (op) Greasing 2 point
20. Engine Oil Pan Check Engine Oil
21. Oil Case Transmission Check Transmission Oil
22. Oil Case Final drive Check Oil
23. Tandem Drive Case Check Oil
24. Hydraulic Oil Check Hydraulic Oil
25. Oil Case Worm Gear Check Multi Purpose gear oil
26. Front Wheel Spindle Bearing Oil Check Oil
INITIAL 250 HOURS SERVICE
a. Engine oil pan Change Oil
b. Engine oil filter Cartridge Change Oil
c. Centrifugal Oil Filter Clean and Replace paper insert
d. Main Fuel Filter Cartridge Change Oil
e. Pre Fuel Filter Cartridge Change Oil
f. Crank Case Breather Check and Clean
g. Oil Case Transmission Change
h. Oil Case Final drive Change
i. Tandem Drive Case Change
j. Hydraulic Oil Change

BG825 B10
 
 
 
No. Item Service
k. Oil Case Worm Gear Change
l. Hydraulic Oil Filter Element Change
EVERY 250 HOURS SERVICE
a. Engine oil pan Change Oil
b. Engine oil filter Cartridge Change Oil

Filters to be cleaned by removing sediments &

c. Centrifugal Oil Filter
Replace paper insert

d. Main Fuel Filter Cartridge Change Oil

e. Pre Fuel Filter Cartridge Change Oil
f. Crank Case Breather Check and Clean
EVERY 500 HOURS SERVICE
a. Transmission Filter Element Change
EVERY 1000 HOURS SERVICE
a. Oil Case Transmission Change
b. Oil Case Final drive Change
c. Tandem Drive Case Change
d. Hydraulic Oil Change
e. Oil Case Worm Gear Change
f. Hydraulic Oil Filter Element Change
EVERY 2000 HOURS SERVICE
a. Front Wheel Spindle Bearing Oil Change Oil
WHEN REQUIRED
a. Cooling system Clean

Check, clean or replace when required

b. Air cleaner
Note: To be replaced along with the inner
element after 6 times of cleaning

c. Electrical intake air heater Check

d. Air condenser Clean
e. Water separator Drain water

BG825 B11
 
 
 
7.1. EVERY 50 HOURS SERVICE

 Greasing -:  Draw Bar Ball Joint (1 point)

In every 50 hours the below points should Grease all over the part
be greased properly.
Check ball joint connecting nuts at the
 Circle Guide (6 points) front of the drawbar for loosening. If the
connecting portions are loose, retighten
Grease all around the circle part. them.

Details shown in the Figure 7.1.1. Details shown in the Figure 7.1.3.

FIGURE 7.1.1.
FIGURE 7.1.3.
 Blade guide rail (2 points)
 Bank - Cut Control Bracket (2 points)
Apply grease all over the guide rail
Grease all over the part
Details shown in the Figure 7.1.2.
Details shown in the Figure 7.1.4.

FIGURE 7.1.2. FIGURE 7.1.4.

BG825 B12
 

 Blade lift cylinder yoke (6 points)
Grease all over the part.
Details shown in the Figure 7.1.5.
FIGURE 7.1.5.
 Blade lift cylinder ball joint (2 points)
Grease all over the part.
Details shown in the Figure 7.1.6.
FIGURE 7.1.6.
BG825
 Draw bar side shift cylinder joint
(2 points)
Grease all over the part
Details shown in the Figure 7.1.7.
FIGURE 7.1.7.
 Power tilt cylinder pin (1 point)
Grease all over the part
Details shown in the Figure 7.1.8.
FIGURE 7.1.8.
B13
 
 
 Ripper linkage pin (op) (8 points)  Leaning cylinder pin (1 point)

Grease all over the part Grease all over the part

Details shown in the Figure 7.1.9. Details shown in the Figure 7.1.11.

FIGURE 7.1.9. FIGURE 7.1.11.

 Ripper cylinder pin (op) (3 points)  Tie rod (2 points)

Grease all over the part Grease all over the part
Details shown in the Figure 7.1.10. Details shown in the Figure 7.1.12.

FIGURE 7.1.12.
FIGURE 7.1.10.

BG825 B14
 
 
 
 Steering cylinder (4 points)  Leaning rod pin (2 points)

Grease all over the part Grease all over the part

Details shown in the Figure 7.1.13. Details shown in the Figure 7.1.15.

FIGURE 7.1.13. FIGURE 7.1.15.

 Leaning pin (2 points)  Centre pin (1 point)

Grease all over the part Grease all over the part

Details shown in the Figure 7.1.14. Details shown in the Figure 7.1.16.

FIGURE 7.1.14.

FIGURE 7.1.16.

BG825 B15
 
 
 
 King pin (6 points)  Hitch pin (2 points)

Grease all over the part Grease all over the part

Details shown in the Figure 7.1.17. Details shown in the Figure 7.1.19a.

FIGURE 7.1.17.
 Articulation cylinder pin (4 points)
Grease all over the part
Details shown in the Figure 7.1.18.
FIGURE 7.1.19a.
 Console tilt bracket (2 points)
Grease all over the part
Details shown in the Figure 7.1.19b.

FIGURE 7.1.18. FIGURE 7.1.19b.

 Propeller shaft (2 points)  Power tilt cylinder mtg. Bracket (op)

(2 points)
Grease all over the part Grease all over the part

Details shown in the Figure 7.1.19. Details shown in the Figure 7.1.19c.

FIGURE 7.1.19. FIGURE 7.1.19c.

BG825 B16
 
 
 
 Checking -:

In every 50 hours the below points should

be checked properly.

 Engine Oil Pan

Check the Engine Oil Pan

Details shown in the Figure 7.1.20.

FIGURE 7.1.21.

 Oil Case Final drive

Check the oil level with oil level gauge. If

necessary, and oil through filler .

The type of lubricant used depends on the

ambient temperature. Select according to
the table “FUEL, COOLANT AND
LUBRICANTS".

Details shown in the Figure 7.1.22.

FIGURE 7.1.20.

 Oil Case Transmission

Check the oil level with oil level gauge five

minutes after stopping the engine.

If necessary, add oil through filler . FIGURE 7.1.22.

The type of lubricant used depends on the
ambient temperature.
Select according to the table “FUEL,
COOLANT AND LUBRICANTS”.
Details shown in the Figure 7.1.21.
BG825
 Tandem Drive Case
Check the oil level with oil level gauge. If
necessary, add oil through filler .
The type of lubricant used depends on the
ambient temperature.
B17
 
 
Select according to the table “FUEL,
COOLANT AND LUBRICANTS.”

Details shown in the Figure 7.1.23.

2. Close valve (1).

3. Loosen oil filler port slowly and release

the air inside the hydraulic tank
completely.

4. Check the oil level with oil level gauge.

Add engine oil through filler , if
necessary.

The type of lubricant used depends on the

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

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

valve (1).

FIGURE 7.1.23. Details shown in the Figure 7.1.24

 Hydraulic Oil

1. Set the machine in position as follows

to check the oil level.

 Return the leaning of the front tires

to the upright position and face the
wheels straight to the front.

 Set the front frame and rear frame

facing straight (articulated angle).

 Return the drawbar side shift and

blade side shift to the center of the
machine, set the blade at right
angles to the chassis and lower it
lightly to the ground. FIGURE 7.1.24.

 Raise the scarifier fully.

BG825 B18
 

 Oil Case Worm Gear
Check the Oil Case Worm Gear
Details shown in the Figure 7.1.25.
FIGURE 7.1.25.
 Front Wheel Spindle Bearing Oil
Check the Front Wheel Spindle Bearing
Oil.
Details shown in the Figure 7.1.26.
FIGURE 7.1.26.
BG825
7.2. EVERY 250 HOURS SERVICE
 Changing -:
In every 250 hours the below items should
be changed .
 Engine oil pan
Change the Engine Oil
Before draining the oil, warm up to a
temperature 20 to 40 degree centigrade.
Loosen drain plug to drain oil after
draining, tighten it.
The type of lubricant used depends on the
ambient temperature. Select according to
the table “FUEL, COOLANT AND
LUBRICANTS”.
Refill capacity: 34 lts.
Details shown in the Figure 7.2.1.
FIGURE 7.2.1.
B19

Use API category CD class oil. If CC class
oil must be used, change the oil and
replace the oil filter at half the usual
interval.
 Engine oil filter Cartridge
If filter cartridge is removed immediately
after stopping the engine, oil will spill. Wait
at least 10 minutes after stopping the
engine before replacing the filter cartridge.
Change the Engine Oil filter cartridge
using the tool provided, rotate cartridge
element counterclockwise. Fill the new
cartridge with clean oil and refit it after
applying a dab of oil to the gasket face.
Be careful not to tighten cartridge up
excessively.
After replacing the cartridge fill engine oil
through oil filler.
Then idle the engine for a while, and use
dipstick to check oil level.
Be sure to use a genuine cartridge.
Details shown in the Figure 7.2.2.
FIGURE 7.2.2.
BG825
 Main Fuel Filter Cartridge
Using the tool provided, rotate cartridge
element counterclockwise.
Fill the new cartridge. With clean fuel and
refit it after applying a dab of oil to the
gasket face.
To refit the cartridge, place the gasket
face in contact with the seal face of the
filter stand, then screw up the cartridge
1/2 to 3/4 of a turn (be careful not to
tighten it up excessively.)
After replacing the cartridge, slacken off
air vent plug .
Loosen feed pump knob and move the
pump up and down to draw off fuel until air
ceases to come out of vent plug.
Tighten air vent plug, push feed pump
knob into place, and tighten it.
 After replacing the cartridge, start up
the engine and check the filter seal
face for possible fuel leakage.
 Be sure to use a genuine BEML
cartridge.
Details shown in the Figure 7.2.3.
FIGURE 7.2.3.
B20
 
 
 Pre Fuel Filter Cartridge  Crank Case Breather

Change the Pre fuel filter cartridge Check and clean -

Details shown in the Figure 7.2.3. In every 250 hours Crank Case breather
should be checked and cleaned.

If required replace 'O'- Ring

Details shown in the Figure 7.2.5.

FIGURE 7.2.3.

 Centrifugal Oil Filter

Clean and Replace Paper Insert -

In every 250 hours Clean Centrifugal Oil FIGURE 7.2.5.

filter by removing sediments and replace
paper insert. 7.3. EVERY 500 HOURS SERVICE

Details shown in the Figure 7.2.4.  Changing -:

In every 500 hours following element to be

changed.

 Transmission Filter Element

Change the transmission filter element.

Remove bolts fastening the filter case,

remove case.

Remove the element and discard.

Thoroughly clean the case interior and

removed parts.

Install a new element.

FIGURE 7.2.4.
Use a genuine element.

If required replace 'O'- Ring

BG825 B21
 
 
 
Details shown in the Figure 7.3.1. Details shown in the Figure 7.4.1.

FIGURE 7.3.1.

7.4. EVERY 1000 HOURS SERVICE

 Changing -:

In every 1000 hours below to be changed.

 Oil Case Transmission

Change the transmission oil by removing

drain plug. After draining oil, tighten drain
plug. FIGURE 7.4.1
Take out strainer and wash out dust with
 Oil Case Final drive
diesel fuel.
After draining oil through drain plug hole,
After cleaning it, install strainer.
refill the gear oil through filler up to the
Refill transmission oil in specified amount prescribed level.
through filler (F).
For the refilling procedure, see the item
For the refilling procedure, see the item “ Initial 250 hour’s service.”
“ Initial 250 hour’s service.”
The type of lubricant used depends on the
The type of lubricant used depends on the
ambient temperature. Select according to
ambient temperature. Select according to
the table “FUEL, COOLANT AND the table “FUEL, COOLANTAND
LUBRICANTS”. LUBRICANTS”.

Refill capacity : 35 lts. Refill capacity : 57 lts.

BG825 B22
 
 
 
Details shown in the Figure 7.4.2. Details shown in the Figure 7.4.3.

FIGURE 7.4.2.

 Tandem Drive Case

FIGURE 7.4.3.
Change the Tandem oil Drive Case as
below.
 Hydraulic Oil
After draining oil through drain plug hole.
Change the Hydraulic oil as below.
Refill the oil (SAE 30W) up to the
Loosen oil filler port slowly to completely
prescribed level through the gauge hole .
release the air inside the hydraulic tank.
For the refilling procedure, see the item
Set the container under drain plug to catch
“ Initial 250 hour’s service.”
the oil.
The type of lubricant used depends on the
To prevent getting oil on yourself, loosen
ambient temperature. Select according to
drain plug and drain the oil. To prevent the
the table “FUEL, COOLANT AND
oil from spurting out, loosen drain plug,
LUBRICANTS”
then gradually remove it.

Refill capacity: 95 lts. (each side) After draining the oil, tighten drain plug.

For the refilling procedure, see the item

“ Initial 250 hour’s service.”

BG825 B23
 
 
 
The type of lubricant used depends on the Details shown below in Figure 7.4.6.
ambient temperature. Select according to
the table “FUEL, COOLANT AND
LUBRICANTS”

Refill capacity: 80 lts.

Details shown in the Figure 7.4.4.

FIGURE 7.4.6.

7.5. EVERY 2000 HOURS SERVICE

 Front Wheel Spindle Bearing Oil

Change the Front Wheel Spindle bearing

FIGURE 7.4.4. oil.

 Oil Case Worm Gear Details shown below in Figure 7.5.

Change Oil in the Oil case worm gear.

Details shown below in Figure 7.4.5.

FIGURE 7.5.

Maintenance for every 50, 250, 500,

1000 and 2000 hours should be carried
out at the same time.
FIGURE 7.4.5.

 Hydraulic Oil Filter Element

Change Hydraulic oil filter element.

BG825 B24
 
 
 
7.6. WHEN REQUIRED

7.6.1 CLEAN INSIDE OF COOLING Check the coolant for any traces of oil
SYSTEM during daily maintenance.

Maintenance : Do not remove strainer from radiator filler

tube.
Follow the below instructions for
maintaining (particularly during cold
season) the cooling system.

 
Radiator cap is always to be fitted. This
will avoid dust collection, coolant loss and Antifreeze is flammable, so keep it
system pressure loss. away from any flame.

Clean / wash radiator fins periodically.

Periodicity to be determined based on the
usage and site condition.

Sharp tools should not be used for

cleaning tubes / fins as it may puncture
them.

If anticorrosive solution or antifreeze

solution is used, always keep extra
solution ( water + antifreeze or
anticorrosive ) in a container so that any
loss of coolant during day to day operation
could be replenished easily.

Check leakage of coolant during engine

‘ON’ and ‘OFF’ condition.

Avoid switching off the engine unless

there is leakage of coolant or any
abnormality.

Change the coolant at least once in a

year.

Observe the coolant temperature rising

rate. This will give an indication about the
cooling system problem.

Radiator (top tank) should not be filled up

to the mouth. It should be filled only up to
the filler neck. The empty space is meant
for coolant expansion and de-aeration.

BG825 B25
 
 
 
ANTI CORROSION FLUID DRAIN VALVE ( BOTTOM OF
RADIATOR)
BEML Anti corrosion fluid is being
recommended for all equipment fitted with Open drain valve at the bottom of the
BEML engines. radiator and plug on the side of cylinder
block to drain off the cooling water.
The details of the concentrate along with  
other recommendations are appended
below:

ACF-ALP: Anti corrosion fluid aluminum

protection.

ACF-ALP (EGB): Anti corrosion fluid with

aluminum protection. (Ethylene glycol
based)

The details of the concentrate along with

recommendations are appended below.

ACF-ALP: Colour of diluted solution:

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

The PH value of the mixture (water +

concentrate) has to be maintained  
between 7.5~9.5 (Check through pH
paper). Do not remove the cap while cooling
water is hot. Hot water may spout out.
Depending on the quality of raw water
used, an additional concentration of
concentrate beyond 1:10 may be required.
 
Before filling the radiator with the anti-
corrosion fluid the radiator has to be When removing radiator cap, lift the
flushed completely with clean water. lever to relieve inner pressure.

WATER FILLER
7.6.2 CHECK, CLEAN AND REPLACE
Radiator water filling is done from the cap AIR CLEANER ELEMENT
shown below.
Checking

When the dust indicator (1) shows red the

air cleaner element needs cleaning.

Details shown in the Figure 7.6.2.

RADIATOR WATER FILLING CAP

BG825 B26
 

FIGURE 7.6.2.
 Cleaning and replacing the outer
element
1. Loosen clamp (1) and remove the
Cover (2) and outer element.
2. Clean the inner body and the cover.
3. Clean and check the outer element
(Following pages) and reattach.
4. Press the dust indicator button and
return the red piston to its place.
 Replace the outer element which
has been cleaned 6 times repeatedly
or used throughout the year.
 Replace the inner element at the
same item.
 Replace seal washer (4) or wing nut
(3) if they are broken.
Details shown in the Figure below.
BG825
AIR CLEANER ELEMENT
 Replacing inner element
1. First remove the cover and the outer
element, and then remove the inner
element.
2. Cover the air inlet port.
3. Clean the air cleaner body interior.
Remove the cover from the air inlet
port.
4. Install a new inner element and
tighten it with nuts.
5. Install the outer element and the
cover. Push the dust indicator reset
button.
 Replace both inner and outer
elements when the dust indicator red
piston appears soon after installing
the cleaned outer element even
though it has not been cleaned 6
times.
B27

 Check inner element mounting nuts
for looseness and, if necessary,
retighten.
NOTE: Do not attempt to reinstall a
cleaned inner element.
Do not clean or replace the air cleaner
element with the engine running.
 Cleaning outer element
 With compressed air
Use correct air jet and avoid excess air
pressure ( less than 7 kg/cm.²)
 
When using compressed air, wear
safety glasses and other things
required to maintain safety.
The following methods require spare
parts.
 With water
2
Splash city water ( less than 3 kg/cm ) on
element from 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.
BG825
 Drying can be speeded up by
blowing dried compressed air ( less
than 7 kg/cm2 ) from the inside to
the outside of the element.
 Never attempt to heat the element.
 Using warm water (about 40 deg
centigrade) instead of soapy water
may also be effective.
 If small holes or thinner parts are
found on element when it is checked
with an electric bulb after cleaning
and drying, replace the element.
 If element is usable, wrap it and
store it in dry place.
 Do not use element whose folds or
gasket or seal are damaged.
 When cleaning element, do not hit it
or beat it against something.
7.6.3 ELECTRICAL INTAKE AIR
HEATER
Check electrical intake air heater (1) once
a year before commencing work in the
cold season.
Remove electrical intake air heater (1)
from the engine intake connection, and
check it for possible open-circuits and dirt.
When inspecting and replacing electrical
intake air heater (1), replace the gasket
with new one.
Details in the Figure 7.6.3.
FIGURE 7.6.3.
B28

7.6.4 CLEAN CONDENSER OF AIR
CONDITIONER
Pull knob (1), remove filter (2), and clean
it. Details in the Figure 7.6.4..
FIGURE 7.6.4.
7.6.5 WATER SEPARATOR
The water separator separates water
mixed in the fuel. If the float is at or above
the red line, drain the water.
 Even though water separator is
installed, be sure to check the fuel
tank to remove water and sediment in
the fuel.
Water separator is shown in Figure 7.6.5
FIGURE 7.6.5.
BG825
When float (2) is at or above red line (1),
drain the water according to the following
procedure:
 Loosen drain plug (3) and drain the
accumulated water until the float
reaches the bottom.
 Tighten drain plug (3).
 If the air is sucked into fuel line when
drain the water, be sure to bleed air in
the same manner as for the fuel filter.
(See Fuel Filter Cartridge in EVERY 250
HOURS SERVICE section.)
8. ADJUSTMENT
8.1 ADJUSTMENT OF INCHING
PEDAL
When any abnormal pedal condition such
as mentioned below is noticed, consult
your BEML service personnel for
checking, readjustment or repair of the
inching pedal system.
At full engine speed, the machine moves
when the inching pedal (1) is depressed
and the gear shift lever (2) is placed in the
forward 1st speed position (The parking
brake is left released.) Details shown in
the Figure 8.1.
FIGURE 8.1.
B29

These abnormal conditions concerning
inching pedal operation are sometimes
caused by transmission troubles.
Therefore, careful inspection of faulty
conditions must be made by your BEML
service personnel not only about the
inching pedal control system, but also
about the transmission.
9. TROUBLE SHOOTING GUIDE
This guide is not intended to cover to
cover every conditions, however many
of the more common possibilities are
listed.
9.1 ENGINE
Oil pressure gauge pointer will not
return to its original position, when the
engine is shut down and Oil pressure
gauge pointer fluctuates abnormally.
 Defective oil pressure gauge.
 Insufficient oil in oil pan.
Oil pressure gauge pointer stays within
the red range on dial.
 Insufficient oil in oil pan.
 Oil leakage due to damaged piping,
 Loose piping joints or connections.
 Defective oil pressure gauge.
 Oil leakage from full-flow filter.
Steam spurts out through the pressure
relief valve on the radiator.
 Insufficient coolant or coolant leakage.
 Loose fan belt.
 Clogged radiator fins or damaged fins
 Defective coolant temperature gauge.
 Defective thermostat or its seal.
 Leaky thermostat seal.
Coolant temperature gauge pointer
stays in the red range on dial during
engine running.
 Defective thermostat.
 Defective coolant temperature gauge.
BG825
 Clogged radiator fins or damaged fins.
 Defective fan belt/tension
 Rise in oil temp. of power train.
 Lack of coolant.
Engine fails to start.
 Insufficient fuel in fuel tank.
 Air in fuel line.
 Insufficient torque of starting motor to
crank up engine.
 No fuel in fuel filter.
 Poor battery condition
Engine does not start when the starting
motor is operated.
 Check for sufficient fuel.
 Check for air leaks in the fuel system.
 Check whether fuel filters have
choked.
 Replace the injection pump or the
nozzle.
 Check the valve clearance.
 Check engine compression pressure.
 Use cold starting aid where required.
Engine emits white or blue-white
exhaust gas.
 Excessive oil in oil pan.
 Improper fuel use.
 Oil leaks in turbocharger.
Exhaust gas occasionally turns black.
 Clean or replace the air cleaner
element.
 Check & replace the FIP nozzle.
 Check engine compression pressure.
Engine emits black exhaust smoke.
 Clogged air cleaner elements.
 Worn cylinder components.
 Failure of turbo charger.
 Excessive injection of fuel.
B30

Engine runs but operates erratically
(Hunting)
 Air in fuel supply lines.
 Defective governor mechanism.
Engine knocks.
 Use of improper fuel.
 Overheat.
 Excessive usage of air heater.
 Improper FIP timing.
Fuel sometimes stops flowing.
 Strainer in fuel feed pump clogged.
 Breather in fuel tank clogged.
 Leak of fuel
 Air entry in the fuel system
Engine stops during operation or does
not take load.
 Insufficient supply of fuel.
 Clogged fuel filter.
 Clogged feed pump strainer.
 Leakage from fuel piping.
 Breather in fuel tank clogged
Engine does not pickup smoothly.
 Insufficient intake of Air
 Insufficient supply of fuel.
 Improper condition of fuel injection
system.
 Improper fuel used.
Abnormal wear of fuel system
components (sub-zero operating
condition).
 Improper fuel (poor lubricity of fuel).
 Premature clogging of fuel filters due
to fuel gel formation.
 Excessive water in the fuel.
BG825
9.2 CHASSIS
Tractive force is lacking. ( Insufficient
travel speed )
 Refer to the section of engine.
 Check transmission.
 Release parking brake lever.
If machine falls to start at any gear shift
lever position.
 Add oil to transmission case.
 Check and adjust transmission.
Loud noise in the power transmitting
system
Add oil to transmission case and tandem
case.
Excessive wear of front wheels
 Adjust toe-in.
Heat generation at front wheel hub
 Adjust wheel bearing installation nut.
 Apply grease.
Front wheel sway while traveling
 Adjust toe-in and tie rod.
 Replace steering linkage.
 Equalize tire pressure on each side
 Check wheel installation.
 Retighten front wheel bearing
installation nut.
Steering wheel feels heavy
 Check front tire pressure.
 Apply grease on each bearing.
 Adjust ball joint of pitman arm.
 Repair piping.
B31

Parking brake does not operate
satisfactorily
 Adjust brake pad.
 Polish lining surface with sandpaper.
 Disassemble and clean brake drum.
Excessive blade swing during work
 Adjust shims of ball joint and circle
guide.
 Replace side bushing.
 Correct blade rail.
Excessive vibration of the blade when
rotating during work
 Adjust radial clearance of the circle.
Work equipment is slow to move by
operating the control lever
Add the oil to the specified level.
Wear of parking brake lining
Adjust clearance of lining.
9.3 ELECTRICAL SYSTEM
Lamp does not glow brightly even
when engine runs at high speed.
Lamp flickers while engine runs.
 Check for loose terminals and open-
circuit wiring.
 Adjust belt tension.
Charge monitor does not go out even
when engine runs at high speed.
 Replace the charge lamp.
 Replace the alternator.
 Inspect and repair wiring.
Unusual noise is emitted from
alternator
BG825
 Replace the alternator.
Starting motor does not turn when
starting switch is turned on.
 Inspect and repair the wiring.
 Charge the battery.
The pinion of the starting motor keeps
going in and out.
Charge the battery.
Starting motor turns the engine sluggishly.
Charge the battery.
Replace the starting motor.
The starting motor disengages before the
engine start up.
 Check and repair the wiring.
 Charge the battery.
The engine pre-heating monitor does not
flash.
 Check and repair wiring.
 Replace the heater relay.
 Replace the monitor.
Charge monitor does not light up when
the engine is stationary.
(When the starting switch is in ON
position.)
 Replace the monitor.
 Inspect and repair the wiring.
Outside the electrical intake air heater is
not warm when torched with the hand.
 Check and repair wiring.
 Replace the electrical intake air
heater.
 Check and repair the heater switch.
B32
 
 
9.3.1 TROUBLE SHOOTING FOR MURPHY

9.3.1.1 Overview

BG825 B33
 
 
 
9.3.1.2 Power View 750 Display

a. Connections

 
 
BG825 B34
 
 
 
Only connection A is used with the following connections
 
1 VBATT + Red
2 CAN High Yellow
3 CAN low Green
4 - -
5 Ignition White/Purple
6 VBATT - Black

b. Display

Active gauges Screen – I

Screen – II

BG825 B35
 
 
 
Inactive Gauges

IN ACTIVE STATE

BG825 B36
 
 
 

9.3.1.3 I/O Module

Connections – Manual Engine and Gearbox

BG825 B37
 
 
 

Power and CAN

The 12 way connector has the following connections

Pin 1 Battery Positive Red

Pin 2 Battery negative Black
Pin 3
Pin 4
Pin 5 Mute (if fitted) White/black
Pin 6 Buzzer (if fitted) Grey
Pin 7 CAN high Yellow
Pin 8 CAN low Green
Pin 9 Clock supply White/Purple
Pin 10
Pin 11
Pin 12

Analogues

The analogue inputs are connected to 24 way part of the 64 way connector
Please refer to the individual vehicle connection diagram for senders that are
fitted.

Digitals

The digital inputs are connected to 40 way part of the 64 way connector
Please refer to the individual vehicle connection diagram for senders that are
fitted.

BG825 B38
 
 
 

9.3.1.4 Troubleshooting

a. Display

 
Power up display 
  Ignition on 

Check Supply to PV750 display pins 1 
Buttons lit  No  (+ve), 6 (‐ve) and 5 (+ve with IGN on) 
and display 
 
on? 

Yes 
Check CAN connections to PV750 display 
pin 2 – CAN high 
All gauges  Yes  pin 3 – CAN low 
inactive?   
 

No 

All Engine  Yes  Electronic  Yes Check CAN connection to 

gauges  Engine  engine ECU 
inactive  Check engine ECU 

Check Battery negative 
No  No connection to engine 
Go to 4.2.1

All Gearbox  Yes  Electronic   Yes

Check CAN connection to 
gauges  Gearbox  engine ECU 
inactive  Check engine ECU 

Check battery negative 
No  connection to gearbox 
No
Go to 4.2.1
One gauge  Yes 
or symbol  Go to 4.2.1
inactive 

End 
No 

BG825 B39
 
 
 
b. I/O module

Check individual 
gauges/symbols 
 

 
 
 
c. I/O unit  No 
connectors  Tighten connectors 
tight 

Yes 

Analogue  Yes  Resistive  Yes Remove connection to 

input?  Sender?  sender and connect to 
battery negative (ground) 

No
Go to 4.2.4  Is DM1 for  No
Yes  Frequency  input  FMI 4? 
Go to 4.2.2 
sender?

No Yes
Yes  4‐20mA  Remove connection to 
Go to 4.2.3 
sender? sender and leave 
disconnected

Yes Is DM1 for 
Fit known suitable resistance to input input FMI 3? 

No

Reading  No Check wiring 
correct  Check input is active in 
profile

Yes 

Replace sender 

BG825 B40
 
 
 
Frequency

Frequency 
  sender? 
 
  Yes 
 
  Inject frequency signal 
   
 
 
  No Check wiring
Gauge 
  Check input is active in profile 
operational
Replace I/O module 

Yes 

Replace MPU

 
 
 
 
  4‐20mA 
  sender 
 
  Yes 
 
  Disconnect sender and 
  connect wire to ground 
 
 
  No Check wiring 
  DM1  Check if input is active in profile 
  SPN/FMI?  Replace I/O module 
 
  Yes 
 
  Replace Sender
 
 
 
 
 
BG825 B41
 
 
 
d. Digital inputs

D1‐D7?  Yes With input active check battery 

positive is present at switch 

No 
Yes Check wiring 
Battery 
 Check if input is active in profile
positive?
Replace I/O module 
 
No

D8‐D32  Check wiring
Replace switch 

Yes 

Close to  Yes Disconnect sender and connect 

negative  to battery negative 

No 
No
Check wiring 
Sender is open from negative  Correct  Check if input is active in profile
Disconnect sender  operation Replace I/O module 

Yes

Change switch 

  Correct  No Disconnect 40 way connector 
  operation  on I/O module 
  l / d l
 
Yes 
  No Check if input is active
Change switch
    Correct 
operation Replace I/O module 
 
 
  Yes
 
Check wiring 
 
 
 
 
 
 
 

BG825 B42
 
 
 
10. STORAGE

10.1 BEFORE STORAGE

To place the machine in storage for an
extended period of time, the following
measures must be taken to insure that it
can be returned to operation with
minimum of service.
After every part is washed and dried, the
machine shall be housed in a dry building.
Never leave it outdoors.
In case it is indispensable to leave it
outdoors, lay wood plates on the ground,
and park the machine on the wood plates
and cover it with canvas etc.
Completely fill fuel tank. Lubricate and
change oil before storage.
Lower the air pressure in the tires to about
80% of the standard operating pressure.
Give a thin coat of grease to metal surface
(hydraulic piston rods and oil seal).
As to batteries, remove the terminals and
place cover on them, or remove them from
the machine and store separately.
In case the atmospheric temperature may
drop below 00C, add antifreeze in the
cooling water.
Set the gear shift lever to neutral position,
set the fuel control lever to engine stop
position, and leave the steering pedal not
locked.
When it is unavoidably necessary to
carry out rust preventive operation
indoors, open all windows and doors to
circulate the air and prevent the
accumulation of poisonous gases.
10.3 AFTER STORAGE
Carry out the following procedure when
taking the machine out of long term
storage.
Wipe off grease on the hydraulic piston
rod.
Completely fill fuel tank, lubricate and add
oil.
If the machine is stored without carrying
out the monthly rust prevention operation,
request your BEML service personnel.
11. MACHINE AND ENGINE
SERIAL NUMBERS
When calling for service of mechanic or
when making replacement parts order, be
sure to give your BEML service
personnel the machine and engine serial
numbers as well as the service meter
reading before mentioned.

10.2 DURING STORAGE

Operate the engine and move the

machine for a short distance once a
month so that new oil film will be
generated and exhaustion of oil film in a
long period will be prevented.

Before using work equipment, wipe off the

grease from the pressure cylinder rod.

 
 
 

BG825 B43
 
 
 SECTION - C

SPECIFICATION
 
 Section C
SPECIFICATIONS
INDEX

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

1. 1. BG825DETAILS C3
1.1. Performance C3
1.2. Weight C3
1.3. Engine C3
1.4. Axles C3
1.5. Steering C3
1.6. Blade Range C3
2. 2. BG825 LAYOUT C4

BG825 C1
 
 

NOTES:

BG825 C2
 
 
 
SPECIFICATIONS
1. BG825 DETAILS

1.1. PERFORMANCE

 Travel speed (In Km/hr)

Forward

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

4.0 5.4 8.0 11.5 15.8 21.4 31.3 44.9

Reverse

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

4.3 5.8 8.5 12.2 16.9 22.8 33.4 47.9

Maximum Drawbar Pull : 14,420kg

1.2. WEIGHT

Operating weight 25,750 kg

1.3. ENGINE

Model: BS6D140-1

Rated rpm 2100 rpm

Horse power 280 hp

Staring motor 24V,7.5 KW

1.4. AXLES

Oscillation angle: 32deg

Front Wheel Leaning : 18deg (each side)

1.5. STEERING

Minimum turning radius 7.9 m

Maximum steering angle 50 deg left and right of front wheels

1.6. BLADE RANGE

Maximum Bank cutting angle 90deg

BG825 C3
 
 
 
2. BG825 LAYOUT
(UNIT: mm)

BG825 C4
 
 SECTION - D

FUEL AND LUBRICANTS

 
 
 

Section D
FUEL AND LUBRICANTS
INDEX

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

1. 1. PROPER SELECTION OF FUEL AND D3
LUBRICANTS

BG825 D1
 
 
 

NOTES:

BG825 D2
 
 
 
FUEL AND LUBRICANTS

1. PROPER SELECTION OF FUEL AND LUBRICANTS

* ASTM D 975 No. 1

Note:

 When fuel sulphur content is less * ASTM : American Society of

than 0.5 % change oil in the oil pan Testing and Material
every periodic maintenance hours
described in this manual. * SAE : Society of Automotive
Engineers
 Change oil according to the following
table if fuel sulphur content is above * API : American Petroleum
0.5 % Institute

BG825 D3
 
 
 
 Suitable multi grade oil can be used
Fuel sulphur Change interval of oil for varying ambient temperature
content in engine oil pan (day/night)

0.5 to 10% ½ of regular interval  Avoid mixing of different brands of oils

Above 1.0 % ¼ of regular interval
 When starting the engine in an
atmospheric temperature of lower
than zero degree centigrade, be sure
to use engine oil of SAE 10W, even
though an atmospheric temperature
goes up 10 degree centigrade more or
less in the day time.
even if the grade of oil is same.
 Use API classification CD as engine
oil and if API classification CC, reduce
the engine oil change interval to half.
 We recommend BEML genuine oil
which has been specifically
formulated and proved for use in
engine and hydraulic work equipment
applications.

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

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

BG825 D4
 
 
 

HYDRAULIC OIL

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

1 I.O.C SERVO ULTRA KB 10W
2 CHEMOLEUMS BEML SUPER CLEAN EH 10W
3 I.B.P IBP ULTRA 10W
4 SAE 10W B.L PROTOMAC ULT 10W
5 B.P.C.L MAK CD 10W
6 T.W.O VEEDOL 901-S3-10W

TRANSMISSION OIL

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

1 I.O.C SERVO ULTRA KB 30
2 CHEMOLEUMS BEML SUPER CLEAN ET 30
3 I.B.P IBP ULTRA 30
SAE 30W
4 B.L PROTOMAC ULT 30
5 B.P.C.L MAK CD 30
6 T.W.O VEEDOL 903-S3-30

GEAR OIL

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

1 I.O.C SERVO GEAR SUPER 90
2 CHEMOLEUMS TURBO SAE 90
SPECIAL GEAR OIL 90
3 SAE 90 I.B.P
EXTRA SPECIAL GEAR OIL 90
4 B.L BALMEROL PROTOMAC SAE HP90
SPIROL EP 90
5 B.P.C.L
SPIROL HD 90

GREASE

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

1 LITHIUM BASE B.L LIPREX EP-2
2 EP-2 T.W.O ALITHEX 20 GREASE

BG825 D5