BG825 Om 27.02.15

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:
Changing all oil, filter elements and cartridges.
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
OPERATIONS
MAINTENANCE
SPECIFICATION
FUEL AND LUBRICANTS
SECTION - A
OPERATION
Section A
OPERATION
INDEX
Sl.no.
1.
2.
3.
4.
BG825
Section reference no. and Description

1. SAFETY HINTS
1.1. General
1.2. Safety Rules
1.3. Safety features
1.4. Unauthorized modification
1.5. Before starting operation
1.6. After starting engine
1.7. During operation
1.8. Parking
2. GENERAL LOCATIONS
3. DASH BOARD SYSTEM
3.1. Introduction
3.2. Power supply
3.3. PV750 Murphy display
3.4. Transmission controller
3.5. Inspection chart for transmission control module (Table-I)
3.6. Solenoid combination Check as per table -II
3.7. Trouble shooting
3.8. Precautions for welding on machines with electronic
controls
3.9. Steps for improving the reliability of Murphy dash board
System
3.10. Emergency steering system on motor grader
3.11. Starting motor trouble Shooting
3.12. Alternator wiring test
3.13. Batteries
3.14. Care of the battery
3.15. Battery and charging System
3.16. Servicing battery
3.17. Recharging batteries
3.18. Starter motor
4. INSTRUMENTS AND CONTROLS
4.1. Work equipment control lever
4.2. Steering wheel tilt lever
4.3. Steering post tilt pedal
4.4. Work equipment control lever safety lock
4.5. Fuel control lever
4.6. Gear shift lever (& parking brake)
4.7. Inching pedal
4.8. Brake pedal
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Sl. no.
5.
6.
7.
8.
9.
10.
11.
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Page no.
4.9. Accelerator pedal
A56
4.10. Dust indicator
A56
4.11. Articulate lock pin
A56
4.12. Operators seat
A57
4.13. MCB
A58
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. 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. 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. CAUTIONS AFTER COMPLETION OF WORK
A70
9. AFTER COLD WEATHER
A70
10. WORKS TO BE CARRIED OUT BY A MOTOR GRADER
A70
11. JOBS EFFECTUATED WITH ARTICULATED FRONTFRAME
A73
A2
Sl. no.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
BG825

12. OPERATING OF WORK EQUIPMENT
12.1 Operation method of the work equipment control lever
12.2 Cautions in operation of work equipment
13. ADJUSTMENT IN SHIFTING OF WORK ATTACHMENT
13.1 Blade projection
13.2 Propulsion angle of blade
13.3 Adjustment of blade cutting angle
13.4 Bank-cutting posture (right side)
13.5 Shoulder reach posture (right side)
13.6 Operation of the blade accumulator
13.7 Features of the blade accumulator
14. REVERSING AND REPLACEMENT OF CUTTING EDGE
AND END BIT
14.1 Turning and replacing
14.2 Replacing ripper point
15. CHANGING TIRES
15.1 How to changes tires
16. HOW TO USE LEANING STOPPER
17. DRIVING ALONG ROAD
17.1 Position of blade when traveling
17.2 Way to insert shack when transporting
17.3 Articulated operations
17.4 Precautions when travelling on road
18. HANDLING OF BATTERY
18.1 Precautions for charging battery
18.2 Removal and installation of battery
18.3 Starting engine with a booster cable
19. TOWING
19.1 Towing the machine
19.2 Releasing parking brake
20. TRANSPORTATION
21. EMERGENCY STEERING SYSTEM
21.1 Function
21.2 Checks
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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. OPERATORS SAFETY
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.
Take care of your health. Do not drive

when tired, or after drinking.
Learn the prohibitions, cautions, and rules
about work procedures in the work site.
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.
FIGURE 1-3. SAFETY APPARATUS
Accidents or injuries are liable to occur

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

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.
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.
BG825
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
the emergency contact system.
Learn about the safety devices on your
own machine and about how to use them.
Confirm that they are correctly attached in
the prescribed position.
Such safety devices include:
FIGURE 1-5. FLAME RESTRICTED

Exhaust gas dangerous. When running
the engine for long periods in a poorly
ventilated area, there is a danger of gas
poisoning, so open the windows or doors
to ensure a good supply of fresh air as
shown in the Figure 1-6.
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 oiltainted clothing because it is likely to catch
fire.
Keep fire away from stored fuel, lubricants
and anti-freeze.
Thoroughly remove wood chips, leaves,
paper and other flammable things
accumulated in the engine compartment.
These could cause a fire.
FIGURE 1-6. AVIOD FUMES

Read Operation and Maintenance Manual
carefully as shown in the Figure 1-7.
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.
BG825
FIGURE 1-7. READ MANUAL

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

devices are functioning correctly, and that
the gauge readings are within the
prescribed range.
Check the play and travel of each lever
and pedal before giving the clearance for
operation as shown in the Figure 1-12.
FIGURE 1-12. CHECK FOR

CLEARANCE BEFORE OPERATION
FIGURE 1-10. HORN BEFORE MOVING
BG825
Operate the blade to confirm that they are

functioning normally.
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
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
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.
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.
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
FIGURE 1-15. DONT 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.
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.
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 1-18. CHECK LOAD LIMIT OF

THE BRIDGES BEFORE CROSSING
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.
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.
FIGURE 1-17. PROPER PARKING OF

THE M/C
BG825
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
BG825
A11
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 1-20. 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.
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.
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
FIGURE 1-22. PARKING THE VEHICLE
BG825
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.
LCD Murphy Display consists of following

gauges, pilot indicators & warning
messages.
Engine oil pressure gauge : 0-10 bar
Engine Water temp gauge: 40-120 C.
Fuel level gauge
Voltmeter
Tachometer
Air Pressure gauge (2 nos.)
Engine Oil temp Gauge 40 -120 C
Transmission oil temp gauge

40-160C
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.
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
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
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
FIGURE 3.3a MURPHY PV750

DISPLAY-FRONT PANEL
(FIRSTSCREEN)
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.
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
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
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
by
pressing the key as show below.
LH panel assy. consists of Emergency

Steering switch, Rops lamp switch (front
& rear) and roof lamp switch and fan
switch. Emergency Steering switch can
be actuated in case of regular steering
pump fail. When this push bottom switch
is actuated emergency steering motor will
be ON and the lamp in the steering
switch goes ON when pressed. Details as
shown in the Figure 3.3e.
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.
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 :
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.
Non contact type Hall Effect sensors are

used to sense the shift lever position.
Details as shown in the figure 3.4. below
FIGURE 3.4. TRANSMISSION CONTROL
BG825
A18
3.5.
SL.
NO.
INSPECTION CHART FOR TRANSMISSION CONTROL MODULE :BG825(Table-I)

CONDITION
01
Power supply
02
Reverse polarity
protection
Gear shift lever
03
04
05
a) Operating force
b) Lever position
Engine start
Reverse alarm
Shift lever position
REMARKS
Should operate between 18-32v DC
Should not affect the controller

2-4 kg
Centre of knob and graduation on FRP
console should coincide for every range.
Put shift lever in P position. Check for
actuation of start relay coil (CNRST) and
ground signal from this relay to starting
circuit
Put shift lever in R position. Check for the
following
a) Proximity switch (CNSWR) get on
(red LED on)
b) Relay (CNRTR) coil to be
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.
Engine should not

start other than
P position &
check the same.
Check power to
backup alarm in
reverse gear
position (N to 8)
i) Proximity (F) switch get on (red

LED on)
i) Neutral forward
Relay (F) coil will be energized and

provides ground to forward solenoid
j) Neutral reverse
ii) Proximity (R) switch get on (red LED

on)
06
07
ACTION
Check the
forward solenoid
energized in all
gear position
(F1-8 )
Relay (R) coil will be energized and

provides ground to reverse solenoid
Differential relay
When shift lever position is between 1 to 4

gear the differential relay (CNRD1) coil is
energized and provides NC contact
Both in forward &

reverse direction
Check shifting of shift lever by pressing

knob
08
Mechanical lock for

gear shifting
Shifting from n to p position

(N
P)
Both in forward &

reverse direction
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
POSITION
P
NFORWARD
N-REVERSE
1
2
3
F
4
5
6
7
8
1
2
3
R
4
5
6
7
8
NOTE: 1.
SOLENOID COMBINATION
L
H
1
2
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
(*) Indicates solenoids are energized
2. All solenoid will be driving in sinking mode

Shift lever
position
P
1
2
3
4
5
6
7
8
BG825
Ground details @ CNT 02 connector

Pin 2
Pin 4&6
Pin 4&7
Pin 4&8
Pin 4&9
Pin 5&6
1. The ground signal is same for

both forward & reverse range.
2. Check ground points with
respect to +24v using multimeter.
3. In neutral position both reverse
& forward solenoids get ground
signal through respective relays.
Pin 5&7
Pin 5&8
Pin 5&9
A20
3.7.
TROUBLE SHOOTING
Supporting tools required
D)
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 noncontact 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.
Shift tower @ 'P position no ground

signal
Parking brake not working
A)
Shift tower position check as per

table - II
B)
Functional checking as per

table - I
C)
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).
Engine not starting
Probable fault
Shift tower @ 'P" position no ground

signal
Starting
relay
functioning
(CNRST)
not
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
.
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 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 welder to the ECM. Welding on
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.
Do not use electrical components

(ECM or ECM Sensors) or electrical
component grounding points for
grounding the welder.
BG825
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

engine, make sure to connect
cables in parallel: Positive (+)
positive (+) and negative (-)
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
the
the
to
to
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
troubleshooting electric circuits
when
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.
BG825
STEPS FOR IMPROVING THE RELIABILITY OF MURPHY DASH BOARD

SYSTEM
A26
Shield: Braided
Silver Plated Wire
Jacket:: ETFE
Fluropolymer
Noise Source
The total Effect

is 14-14-0
Insulation: PTFE
over e PTFE
Conductor: Silver
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 its 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.
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.
Emergency steering system of BG825 Motor grader is shown in the Figure 3.10.a below.
FIGURE 3.10.a. EMERGENCY STEERING SYSTEM
BG825
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
Emergency
Steering Motor
BG825
Battery
A34
Preventive Maintenance Procedures:
Corrosion, dirt, and dust:
The object of preventive maintenance is to

identify and correct potential problems
before they occur.
The Motor operates less efficiently when

corrosion forms or dirt particles build up
around wire and cable connection points.
Corroded and dirty connection points
impair the flow of electrical current. Clean
all connections on a periodic basis.
Wires and cables:

For any type of vehicle electrical system,
its important to keep all connection Points
clean. Road dirt and grease create
resistance that interferes with electrical
current flow. In order to get the necessary
power from a unit , there must be little or
no resistance between the batteries and
the motor. In the same vein, you need to
make sure that wires and cables are
clean, properly tightened, and of the
proper size. Any loss of current due to
poor connections will reduce power to
motor.
Timely preventive maintenance of the

system provides smoother operation and
long life for Motor and pump components.
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.
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.
FIGURE 3.11 STARTING MOTOR TROUBLE SHOOTING
BG825
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
TEST
SWITCH
CONTACTOR
The figure for Magnetic Switch Contactor

test is shown below.(Figure 3.12.)
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.
FIGURE 3.12. MAGNETIC SWITCH

CONTACTOR
With carbon pile connected as for previous
Starter Solenoid Circuit Test, proceed as
follows:
Connect
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.
1. Digital voltmeter set on low scale

across large terminals of magnetic
switch. Battery voltage will show
immediately.
BG825
A37
Cranking Circuit
3.14.
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.
When handling a battery, the following

safety precautions should be followed
Solenoid Circuit.
Battery fluid is highly acidic.
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.
Avoid spilling on clothing or other fabric.

Any spilled electrolyte should be flushed
with large quantity of water and cleaned
immediately.
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.
CARE OF THE BATTERY
Hydrogen gas is produced by the

battery.
A flame or spark near the battery may
cause the gas to ignite.
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.
BG825
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
DISCHARGED STATE
NEARLY
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!
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 50C.
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
BG825
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.
The use of digital voltmeters is highly

recommended for the following reasons:
Digital voltmeters are generally more

accurate
than
analog
(needle
movement) instruments.
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.
The condition of the earth straps
The condition of the power fuse (if

fitted).
STARTER
faulty
Check the presence and the condition

of the fuses.
Check, on the starter motor, the

connection and the condition of the
control terminal.
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 shortcircuited.
If there is a problem, carry out a fault
search (damaged wiring, relays
sticking, etc.).
Diagnostic - Fault finding chart

@
battery
Repair if necessary.
STARTER MOTOR
Chart - 1
INACTIVE
the
Replace if necessary.
Digital readings need no interpretation;

everyone sees the same number.
3.18.
The condition of
wiring and terminals
Repair
or
replace
the
components, if necessary.
NOTES :
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:
MOTOR
If the vehicle is fitted with a circuit

breaker or additional alarm:
The solenoid valve cannot be heard

clicking.
Check if it is acting on the starter

motor control line.
NOTES :
Check the insulation and condition of

the connections with the circuit
breaker or the alarm.
Ensure that these are both operating

correctly.
Check
BG825
The condition and voltage of the

battery
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

operating correctly.
switch
Check the supply to the rotary switch.
If the model is controlled by the

immobilizer:
Check the line between the switch and

the control terminal.
Carry out a fault finding procedure on

the immobilizer.
Repair
or
replace
the
faulty
If not correct,
is
Check the insulation and the continuity

of the power line between the battery
and starter motor.
Put the vehicle in neutral (also neutral

on automatic gearboxes) and try to
turn the starter motor by hand.
If not correct, check
If there is oil in the engine (seizure),
The timing adjustment,
faulty
That no auxiliary is slowing down the

motor,
If everything is correct, replace the

starter motor.
That the gearbox and its control are

not faulty,
That there are no objects which could

be blocking the free movement of the
motor at the flywheel end,
That the engine is not flooded and that

there is no object (dropped valve...) in
the cylinders.
Repair
or
replace
the
AFTER REPAIR
Check for the presence of + 24 volts at the

starter motor power terminal.
Check that the starter

CHART - 2
BLOCKED
STARTER
motor
is
MOTOR
The solenoid clicks, but the starter motor

does not run.
NOTES :

Check
The condition, the voltage

conformity of the battery,
The condition of the battery wiring and

terminals,
The condition of the earth straps,

fitted).
BG825
and

search (damaged wiring, sticking relays,
etc.).
If everything is correct, replace the starter
motor.
AFTER REPAIR

motor
is
A44
CHART - 3 @
STARTER MOTOR
UNDERPOWERED
That there are no objects which could

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,
The valve clearances.
NOTES
Check
The condition, the voltage

conformity of the battery,
and

terminals,

fitted).
Repair or replace the faulty components, if

necessary.
search (stripped wiring, sticking relays,
etc.).
Check the insulation and continuity of the
starter motor power wiring to the battery.
Put the vehicle in neutral (also neutral on
automatic gearboxes) and try to turn the
starter motor by hand.
If not correct, check
If everything is correct, remove the starter

motor and check for signs of wear.
motor.
CHART
4
OPERATION
INTERMITTENT
The starter motor does not operate during

all the starting sequences.
NOTES
Check
The condition, the conformity and the

voltage of the battery,

terminals,

fitted).

necessary.
If there is oil and water in the engine

(seizure),
Check that the immobilizer is not faulty

and that it becomes inactive each time the
ignition is switched on.
That no other auxiliary is slowing down

the motor (coolant pump, air
conditioning compressor, etc.),
Perform a fault finding procedure on the

engine immobilizer system if necessary.
The adjustment and condition (tension

wheel sticking...) of the timing system,
Check the condition and the connection of

starter motor control circuit terminal.
That the gearbox and its control are

not faulty,
BG825
A45
Check if the vehicle is fitted with circuit

breaker or an additional alarm.
Check the mountings securing the starter

motor to the engine.
Check they are working correctly.
Reaffix if necessary.
Check the condition and insulation of

starter motor control circuit line.
Check the condition of the flywheel ring

gear.
Repair or replace it, if necessary.
Check that the starter motor switch is

Check the condition of the starter motor

drive pinion.
Repair or replace it, if necessary.
Check that the centering pin is present.
Connect the diagnostic tool and check

that the immobilizer is operating correctly
(vehicles with immobilizer controlling the
starter motor).
Replace the starter motor if necessary.
Perform a fault finding procedure on the

engine immobilizer system if necessary.
Remove the starter motor and check that
there are no bad contacts (contact brush).
motor.
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.
CHART - 5 @ NOISY STARTER MOTOR
Check that the solenoid is operating

correctly and the starter motor fork is
returning.
The noise is only present during the

starting phase and afterwards.
Replace the starter motor if necessary.
NOTES
AFTER REPAIR
Check

battery,
terminals,

fitted).

necessary.
BG825

CHART - 6 @
OVERHEATING
STARTER
motor
is
MOTOR
Odour / smoke coming from under the

bonnet during the starting sequence.
NOTES
Check

battery,
A46

terminals,

fitted).

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.
AFTER REPAIR
motor
is
The Primary Causes of Starting System

Malfunction:
Before
discussing
the
preventive
maintenance and diagnostic procedures
for the starting system, we are going to
cover certain environmental and product
application factors that can cause the
starting system to malfunction.
Battery charge
A battery having a low / poor state of
charge will place abnormal stresses on
the starting system. When measuring
battery voltage, make sure voltage is 24 V
or greater.
BG825
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.
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.).
Excessive heat
If starting system components are poorly

or loosely mounted to the vehicles
engine, the resulting vibration can
damage sensitive internal components.
Corrosion, dirt, and dust.
Starting system components operate less
efficiently when corrosion forms or dirt
particles build up around wire and cable
connection points. Corroded and dirty
connection points impair the flow of
electrical current.
Defective solenoid.
If the starter fails to engage or fails to 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.
diagnosing
(i.e.
troubleshooting)
a
problem in the vehicles 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.
Jammed Gear
Wires and cables.
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.
For any type of vehicle electrical system,

its 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.
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 systems
functions.
These two procedures also represent the
initial steps one should take when fully
BG825
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 systems
components for signs of damage.
Diagnostic
Procedures
Troubleshooting
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, its 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 its 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 72F (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.
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.
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 wont 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
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
engines poor condition.
the starters 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.
STARTER MOTOR TEST, POSITIVE

CABLE
POSITIVE CABLE TEST

Negative cable test
STARTER MOTOR TEST, NEGATIVE

CABLE
Voltage drop 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.
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
A51
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.
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.
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.
SOLENOID VOLTAGE DROP TEST

BG825
A52
4.
INSTRUMENTS AND
CONTROLS
CONTROL LEVERS AND

PEDALS
4.1
WORK EQUIPMENT CONTROL

LEVER
Control
levers
equipment.
operate
the
4.
Power tilt control lever
5.
Blade rotation control lever
6.
Drawbar side shift lever
7.
Articulation control lever
8.
Leaning lever
9.
Scarified life lever
10.
work
4.2
Right blade lift lever
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.
follows:
FIGURE 4.1. CONTROL LEVERS

1.
Left blade lift lever
2.
Ripper lift lever
3.
Blade side shift lever
BG825
FIGURE 4.3. STEERING POST TILT

PEDAL
A53
4.4

LEVER SAFETY LOCK
Fuel control lever (1) is shown in the

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

transmission gear.
to
change
the
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:
FIGURE 4.4. CONTROL LEVER SAFETY

LOCK
4.5
P
N
N
FUEL CONTROL LEVER
This adjusts the engine speed and output.

Engine stop:
Lever at S position
Low idling:
Pull lever from S position to position
where operating force changes.
High idling:
(BOTH FORWARD AND REVERSE).

When starting the engine, the engine will
not start if the gear shift lever is not in the
P position.
The parking brake does not work unless
the staring switch at ON.
Gear shift lever (1) is shown in the Figure
4.6. as follows
Lever at F position
BG825
A54
The inching pedal can be used in

Forward and Reverse, but should not
be used for starting in 4th speed or
above.
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.
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.
follows:

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
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

follows:
ARTICULATE LOCK PIN
This pin is used to lock the front frame

and rear frame to prevent the machine
from
bending
when
servicing
or
transporting the machine.
as follows:
FIGURE 4.9. ACCELERATOR PEDAL

4.10
DUST INDICATOR
This device indicates clogging of the air

cleaner element. When red piston (1)
appears in the transparent part of this
indicator, the element is clogged.
Immediately clean element.
After cleaning, push indicator button (2) to
return red piston to original position.
BG825
FIGURE 4.11. ARTICULATE LOCK PIN
When servicing or transporting the

machine always use this lock pin.
A56
C: Seat cushion adjustment
For normal traveling, always remove

the lock pin.
Turn knob (3) to make the

comfortable and match your weight.
seat
For LIGHT weight, turn to RIGHT.

4.12
OPERATORS SEAT
Adjust the seat position at the beginning

of each shift or when operators change.
Adjust the seat so that the brake pedal
can be depressed all the way with the
operator's back against the back rest.
For HEAVY weight, turn to LEFT.

D: Seat angle adjustment
Move lever (4) up and push back to adjust
seat angle (2 stages).
E: Backrest adjustment
Pull lever (5), set backrest to desired
position, then release lever.
Adjustment range: 4 stages
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

wiring from burning out.
The Circuit breaker decal with rating is

shown below Figure 4.13.a

as follows:
FIGURE 4.13. MCB

Replace a fuse with another of the same
capacity.
FIGURE 4.13. CIRCUIT BRAKER

DECAL
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

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.
5.1
CHECK AND REFILL

COOLANT
FIGURE 5.1. REFILL COOLANT
Do not remove the cap while cooling

water is hot, hot water may spout out.
When removing the radiator cap, lift
the lever to relieve inner pressure
Remove radiator cap (1) at the top rear of

the machine and check that the cooling
water reaches the area marked by shaded
lines. Add water if necessary.
Use fuel gauge

level.
If volume of coolant added is more than

usual, check for possible water leakage.
Top up the tank through the filler after

the days work is over.

follows:
A clogged cap breather hole may stop

the fuel flow to the engine.
Check it from time to time and clean.
Fuel capacity : 500 lts
5.2
CHECK AND REFILL FUEL

TANK
to check the
fuel

follows:
BG825
A59
FIGURE 5.4. DRAIN WATER FROM AIR

TANK
5.5
FIGURE 5.2. REFILL FUEL TANK

When adding fuel, never let the fuel
overflow. This may cause a fire.
5.3
DRAIN WATER AND SEDIMENT

IN FUEL TANK
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
filler (F) .

follows:
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.
follows:
BG825
FIGURE 5.5. OIL LEVEL IN ENGINE OIL

PAN
A60
The type of lubricant used depends on

the ambient temperature. Select
according to table FUEL, COOLANT
AND LUBRICANTS".
When checking the oil level, park the
machine on a level surface, stop the
engine and waits for 15 minutes
before checking.
5.6
CHECK ELECTRICAL WIRING
Check for damage of the fuse and any

sign of disconnection of short circuit in the
electric wiring. Check also for loose
terminals and tighten any loose parts.
Check the following points carefully.
Battery
Starting motor
Alternator
If the fuse is damaged or there is any

sign of short circuiting in the electric
wiring, always, investigate the cause
and correct it.
In that case, clean element referring to the

section WHEN REQUIRED.
After cleaning element, push button to
return red piston.
5.8
CHECK AND ADJUST TIRE

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

40 PSI ( 2.81 kg/cm2 )
Make sure that tire and rim is free from

wear and damage, and that hub nuts are
not loose.
5.9
CHECK AND ADJUST

STEERING WHEEL
When checking steering wheel play, start

engine and raise front wheels off ground.
The standard steering wheel play is 10 to
12 mm. If the play is beyond standard or
steering is abnormal, contact your BEML
service personnel.
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.
follows:
FIGURE 5.7. CHECK DUST INDICATOR

BG825
FIGURE 5.9. CHECK AND ADJUST

STEERING WHEEL
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.
CHECK FOR DIRT AND DAMAGE

ON REFLECTOR
CHECK HORN
IS THE COLOR OF EXHAUST

GAS NORMAL
DO THE INSTRUMENTS
FUNCTION NORMALLY?
HAVE ANY DEFECTS WHICH WERE

FOUND DURING THE PREVIOUS
DAYS
OPERATION
BEEN
CORRECTED?
CHECK THE DOOR LOCK FOR

NORMAL FUNCTION.
5.12
FIGURE 5.12. WINDSHIELD WASHER

5.13
The water separator separates water

mixed in the fuel. If float (2) is at or above
red line (1), drain the water.
CHECK
THE
WINDSHIELD
WIPER, WINDOW WASHER AND
DEFROSTER FOR NORMAL
FUNCTION.
CHECK
FOR
SUFFICIENT WASHER FLUID
LEVEL.
If the windshield washer fluid level is

low, add fluid through cap (1).
FIGURE 5.12. WATER SEPARATOR

For the draining procedure, see section
WHEN REQUIRED
BG825
CHECK FOR SEDIMENT AND

WATER
IN
THE
WATER
SEPARATOR
Check the fuel tank to remove water

and sediment in the fuel.
A62
6.
OPERATING YOUR MACHINE
6.2
6.1
BEFORE STARTING THE

ENGINE
Set fuel control lever (1) at the HALF

OPEN position.
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.
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

follows:

follows:
FIGURE 6.1. CHECKS BEFORE

STARTING ENGINE
FIGURE 6.2. TO START ENGINE
BG825
A63
Do not leave key in START for more

than 20 seconds.
If engine will not start, repeat the
starting procedure after about 2
minutes.
Avoid sudden acceleration of the

engine until the warming up operation
is completed.
Do not run the engine at low idling or

high idling for more than 20 minutes. If
it is necessary to run the engine at
idling, apply a load from time to time or
raise the engine speed to a midrange
speed.
To start engine in cold weather refer to

COLD WEATHER OPERATION.
6.2.1
SPECIAL STARTING
When starting after running out of fuel, fill

with fuel, then bleed the air from the fuel
system before starting.
6.3
Pull the fuel control lever (1) and run

the engine at mid range speed for
about 5 minutes with no load.
Idle the engine at low speed for about

5 minutes to cool it.
Set fuel control lever (1) to the STOP

position to stop the engine.
It is also possible to release the

accelerator pedal to STOP position and
stop the engine.
Details shown in the Figure 6.3. below
TO STOP THE ENGINE
CHECK AFTER STARTING
After starting the engine, do not operate

the machine immediately. First carry out
the following operations and checks.
6.4
Return the starting switch (2) to the

OFF position, and withdraw the key.
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

exhaust, any abnormal sound
vibration.
of
or
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.
Depress inching pedal (1) and set

gear shift lever (2) to 1st, 2nd and 3rd
speed.
FIGURE 6.5. TO MOVE THE M/C OFF

6.6
CHANGING GEAR SPEED

Acceleration
Partially release the accelerator pedal
(1) and shift the gear shift lever (2) to
the next stepped-up position.
Release inching pedal (1), depress

accelerator pedal (3), and the machine
will start.
When starting the machine, check that

the air pressure monitor is OFF.
Deceleration
Release accelerator pedal (1) to
decrease traveling speed and shift
gear shift lever (2) to the next steppeddown position. When shifting gear,
always shift one speed at a time.

BG825
A65
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.
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.
BG825
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.
A66
6.9
TO STOP THE MACHINE ( IN

EQPT RUNNING CONDITION )
Release the accelerator pedal (1)
6.10
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
Depress the brake pedal (2). Before

the machine come to a stop, depress
the inching pedal (3).
CAUTIONS FOR OPERATING

HILLS
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.
FIGURE 6.9. STOPPING THE M/C
Place gear shift (parking brake) lever

at the P position to apply the parking
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
STOPPING
OR
MACHINE
WHEN
PARKING
Lock safety lock for work equipment

levers.
When stopping or parking, pay attention to

the following points.
Stop the machine on hard and even

ground to prevent it from falling down
or slipping.
Stop the machine on firm level ground in a

safe place where there is no danger from
falling rocks, landslips or floods. Lower the
BG825
A67
work equipment to the ground, place all

control levers in NEUTRAL or HOLD and
lock in place.
7.
COLD
OPERATION
7.1
PREPARATION
TEMPERATURE
FOR
Where no permanent antifreeze is

available, an ethylene glycol antifreeze
without corrosion inhibitor may be
used only for the cold season. In this
case, clean the cooling system twice a
year (in spring and autumn). When
refilling the cooling system, add
antifreeze in autumn, but do not add
any in spring.
Absolutely avoid using any water leak

preventing agent irrespective of
whether it is used independently or
mixed with antifreeze.
Do not mix one antifreeze with a

different brand.
FUEL AND LUBRICANTS
For details of the specified viscosity, see

the
TABLE OF FUEL,
LUBRICANTS.
7.3
COOLANT
AND
COOLANT
After cleaning inside of the cooling

system, add antifreeze to the coolant to
prevent the coolant from freezing when
the machine is not being used.
For details of the antifreeze mixture
when changing the coolant, see when
REQUIRED.
Care in using Antifreeze

Use a permanent Anti freeze (ethylene
glycol mixed with corrosion inhibitor,
antifoam agent, etc.) meeting the standard
requirements as shown below.
With permanent antifreeze, no change of
coolant is required for a year. If it is
doubtful that available antifreeze meets
the standard requirements, ask the
supplier of that antifreeze for information.
Standard requirements for permanent
antifreeze
SAE.......J1034
FEDERAL STANDARD
O-A-548D
BG825
or
LOW
Change fuel and oil with low viscosity for

all systems.
Never use methanol, ethanol

propanol based antifreeze.
WEATHER
If the temperature becomes low, it

becomes difficult to start the engine, and
the coolant may freeze, so do as follows.
7.2
Antifreeze is flammable, so keep it

away from any flame.
7.4
BATTERY
As ambient temperature drops, battery

capacity will drop, and electrolyte may
sometimes freeze if battery charge is low.
Maintain battery at a charge level of
approx. 100% and insulate it against cold
temperature so that machine can be
readily started the next morning.
Measure specific gravity of fluid and
obtain rate of charge from the following
conversion table:
Temp of
Fluid /
Rate of
Charge
200C
00C
-100C
- 200C
100%
1.28
1.29
1.30
1.31
90%
1.26
1.27
1.28
1.29
80%
1.24
1.25
1.26
1.27
75%
1.23
1.24
1.25
1.26
When electrolyte level is low, add distilled

water in the morning before work instead
of after the days work. This is to prevent
fluid from freezing at night.
A68
To avoid gas explosions, do not bring

fire or sparks near the battery.
If the electrolyte gets on your skin or

clothes, immediately wash with plenty
of clean water.
7.5
Necessary preheating time is as follows.
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

OPEN position.
Place starting key (2) in HEAT position
to flash preheating monitor (3).
Details shown in the Figure 7.5.1 below
Ambient temperature
Preheat time
Above 0 deg cent

0 deg cent to -10 deg cent
-10 deg cent to -20 deg cent
20 seconds
30 seconds
If the preheating time is too short or

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.
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)
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
9.
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.
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.
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.
FIGURE 10.3.
Scarifying (With Scarifier - OptionAttached) (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).
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.)
Ditching (Figure 10.7.)
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.
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 10.5.
FIGURE 10.7.
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.
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.
FIGURE 10.6.
BG825
A72
11.
leaned front wheels and articulated

front frame). (Figure 11.3.)
JOBS EFFECTUATED WITH

THE ARTICULATED FRONT
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

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 12.1.a.
FIGURE 11.2.
By concurrent use of blade side shift
and front wheel offset, road corners
are made easy for operations(with
BG825
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
A73
hydraulic cylinder possibly hit against

parts, damaging them.
Blade and step
(Figure 12.2.c)
FIGURE 12.2.c.
FIGURE 12.2.b
13.
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.)
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
BLADE
ANGLE
breaking is available to cut the frozen

surface during snow removal.
OF
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.
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
Fully protrude the blade drawbar to the

right.
Place lifter lock switch in RETRACT

position
on
the
operators
compartment to remove pin .
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
BANK-CUTTING POSTURE
(RIGHT SIDE)
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

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.
Drawbar and lifter (Figure 13.4.a.)
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 bankcut posture, be careful not to clash
the blade against various portions
of the machine.
FIGURE 13.4.a.
Drawbar and frame (Figure 13.4.b.)
FIGURE 13.4.b.
13.5
SHOULDER REACH POSTURE

(RIGHT SIDE)
Rotate the lifter in a similar manner to

the bank cutting posture, and lock it
using the bank control lock pin.
Rotate the
position.
FIGURE 13.4.
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
circle
to
the
desired
Put the machine in the left hand side

shoulder reach posture using the
same procedure as the above.
When increasing the size of the
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.
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.
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.
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
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.
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.
BG825
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 blades 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.
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
Details shown in the Figure 15.1.
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.
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
STOPPER
USE
LEANING
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.
FIGURE 15.1.
BG825
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.
Fix the leaning rod (2) to the front axle

using the bolts (1) provided in the tool
box.
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.
17.2
WAY TO INSERT SHACK WHEN

TRANSPORTING
The way to insert the shank when

transporting is as shown in the diagram
below.
If the machine is traveled with the
leaning cylinder piston rod fluctuating
or the front wheels leaning on one
side, because of damaged leaning
piping, dangerously unstable steering
and excessively worn tires will result.
Have the faulty leaning pipe repaired
by mechanics quickly.
17.
Install the shank that comes in the center

of the ripper body with the point facing to
the rear, or install it in a position other
than the center.
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

set it so that it does not extend outside the
machine. (Figure 17.1.)
Do not install the shank in the center of

the ripper body with the point facing
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 operators 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
TRAVELING ON ROADS
WHEN
To relieve operators fatigue, take a rest

by 30 minutes 1 hour 30 minutes
mode, every 80 kilometers or every 2
hours of traveling (whichever term expires
earlier).
18.
HANDLING OF BATTERY
18.1
PRECAUTIONS FOR CHARGING

BATTERY
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.
b) Decreasing
electrolyte.
quantity
of
c) Damaging the electrode plate.
If the electrolyte gets on your skin or

clothes, immediately wash with plenty
of clean water.
Do not mix up cables (positive (+) to

negative (-) or negative (-) to positive
(+), as it will damage the alternator as
shown in the Figure 18.1.b.
FIGURE 18.1.b
BG825
the
When inspecting or servicing a

battery, be sure to stop the engine and
A81
turn. The starting switch key to OFF

position.
c) Make sure cables and clips are

firmly secured.
When performing any service to

battery
besides
checking
the
electrolyte level or measuring the
specific gravity, disconnect cables
from the battery.
d) Keep the starting switch key in

OFF position.
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.
e) The battery of the running engine

must be the same capacity as that
of engine to be started.
Connect the booster
following manner.
cables
in
the
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.
FIGURE 18.2.
18.3
STARTING ENGINE WITH A

BOOSTER CABLE
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.
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.
FIGURE 18.3.a.
BG825
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 doesnt start at first, try

again after 2 minutes or so.
After the engine has started, the booster

cables should be disconnected in the
reverse order in which they were
connected.
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.
Disconnecting the booster cables

a) Disconnect the clip of booster cable B
from the body of the machine which
was started.
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.
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.
Always keeps the engine running

when towing the machine, so that the
steering and braking can be used.
Details are shown below in Figure 18.3.b.
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
FIGURE 18.3.b.
BG825
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
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.
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.
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:
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:
Remove the mud form the under

carriage to prevent the machine from
slipping to the side on slopes.
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.
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.
Width, length and thickness of ramp

boards must large enough to assure
safe loading and unloading of the
motor grader.
Determine the optimum transportation

route, taking width of road and
permissible overhead clearance and
weight limitation into consideration.
Remove all the mud from the

undercarriage to prevent the machine
from slipping to the side on hilly roads.
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.
Slowly travel the motor grader on the

ramp straight.
BG825
A84
21.2
CHECKS
WHEN REQUIRED
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.
Check that AUTO/MANUAL selector

switch is at the AUTO position.
When loading the machine, choose a

firm level road surface. Be sure that
you are well clear of the road shoulder.
Start the engine and raise the front

wheels of the ground with the blade.
When transporting this machine,

check with your BEML service
personnel for advice.
Normally keep the AUTO / manual

selector switch at the AUTO position.
21.
EMERGENCY
SYSTEM
Stop the engine. Be sure to leave the

starting switch at the ON position.
21.1
FUNCTION
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.
STEERING
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
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.
Page no.
1.
1. PERIODIC MAINTENANCE
B3
2.
2. PRECAUTIONS FOR MAINTENANCE

2.1. General
3. DURING MAINTENANCE
4. PERIODICAL REPLACEMENT OF SAFETY
PARTS
5. OIL FILLER AND LEVEL GAUGE POSITIONS
6. LUBRICATION CHART
7. MAINTENANCE TABLE
7.1. Every 50 Hours Service
7.6. When Required
7.6.1 Clean inside of cooling system
7.6.2 Check, clean and replace Air cleaner
element
7.6.3 Electrical intake air heater
7.6.4 Clean condenser of Air Conditioner
7.6.5 Water separator
8. ADJUSTMENT
8.1. Adjustment of Inch Pedal
9. TROUBLE SHOOTING GUIDE
9.1. Engine
9.2. Chassis
9.3. Electrical system
9.3.1 Trouble shooting for Murphy
9.3.1.1 Overview
9.3.1.2 Power View 750 Display
9.3.1.3 I/O Module
9.3.1.4 Troubleshooting
10. STORAGE
10.1. Before storage
10.2. During storage
10.3. After storage
11. MACHINE AND ENGINE SERIAL NUMBERS
B3
B3
B4
3.
4.
5.
6.
7.
8.
9.
10.
11.
BG825
B6
B7
B8
B9
B12
B19
B21
B22
B24
B25
B25
B26
B28
B29
B29
B29
B29
B30
B30
B31
B32
B33
B33
B34
B37
B39
B43
B43
B43
B43
B43
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.
All hourly figures given in the following
descriptions are based on service meter
readings. In practice, however, it is
recommended to review and convert
some / all of them into units of days,
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
hammering, always wear protective
goggles.
Fuel or oil is dangerous substance. Never
handle fuel, oil grease or oily clothes in
places where there is any fire of flame. As
precaution in case of fire, always know the
location and directions for use of fire
extinguishers and other fire-fighting
equipment.
FIGURE 2-1. WORK AS PER

INSTRUCTION
Do not handle electrical equipment while
wearing wet gloves, or in wet places, as
this can cause electric shock as shown in
the Figure below 2-2.
FIGURE 2-2. HANDLE ELECTRICAL

EQUIPMENT CAREFULLY
During maintenance do not allow any
unauthorized person to stand near the
machine.
Exhaust gas is dangerous. When working
inside, be particularly careful to have good
ventilation as shown in the Figure below
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.
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.
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.
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
FIGURE 2-5. HYDRAULIC OIL UNDER
PRESSURE
BG825
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

electrolyte as shown in the Figure below
3-2.
When the strainer is located in the oil filter,

the strainer must not be removed while
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.
FIGURE 3-2. AVOID FLAMES

Immediately remove any oil or grease on
the floor of the operators compartment, or
on the handrail. It is very dangerous if
someone slips while on the machine.
When check an open gear case there is a
risk of dropping things in. Before removing
the covers to inspect such cases, empty
everything from your pockets. Be
particularly careful to remove wrenches
and nuts as shown in the Figure 3-3.
When removing parts containing O-rings,

gaskets or seals, clean the mounting
surface and replace with new sealing
parts.
When the work equipment is raised for
inspection or repair, always place blocks
underneath to prevent falling as shown in
the Figure 3-4.
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
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

shop as shown in the Figure 2-11.
4.
PERIODICAL REPLACEMENT
OF SAFETY PARTS
Periodic replacement of safety parts

should be done to maintain the safety
standards.
FIGURE 3-5. WHILE REPLACING TIRES

Always lock the front and rear frames
before inspecting and servicing the
machine. (Inarticulate frame model).
When handling the cutting edges always
wear gloves.
Parts with passage of time have a greater

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.
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
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

GAUGE POSITIONS
LEVEL
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
C
A
B
L
F
A
TYPE OF LUBRICATION
ENGINE OIL
0C TO +32C
ABOVE 32C
SAE 15W40
SAE 15W40
TRANSMISSION OIL
CD SAE 30W
CD SAE 30W
HYDRAULIC OIL
CD SAE 10W
CD SAE 10W
NLGI,GRADE#2
NLGI,GRADE#2
LITHIUM BASE GREASE

MULTI PURPOSE GEAR OIL
HIGH TEMPERATURE AXLE OIL
SL. NO.
DESCRIPTION
LUBEKEY
GO SAE 90
GO SAE 140
CD SAE 30W
CD SAE 30W
NO. OF
SERVICE
POINTS
50
CIRCLE GUIDE
GREASE
BLADE GUIDE RAIL (SMEAR)
GREASE
DRAW BAR BALL JOINT
GREASE
BANK-CUT CONTROL BRACKET
GREASE
BLADE LIFT CYLINDER BALL YOKE
GREASE
BLADE LIFT CYLINDER BALL JOINT
GREASE
DRAW BAR SIDESHIFT CYLINDER JOINT
GREASE
POWER TILT CYLINDER PIN
GREASE
RIPPER LINKAGE PIN (OP)
GREASE
10
RIPPER CYLINDER PIN(OP)
GREASE
11
LEANING CYLINDER PIN
GREASE
12
TIE ROD
GREASE
13
STEERING CYLINDER
GREASE
14
LEANING PIN
GREASE
15
LEANING ROD PIN
GREASE
16
CENTER PIN
GREASE
17
KING PIN
GREASE
250
500
1000
18
ARTICULATION CYLINDER PIN
GREASE
19
PROPELLER SHAFT
GREASE
19A
HITCH PIN
GREASE
19B
CONSOLE TILT BRACKET
GREASE
19C
POWER TILT CYLINDER MTG. BRACKET
GREASE
20
ENGINE OIL PAN
CHECK
21
OIL CASE TRANSMSSION
CHECK
22
OIL CASE FINAL DRIVE
CHECK
CHANGE
23
TANDEM DRIVE CASE
CHECK
CHANGE
24
HYDRAULIC OIL
CHECK
CHANGE
25
OIL CASE WORM GEAR
CHECK
CHANGE
26
FRONT WHEEL SPINDLE BEARING OIL
CHECK
27
ENGINE OIL FILTER CARTRIDGE
28
CENTRIFIGAL OIL FILTER
29
MAIN FUEL FILTER CARTRIDGE
CHANGE
30
PRE FUEL FILTER CARTRIDGE
CHANGE
31
TRANSMISSION FILTER ELEMENT
32
HYDRAULIC OIL FILTER ELEMENT
33
CRANK CASE BREATHER
BG825
2000
CHANGE
CHANGE
CHANGE
CHANGE
CHANGE
CHANGE
**
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
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 days defects
Check
t.
Door lock
Check
u.
Wiper, window washer and defroster
Check
v.
Water separator
Inspect float position

a.
Greasing
1.
Circle Guide
Greasing 6 points
2.
Blade Guide Rail (Smear)
Greasing 2 points
3.
Draw Bar Ball Joint
Greasing 1 point
4.
Bank - Cut Control Bracket
Greasing 2 points
5.
Blade lift cylinder yoke
Greasing 6 points
6.
Blade lift cylinder ball joint
Greasing 2 point
7.
Draw bar side shift cylinder joint
Greasing 2 points
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.
Change
h.
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

a.
Engine oil pan
Change Oil
b.
Change Oil
c.
d.
Change Oil
e.
Change Oil
f.
Crank Case Breather
Check and Clean
Filters to be cleaned by removing sediments &

Replace paper insert

a.
Transmission Filter Element
Change

a.
Change
b.
Change
c.
Tandem Drive Case
Change
d.
Hydraulic Oil
Change
e.
Oil Case Worm Gear
Change
f.
Change

a.
Change Oil
WHEN REQUIRED
a.
Cooling system
Clean
Check, clean or replace when required
b.
Air cleaner
c.
Electrical intake air heater
Check
d.
Air condenser
Clean
e.
Water separator
Drain water
BG825
Note: To be replaced along with the inner

element after 6 times of cleaning
B11
7.1.
Greasing -:
In every 50 hours the below points should

be greased properly.
Grease all over the part
Draw Bar Ball Joint
(1 point)
Grease all around the circle part.
Check ball joint connecting nuts at the

front of the drawbar for loosening. If the
connecting portions are loose, retighten
them.
Details shown in the Figure 7.1.1.
Circle Guide
(6 points)
FIGURE 7.1.1.
Blade guide rail
FIGURE 7.1.3.
(2 points)
Apply grease all over the guide rail

FIGURE 7.1.2.
BG825
Bank - Cut Control Bracket (2 points)

FIGURE 7.1.4.
B12
Blade lift cylinder yoke (6 points)
Grease all over the part.

Draw bar side shift cylinder joint

(2 points)

FIGURE 7.1.7.
FIGURE 7.1.5.
Blade lift cylinder ball joint (2 points)
Power tilt cylinder pin
(1 point)

Grease all over the part.

FIGURE 7.1.8.
FIGURE 7.1.6.
BG825
B13
Ripper linkage pin (op)
(8 points)
Leaning cylinder pin
(1 point)
FIGURE 7.1.11.
FIGURE 7.1.9.
Ripper cylinder pin (op)
(3 points)
Tie rod
(2 points)
FIGURE 7.1.12.
FIGURE 7.1.10.
BG825
B14
Steering cylinder
(4 points)
Leaning rod pin
(2 points)
FIGURE 7.1.15.
FIGURE 7.1.13.
Leaning pin
(2 points)
Centre pin
(1 point)
FIGURE 7.1.14.
FIGURE 7.1.16.
BG825
B15
King pin
(6 points)
Hitch pin
(2 points)
Details shown in the Figure 7.1.19a.
FIGURE 7.1.19a.
FIGURE 7.1.17.
Articulation cylinder pin (4 points)
Console tilt bracket
(2 points)

Details shown in the Figure 7.1.19b.
FIGURE 7.1.18.
Propeller shaft
FIGURE 7.1.19b.
Power tilt cylinder mtg. Bracket (op)

(2 points)
Details shown in the Figure 7.1.19c.
FIGURE 7.1.19.
BG825
(2 points)
FIGURE 7.1.19c.
B16
Checking -:
In every 50 hours the below points should
be checked properly.
Engine Oil Pan
Check the Engine Oil Pan

FIGURE 7.1.21.
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".
FIGURE 7.1.20.
Check the oil level with oil level gauge five

minutes after stopping the engine.
If necessary, add oil through filler .
ambient temperature.
Select according to the table FUEL,
COOLANT AND LUBRICANTS.
BG825
FIGURE 7.1.22.
Tandem Drive Case
Check the oil level with oil level gauge. If

necessary, add oil through filler .
ambient temperature.
B17
Select according to the table FUEL,

COOLANT AND LUBRICANTS.
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.
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.
BG825
FIGURE 7.1.24.
Raise the scarifier fully.

B18
Oil Case Worm Gear
7.2.
Check the Oil Case Worm Gear
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.
LUBRICANTS.
FIGURE 7.1.25.
Refill capacity: 34 lts.

Check the Front Wheel Spindle Bearing

Oil.
FIGURE 7.1.26.
FIGURE 7.2.1.
BG825
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.
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.
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.
FIGURE 7.2.2.
FIGURE 7.2.3.
BG825
B20
Crank Case Breather
Change the Pre fuel filter cartridge
Check and clean -
In every 250 hours Crank Case breather

should be checked and cleaned.
If required replace 'O'- Ring
FIGURE 7.2.3.
Clean and Replace Paper Insert In every 250 hours Clean Centrifugal Oil
filter by removing sediments and replace
paper insert.
7.3.
Changing -:
FIGURE 7.2.5.
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
FIGURE 7.3.1.
7.4.
Changing -:
In every 1000 hours below to be changed.
Change the transmission oil by removing

drain plug. After draining oil, tighten drain
plug.
Take out strainer and wash out dust with
diesel fuel.
After cleaning it, install strainer.
Refill transmission oil in specified amount
through filler (F).
For the refilling procedure, see the item
Initial 250 hours service.
FIGURE 7.4.1
After draining oil through drain plug hole,

refill the gear oil through filler up to the
prescribed level.

LUBRICANTS.

the
table
FUEL,
COOLANTAND
LUBRICANTS.
Refill capacity : 35 lts.
Refill capacity : 57 lts.
BG825
B22
FIGURE 7.4.2.
Tandem Drive Case
Change the Tandem oil Drive Case as

below.
After draining oil through drain plug hole.
Refill the oil (SAE 30W) up to the
prescribed level through the gauge hole .
LUBRICANTS
Refill capacity: 95 lts. (each side)
FIGURE 7.4.3.
Hydraulic Oil
Change the Hydraulic oil as below.

Loosen oil filler port slowly to completely
release the air inside the hydraulic tank.
Set the container under drain plug to catch
the oil.
To prevent getting oil on yourself, loosen
drain plug and drain the oil. To prevent the
oil from spurting out, loosen drain plug,
then gradually remove it.
After draining the oil, tighten drain plug.
BG825
B23

LUBRICANTS
Details shown below in Figure 7.4.6.
Refill capacity: 80 lts.

FIGURE 7.4.6.
7.5.
FIGURE 7.4.4.
Oil Case Worm Gear

Change the Front Wheel Spindle bearing

oil.
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.
Change Hydraulic oil filter element.

BG825
B24
7.6.
7.6.1
WHEN REQUIRED
CLEAN INSIDE OF COOLING
SYSTEM
Maintenance :
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
system pressure loss.
Check the coolant for any traces of oil

during daily maintenance.
Do not remove strainer from radiator filler
tube.
Antifreeze is flammable, so keep it

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

BEML Anti corrosion fluid is being
recommended for all equipment fitted with
BEML engines.
The details of the concentrate along with
other recommendations are appended
below:
DRAIN VALVE ( BOTTOM OF

RADIATOR)
Open drain valve at the bottom of the
radiator and plug on the side of cylinder
block to drain off the cooling water.
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:

Fluorescent Green
The PH value of the mixture (water +
concentrate) has to be maintained
between 7.5~9.5 (Check through pH
paper).
DRAIN VALVE
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 anticorrosion fluid the radiator has to be
flushed completely with clean water.
When removing radiator cap, lift the

lever to relieve inner pressure.
WATER FILLER
7.6.2
Radiator water filling is done from the cap
shown below.
CHECK, CLEAN AND REPLACE

AIR CLEANER ELEMENT
Checking
When the dust indicator (1) shows red the
air cleaner element needs cleaning.
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.
AIR CLEANER ELEMENT
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.
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.
BG825
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.
Drying can be speeded up by

blowing dried compressed air ( less
than 7 kg/cm2 ) from the inside to
the outside of the element.
NOTE: Do not attempt to reinstall a

cleaned inner 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.
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.)
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.
7.6.3
ELECTRICAL
HEATER
INTAKE
AIR
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.
BG825
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..
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.)
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
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.
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
exhaust gas.
white
or
blue-white
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.

Coolant temperature gauge pointer
stays in the red range on dial during
engine running.
Defective thermostat.
Defective coolant temperature gauge.
BG825
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.
9.2
CHASSIS
Tractive force is lacking. ( Insufficient

travel speed )
Engine knocks.
If machine falls to start at any gear shift

lever position.
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
Refer to the section of engine.

Check transmission.
Release parking brake lever.
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
satisfactorily
does
not
operate
Adjust brake pad.

Polish lining surface with sandpaper.
Disassemble and clean brake drum.
Replace the alternator.
Starting motor does not turn when

starting switch is turned on.
Inspect and repair the wiring.

Charge the battery.
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
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.
Adjust radial clearance of the circle.
Work equipment is slow to move by

operating the control lever
Add the oil to the specified level.
The starting motor disengages before the

engine start up.
Check and repair the wiring.

Charge the battery.
Wear of parking brake lining

The engine pre-heating monitor does not
flash.
Adjust clearance of lining.

9.3
ELECTRICAL SYSTEM
Lamp does not glow brightly even

when engine runs at high speed.
Check for loose terminals and opencircuit wiring.

Adjust belt tension.
Charge monitor does not go out even

when engine runs at high speed.
BG825
is
emitted
(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.
Replace the charge lamp.

Replace the alternator.
Inspect and repair wiring.
Unusual noise
alternator
Check and repair wiring.

Replace the heater relay.
Replace the monitor.
Charge monitor does not light up when

the engine is stationary.
Lamp flickers while engine runs.
from
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
2
3
4
5
6
VBATT +
CAN High
CAN low
Ignition
VBATT -
Red
Yellow
Green
White/Purple
Black
b. Display
Active gauges Screen I
Screen II
BG825
B35
Inactive Gauges
INACTIVESTATE
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 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 3
Pin 4
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
Powerupdisplay
Ignitionon
Buttonslit
anddisplay
on?
No
CheckSupplytoPV750displaypins1
(+ve),6(ve)and5(+vewithIGNon)
Yes
Allgauges
inactive?
Yes
CheckCANconnectionstoPV750display
pin2CANhigh
pin3CANlow
No
AllEngine
gauges
inactive
Yes
Yes
No
Onegauge
orsymbol
inactive
No
BG825
Yes
Electronic
Gearbox
No
Yes
CheckCANconnectionto
engineECU
CheckengineECU
CheckBatterynegative
connectiontoengine
Goto4.2.1
No
No
AllGearbox
gauges
inactive
Electronic
Engine
Yes
CheckCANconnectionto
engineECU
CheckengineECU
Checkbatterynegative
connectiontogearbox
Goto4.2.1
Goto4.2.1
End
B39
b. I/O module
Checkindividual
gauges/symbols
c.
I/Ounit
connectors
tight
No
Tightenconnectors
Yes
Analogue
input?
Resistive
Sender?
Yes
Yes
Removeconnectionto
senderandconnectto
batterynegative(ground)
No
Goto4.2.4
Goto4.2.2
Yes
IsDM1for
inputFMI4?
Frequency
sender?
No
Goto4.2.3
Yes
No
Yes
420mA
sender?
Fitknownsuitableresistancetoinput
Removeconnectionto
senderandleave
disconnected
Yes
IsDM1for
inputFMI3?
No
Reading
correct
No
Checkwiring
Checkinputisactivein
profile
Yes
Replacesender
BG825
B40
Frequency
Frequency
sender?
Yes
Injectfrequencysignal
Gauge
operational
No
Checkwiring
Checkinputisactiveinprofile
ReplaceI/Omodule
Yes
ReplaceMPU
420mA
sender
Yes
Disconnectsenderand
connectwiretoground
DM1
SPN/FMI?
No
Checkwiring
Checkifinputisactiveinprofile
ReplaceI/Omodule
Yes
ReplaceSender
BG825
B41
d. Digital inputs
D1D7?
Yes
Withinputactivecheckbattery
positiveispresentatswitch
No
Battery
positive?
Yes
Checkwiring
ReplaceI/Omodule
No
Checkwiring
Replaceswitch
D8D32
Yes
Closeto
negative
Yes
Disconnectsenderandconnect
tobatterynegative
No
Senderisopenfromnegative
Disconnectsender
Correct
operation
No
Checkwiring
ReplaceI/Omodule
Yes
Changeswitch
Correct
operation
Yes
Changeswitch
BG825
No
Disconnect40wayconnector
onI/Omodule
l
/
d l
Correct
operation
No
Checkifinputisactive
ReplaceI/Omodule
Yes
Checkwiring
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.
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.
Lower the air pressure in the tires to about

80% of the standard operating pressure.
If the machine is stored without carrying

out the monthly rust prevention operation,
request your BEML service personnel.
Give a thin coat of grease to metal surface

(hydraulic piston rods and oil seal).
11.
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.
MACHINE
AND
SERIAL NUMBERS
ENGINE
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.
Set the gear shift lever to neutral position,

set the fuel control lever to engine stop
position, and leave the steering pedal not
locked.
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.
1.
2.
BG825

1. BG825DETAILS
Page no.
C3
1.1. Performance
1.2. Weight
1.3. Engine
C3
C3
C3
1.4. Axles
1.5. Steering
C3
C3
1.6. Blade Range

2. BG825 LAYOUT
C3
C4
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
1ST
2ND
3RD
4TH
5TH
6TH
7TH
8TH
4.3
5.8
8.5
12.2
16.9
22.8
33.4
47.9
Reverse
Maximum Drawbar Pull :
1.2.
WEIGHT
Operating weight
1.3.
14,420kg
25,750 kg
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

BG825
90deg
C3
2. BG825 LAYOUT
(UNIT: mm)
BG825
C4
SECTION - D
FUEL AND LUBRICANTS
Section D
FUEL AND LUBRICANTS
INDEX
Sl.no.
1.
BG825

1. PROPER SELECTION OF FUEL AND
LUBRICANTS
Page no.
D3
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

than 0.5 % change oil in the oil pan
every periodic maintenance hours
described in this manual.
Change oil according to the following
table if fuel sulphur content is above
0.5 %
BG825
* ASTM :
American Society of
Testing and Material
* SAE :
Society of Automotive
Engineers
* API :
American Petroleum
Institute
D3
Fuel sulphur
content
Change interval of oil

in engine oil pan
0.5 to 10%
of regular interval
Above 1.0 %
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.
Suitable multi grade oil can be used

for varying ambient temperature
(day/night)
Avoid mixing of different brands of oils

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
BG825
Amount of oil needed to refill system during normal inspection and

maintenance.
D4
HYDRAULIC OIL
SL. NO.
1
2
3
4
5
6
DESCRIPTION
SAE 10W
SUPPLIER (M/S)
I.O.C
CHEMOLEUMS
I.B.P
B.L
B.P.C.L
T.W.O
BRAND NAME
SERVO ULTRA KB 10W
BEML SUPER CLEAN EH 10W
IBP ULTRA 10W
PROTOMAC ULT 10W
MAK CD 10W
VEEDOL 901-S3-10W
TRANSMISSION OIL
SL. NO.
1
2
3
4
5
6
DESCRIPTION
SAE 30W
SUPPLIER (M/S)
I.O.C
CHEMOLEUMS
I.B.P
B.L
B.P.C.L
T.W.O
BRAND NAME
SERVO ULTRA KB 30
BEML SUPER CLEAN ET 30
IBP ULTRA 30
PROTOMAC ULT 30
MAK CD 30
VEEDOL 903-S3-30
GEAR OIL
SL. NO.
DESCRIPTION
1
2
3
SUPPLIER (M/S)
I.O.C
CHEMOLEUMS
SAE 90
I.B.P
B.L
B.P.C.L
BRAND NAME
SERVO GEAR SUPER 90
TURBO SAE 90
SPECIAL GEAR OIL 90
EXTRA SPECIAL GEAR OIL 90
BALMEROL PROTOMAC SAE HP90
SPIROL EP 90
SPIROL HD 90
GREASE
SL. NO.
DESCRIPTION
SUPPLIER (M/S)
1
2
LITHIUM BASE
EP-2
B.L
T.W.O
BG825
BRAND NAME
LIPREX EP-2
ALITHEX 20 GREASE
D5

BG825 Om 27.02.15

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BG825

OPERATION & MAINTENANCE

BG825 MOTOR GRADER

BG825 OPERATION & MAINTENANCE

Please read this manual carefully BEFORE operating the machine.

The specification contained in this manual is subject to change at any time

This ALERT symbol is used with words CAUTION ,

Indicates the potential hazard which may result in personal injury or

Indicates the potential for equipment damage. This is a general

Indicates a specific potential hazard which will result in either personal

BREAKING IN YOUR NEW MACHINE

Avoid operation with heavy loads or at high speeds.

Changing all oil, filter elements and cartridges.

Checking and adjustment of engine valve clearance.

Hours of operation are indicated by the service meter.

FUEL AND LUBRICANTS

Section reference no. and Description

Section reference no. and Description

Section reference no. and Description

Safety records of most organizations will

Read and follow all safety precautions.

Take care of your health. Do not drive

FIGURE 1-1. SAFETY ACCESSORIES

Accidents or injuries are liable to occur

Be sure fire extinguishers have been

When working with another operator or a

Provide a first aid kit at the storage point

FIGURE 1-4. SAFETY FROM

FIGURE 1-5. FLAME RESTRICTED

Take care not to get caught by protruding

FIGURE 1-6. AVIOD FUMES

Check fuel, lubrication, and hydraulic

FIGURE 1-7. READ MANUAL

Learn how to use the control devices,

Trained and authorized personnel should

Any modification made to this vehicle

Examine the lay of the land and the kind

When working with another operator or a

Be sure all guards and covers are in their

FIGURE 1-8. ENSURE SAFETY

Inspect the inside of the engine room and

FIGURE 1-9. TOOLS TO BE IN

FIGURE 1-11. INSPECT THE M/C

AFTER STARTING ENGINE

Confirm that all gauges and warning

FIGURE 1-12. CHECK FOR

Operate the blade to confirm that they are

Move the machine slowly and listen

Never do the following.

Before, careful of those around you, and

FIGURE 1-14. AVOID OBSTACLES

FIGURE 1-13. TAKE TURN

Always concentrate. It is extremely

Always operate slowly in crowded places.

In dangerous places, or where there is

FIGURE 1-15. DONT ALLOW

Always be aware of the operating capacity

Never leave the operator's seat without

If the machine breaks down and needs to

FIGURE 1-18. CHECK LOAD LIMIT OF

When operating on uneven ground, drive

FIGURE 1-17. PROPER PARKING OF

When working on river embankments