GMI-251

DIRECTOR GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION NO. 251

ON OPERATION AND MAINTENANCE OF

HYDRAULIC EXCAVATOR 20 TON CAPACITY MAKE BEML MODEL BE 220

INTRODUCTION:

(a)  The Hydraulic Excavator make BEML model BE 220 having operating weight 22800 Kgs (approx) and mounted on Tractor type under carriage powered by BEML make BS6D105-1 model, 4 stroke, 6 cylinder, water cooled, Turbo charged, inline, direct injection diesel engine developing 148 HP at 2100 rpm including 5.85 meter one piece Boom, 2.5 meter Arm with 1.00 cum SAE heaped capacity general purpose bucket.

(b)  This GMI gives the technical specification and know how on the operation, maintenance and repair procedure of Hydraulic Excavator BEML model BE 220 to ensure maximum performance and safe/satisfactory operation. Compliance with procedures given in this GMI will enable to get desired maximum service from the equipment.

(c)  Maintenance of Hydraulic Excavator BEML model BE 220 will lead to long life, trouble free operation and less frequent break downs and also to reduce maintenance cost. The periodic maintenance must be carried out according to the ‘Periodic Maintenance Schedule’ described in this GMI. Daily care, inspection and Periodic Maintenance are essential for preventing troubles and accidents to ensure satisfaction and safe operation for prolonging the operating life of the equipment. All information and instructions given in this GMI is based on the latest Operator’s manual and service booklet provided by the firm.

AIM:      The instruction is issued as guidelines for general, preventive maintenance schedule and lubrication of Hydraulic Excavator BEML model BE 220 manufactured by  M/s BEML Ltd for regular attention to keep the equipment in good mechanical condition which must be strictly followed.

ACTION BY:

a)	User unit:          To carryout periodic inspection and monitor regular/periodical maintenance as laid down in this instruction and record the tasks done in log book.
b)	Field Workshop :
	i)	To carryout and monitor maintenance schedule and oil changes as per periodical maintenance laid down in the maintenance instructions and to check the record of maintenance including lubrication.
	ii)	To advise the user unit in respect of any lapse noticed.
c)	Mobile Maintenance Team:    To ensure that proper maintenance is carried out and submit report accordingly to Task Force Commander and OC Wksp for their necessary action.

DETAILS:

            This instruction includes the following aspects:-

a)	Operating Procedure	Appendix ‘A’
b)	Periodic Maintenance schedule	Appendix ‘B’
c)	Technical Specification	Appendix ‘C’
d)	Recommended Lubricants with filling capacity and periodicity for change	Appendix ‘D’

         

                                                                                                     Sd/-

                                                                                                (Deepak Kumar)

                                                                                                EE (E&M) SG

                                                                                                Joint Director (Tech)

                                                                                                For Dir Gen Border Roads

                                                                                                           

                                                                                                Appendix ‘A’

OPERATING PROCEDURE

PRECAUTIONS FOR OPERATION:

1.   Be careful not to compact the soil or damage earth mounds as a result of the swinging force. When swinging, do not dig the bucket teeth into the soil.

2.   Do not move off and excavate with the bucket leaving dug into the ground.

3.   When working with the machine, do not move the cylinder to the end of its stroke but leave a small safety margin.

4.   Do not use the dropping force of the bucket as a pickaxe, breaker, or pile driver and dropping force of the machine for digging.

5.   It is better to excavate hard rocky ground after breaking it up by some other means.  This will not only reduce damage to the machine but make for better economy.

6.   When descending a steep slope, adjust the speed by means of the travelling and steering levers and fuel control lever.

7.   Do not immerse the machine in water by more than permissible depth (under swing circle). In addition, properly grease parts which have been immersed in water for a long time, until the old grease comes out from the bearings (vicinity of bucket pins, swing circle system etc).

8.   When removing the machine from water, if the machine is given a posture of climbing at steep angle (less than 30⁰, however) the rear part of the upper swing body may dip into the water with its radiator fan scooping up water. In that event, then fan may break.  Be sufficiently careful when removing the machine from water for this reason.

9.   To stop/brake the machine during downhill runs, put the travelling and steering lever in the neutral position. This will cause the brake to be automatically applied.

10.  When climbing a hill, if the shoes slip or the travel motor relieves, preventing the machine from climbing by means of the tracks alone, it is possible to use the force of the Arm as an aid.

11.  When the engine stops on a slope, move the travelling and steering levers to neutral position and lower the bucket. Thereafter, turn starting key to START.

12.  The wide triple grouser shoe (700, 800, 900 mm) and swamp shoe (860 mm) are designed for use on soft, weak ground. Do not use them on rocky ground, gritty ground or unleveled ground.

13.  When travelling down a hill, adjust the speed with the travel lever and fuel control lever. If the grade exceeds 15⁰, set the machine in such a posture so as to avoid damage and reduce the engine speed.

14.  Do not travel on slopes of over 30⁰ as there is danger that the machine may overturn.

AIR BLEEDING PROCEDURE

      The following procedure needs to be carried out for bleeding  the air whenever any maintenance work is done on the Control valve, Hydraulic pump, Hydraulic motor, pipe lines or there is any chance of air setting in through any leakage points :-

     

i)	Fill the hydraulic oil into the hydraulic oil tank through hydraulic filtration unit.
ii)	Open the metal plug of the pump labeled as R1and allow the oil to fill the void inside. Tighten the metalplug of R1 port of the pump after the case is full with the oil and no air bubbles are coming out.
iii)	Fill the filtered oil in to the housing of both travel and swing motor till there is no sign of entrapped air in both the motors.
iv)	After bleeding the air completely from the pump, start and run the engine at low idle speed.
v)	Remove the air bleed M6 screw located at the top of the pilot of the main control valve.
vi)	Operate the swing joystick gently and allow oil to come out from the swing spool section’s top pilot cover of the main control valve.
vii)	Let the void inside the swing pilot cover be escaped and the pilot cover is full with the hydraulic oil.
viii)	Check and ensure that the oil coming out from the pilot cover should be free from air bubbles when the joystick is operated gently. After bleeding, tighten back M6 air bleeding screw.
ix)	Bleeding of the pilot cover at the bottom of the control valve shall be carried out by operating all the implements and travel in both directions repeatedly.

MISCELLANEOUS

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

2.   Avoid operation with heavy loads or at high speeds.

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

4.   Sudden starting or acceleration, unnecessarily abrupt to breaking and sharp turning should be avoided.

5.   When the engine is started, all the monitor lamps will go off even if there are abnormalities.

6.   The buzzer does not sound if the battery charge is low.  If any monitor lamp flashes, stop the engine or run it at a low idling speed and repair it immediately.

7.   Always Park the machine on level ground to check the monitor lamps.

8.   Do not place your foot on pedals unnecessary.

9.   Swing lock lever must be in the lock position during traveling of machine and after the upper works is parallel with the track frame. Do not attempt to rotate the upper works when the swing lock lever is in lock position.

10.  When removing the radiator cap, release radiator pressure little by little by loosening cap slowly, then remove cap.

11.  After warm up run of engine is completed, check gauges, monitor lamp for proper operation.

12.  Continue to run the engine at light load until the green range of engine water temperature gauge light.

13.  Avoid abruptly accelerating engine until the completion of warm-up.

14.  Do not run for more than 20 minutes at low idling or at high idling.

15.  The hydraulic oil temperature should ideally lie within the range 50 to 80⁰C. If the machine is operated after raising the oil temperature to 20⁰C, the life of the machine will be extended.

16.  When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes. As an additional safety measure thrust the bucket into the ground.

17.  After starting the engine confirm that all gauges and warning devices are functioning correctly and that the gauge readings are within the prescribed range.

18.  Before operating the travelling and steering levers or pedals, check whether the track frame is facing forward or backward. If the track frame is facing backward, operate the travelling and steering levers or pedals in the reverse manner to that when the track frame is facing forward.

19.  Maintain the bucket at a height of 40 to 50 cm above the ground so that it can be quickly lowered to the ground and the machine stopped in an emergency.

20.  When operating on slopes, as far as possible, avoid turning the machine on a slope. It may cause the machine to roll over or slip sideways.

21.  When operating the machine along a road, retract the work eqpt to improve machine ability.

22.  Check the load limits of bridges before crossing.

23.  When stopping/parking the machine, return the work eqpt levers to neutral, apply the brake lock, lower the bucket to the ground and put all safety levers in the lock position.  The safety levers are used to lock the work eqpt levers. Switch off the engine and remove the key.

     

24.  Take care not to swing the bucket against the sides of trenches or dump trucks.  Load the truck from the rear.

25.  Avoid abruptly operating the travelling and steering levers with the fuel control lever fully open, as this will cause the machine to move off suddenly.

OPERATION AND MAINTENANCE TIPS FOR HIGH ALTITUDE AREA

1.   Be familiar with cold starting and maintenance related issues.

2.   If smoke is excess (due to lack of air) even though the air cleaner element is clean, then it may be necessary to reduce the amount of fuel injected.

3.   If engine is over heating (due to lack of air for cooling) even though the engine and radiator are in good condition, then it may be necessary to reduce the amount of fuel injected.

4.   As much as possible, avoid mixing of ATF with diesel to reduce pour/cloud point since it reduces the lubricity of fuel and causes abnormal wear of fuel injection pump and injector elements.  If it is unavoidable, then add proper additives to improve lubricity.

Note:   To avoid premature failure of fuel system components & poor starting of Engine, it is very essential to use proper fuel for sub-zero operating conditions. As a general rule, select a fuel such that the pour/cloud point of the subject fuel is always lower than the prevailing ambient temperature at site.  Colour coding scheme may be followed for the barrels (if used for storage) for easy identification of fuel for the corresponding period or temperature range.

5.   Fuel filter clogging directly depends upon the quality of fuel due to ‘gel’ formation (poor pour/cloud point) and as well as on the prevailing ambient temperature, in addition to dirt in the fuel.  Therefore, filter element change frequency to be altered depending upon the site condition.

6.   It is recommended to store the eqpt in an enclosed chamber preferably with a warming facility to avoid freezing.  Alternatively, it is recommended to cover the entire eqpt with thick polyethylene sheen when stored in open place to protect it during cold weather, snow, other wise, it becomes very difficult to start.  Ensure muffler tail pipe be covered to avoid snow entry.

7.   If starting becomes very difficult in extreme cold condition even after using air heaters then it is advisable to use hot water/hot air (using portable air heaters) to warm fuel, water and oil instead of using naked flame.  Many times naked flame is the root cause for burning of air cleaner elements, fuel hoses, water hoses etc.        

8.   Fuel stored in barrels shall also be protected from cold weather to avoid gel formation.

9.   The engine should not be run without thermostat.

10.  If any over cooling of engine is encountered, radiator shutters/cover may be employed to overcome the same.

Appendix ‘B’

PERIODIC MAINTENANCE SCHEDULE

Maintenance work.

Service intervals in hours.

Remarks.

Daily

100

250

500

750

1000

1250

1500

ENGINE

Check Engine oil level and top up if necessary.

*

Engine oil change .

*

*

*

*

*

*

Engine Breather cleaning.

After every 2000 Hrs.

Replace Engine Breather hose.

After every 2000 Hrs.

Check Eng vibration damper for crack/leakage.

After every. 2000 Hrs

Engine oil filter change .

* (Initial)

*

*

*

*

*

Replace once every 6 months if low idle / utilization .

Check and adjust Engine valve clearance.

* (Initial)

*

*

*

*

*

Also at 2000 Hrs run.

Check around the engine for water and oil leaks.

*

COOLING SYSTEM

Check coolant level and top up if necessary.

*

Check Radiator for water leak.

*

Check and adjust Water pump belt tension .

*

*

*

*

*

*

*

Check for sealing foam around Radiator assy and cover. Ensure all gaps are sealed properly.

*

Clean Radiator/oil cooler fins & Rubber hoses for crack/leak and hose clamp looseness.

*

*

*

*

*

*

Check Water pump.

After every 4000 Hrs.

Clean the inside of the cooling system and replace the Coolant .

As and when required/once a year.

FUEL SYSTEM

Fuel Tank sediment & water draining.

*

*

*

*

Replace Fuel pre-filter and fine filter.

* (Initial)

*

*

*

*

*

Inspect float position (Water separator).

*

Drain water. (Water separator)

As and when required.

Maintenance work

Service intervals in hours.

Remarks.

Daily

100

250

500

750

1000

1250

1500

AIR INTAKE

Check Dust Indicator.

*

Check & clean Air cleaner element (only outer) whenever Red piston in Dust indicator appears.

As and when required.

Check tightness of Air cleaner mounting bolt.

*

Replace the outer element which has been cleaned 6 times repeatedly or used through a year. Replace inner element at same time.

Replace both inner and outer element when the Dust indicator red piston appears soon after installing the cleaned outer element even though it has not been cleaned 6 times.

ELECTRICAL SYSTEM

Check electrolyte  level in Battery & top up, if necessary and clean air hole of Battery cap.

*

*

*

*

*

*

Check electrical intake Air Heater.

As and when required/once a year.

Check tightness of Battery terminal/wiring connections.

*

Check Alternator and Starter Motor.

After every 2000 Hrs.

SWING MACHINERY CASE

Check oil level and top up if necessary.

*

*

*

*

Lubricate grease fittings of Swing circle.

*

*

*

*

*

*

Grease Swing circle pinion. (Grease capacity 14 kg)

*

*

*

After every 500 Hrs.

Oil change

*

FINAL DRIVE CASE

Check oil level and top up if necessary.

*

*

*

*

*

*

Oil change.

After every 2000 Hrs.

HYDRAULIC SYSTEM

Check Hyd oil level and top up if necessary.

*

Hydraulic oil change .

After every 2000 Hrs.

Hydraulic oil tank Strainer cleaning.

After every 2000 Hrs. If damaged, replace with new one.

Maintenance work

Service intervals in hours

Remarks

Daily

100

250

500

750

1000

1250

1500

Check for oil leak at Hydraulic pressure hoses/joints and Hydraulic cylinder seal.

*

Replace Hydraulic filter.

*

*

*

*

*

*

OTHERS

Inspect leakages from fuel, lubricating and hydraulic systems.

*

Check Turbocharger clamping joints for looseness.

*

Clean Blower impeller of Turbocharger.

After every 2000 Hrs.

Axial play by moving Rotor of Turbocharger. (STD: 0.16 mm)

*

If play is over the limit, consult BEML office.

Radial play by moving Rotor of Turbocharger. (STD: 0.43 mm)

*

If play is over the limit, consult BEML office.

Replace Bucket teeth. (Replace the tooth point before the Adaptor starts to wear)

As and when required.

Check the Track shoe bolts for looseness  and tighten if necessary.

As and when required.

Check & Adjust Track tension.

As and when required.

Check final drive case for oil. leaks and check tightness of sprocket mounting bolt.

*

Check tightness of idler mounting bolt.

*

GREASING

Boom / Arm / Bucket cylinder foot pins/rod end pin, Boom-Arm / Arm-Bucket coupling pin, Link coupling pins and other pins.

*

*

*

*

         Note:-  

1.      During initial 100 Hrs, the work equipment fixing pins are to be greased before each operation. Greasing     is to be repeated after operation of the boom, arm and bucket is conducted several times.

2.      When carrying out 250 Hrs, 500 Hrs, 1000 Hrs, 2000 Hrs, etc maintenance, it is mandatory to carry out the maintenance of Daily and 100 Hrs also.

                                                                                                                                    Appendix ‘C’

TECHNICAL SPECIFICATION

Description	:	Hydraulic Excavator 20 Ton BEML BE 220
ENGINE
Model.	:	BEML BS6D105-1.
Type.	:	6 Cylinder inline, diesel, 4 stroke, Water cooled, turbo charged.
Cylinder Bore x stroke.	:	105 mm x 125 mm.
Flywheel Horse power/Net power.	:	148 HP (110 KW)  @ 2100 rpm.
Maximum Torque.	:	56.5 Kgm @ 1400 rpm.
Piston displacement.	:	6494 cc (6.494 l).
Firing Order.	:	1-5-3-6-2-4.
High idling speed.	:	2250 – 2350 rpm.
Low idling speed.	:	800 – 900 rpm.
Dry weight.	:	620 Kgs.
Turbo charger.	:	T04B.
Type of radiator.	:	D- Type corrugate fin.
Engine oil pressure at high idling.	:	3.50 – 5.50 kg/cm.2
Engine oil pressure at low idling.	:	1.00 kg/cm2
Coolant temperature.	:	70 – 800C.
Oil temperature.	:	80 – 1100C.
Fuel injection pressure (Nozzle tester).	:	225 kg/cm2
Fuel injection timing (B.T.D.C).	:	200 + 1.
Compression Pressure.	:	Min. 31.5 kg/cm2 (at Engine speed 320-360 rpm and oil temperature 40-600C.
Valve Clearance at 200C.	:	Inlet – 0.25 mm. Exhaust – 0.45 mm.
ELECTRICAL SYSTEM
Battery.	:	12 V 120 AH (140 AH) Qty – 02 Nos.
Alternator .	:	24 Volt, 30 Amp (25 Amp).
Starting Motor.	:	24 Volt, 4.5 kW (7.5 kW).
BRAKE
Travel/steering type.	:	Hydraulic lock.
Parking brake.	:	Spring applied and hydraulically released oil disc brakes.  Travel Motors equipped with brake valve which regulates speed when making descents.
STEERING
Type.	:	Steering actuated with either hand levers or foot pedals.  Independent drive to each track enables machine to make a pivot turn in either direction.
FILTER SYSTEM
Engine.	:	Two Stage fuel filter with water separator.
Air intake.	:	Dry type, Two stage Air cleaner with dust evacuator.
Hydraulic.	:	One suction strainer, one line filter in the charge pump circuit  &  one return line filter.
UNDER CARRIAGE
Track frame type.	:	H-bar type centre frame is integrally welded with reinforced box-section track frame.
Standard shoe width.	:	610 mm.
Grouser height.	:	26 mm.
No. of shoes ( one side).	:	51 Nos.
No. of Carrier rollers (one side).	:	02 Nos.
No. of Track rollers (one side).	:	8 (10) Nos.
Track shoe.	:	Built-up triple grouser.
Ground pressure	:	0.47 kg/cm2 (46.1 kPa).
HYDRAULIC SYSTEM
Hydraulic Pumps
Type, Number.	:	Variable displacement piston type x 2 Nos Gear type x 1 No.
Delivery/capacity.  (at rated engine speed)	:	Piston type : 2 x 193 ltr/min @ 2100 rpm Gear type : 50 ltr/min @ 2100 rpm.
Set pressure	:	Piston type : 320 Kg/cm2 Gear type : 30 Kg/cm2
Hydraulic Motors
Travel motor.	:	Piston type (with brake valve and parking brake) x 2 Nos.
Swing  motor .	:	Piston type (with swing mechanical brake) (if equipped)  x 1 No.
Control Valves
Type, Number.	:	7-spool type
Control lever operation.	:	Pilot type (travel control hydraulic type)
Relief valve setting
Implement circuits. (Boom, Arm & Bucket)	:	320 kg/cm2 (31.4 MPa).
Swing circuits.	:	275 kg/cm2 (26.97 MPa).
Pilot circuits.	:	30 kg/cm2 (2.94 MPa).
Hydraulic cylinders
Type.	:	Double acting piston.
Hydraulic tank.	:	Closed box type.
No of cylinders / Bore x stroke
Boom.	:	02 Nos / 130 x 1234 mm.
Arm.	:	01 No / 140 x 1628 mm.
Bucket.	:	01 No / 130 x 989 mm.
Hydraulic filter.	:	Tank return side.
Hydraulic  cooler.	:	Air cooled.
SWING SYSTEM
Type.	:	Spur and Planetary reduction Gears, with pin-lock type swing lock.
Swing speed.	:	13 rpm.
Tail Swing radius.	:	2900 mm.
Minimum swing radius. (work eqpt fully retracted)	:	3800 mm.
Reduction ratio.	:	187.086.
DRIVES
Type.	:	Fully hydrostatic, two stage planetary reduction.
Max Drawbar pull.	:	153.96 kN (15700 kg).
Max Travel speed.	:	3.4 km/hr.
Reduction ratio.	:	(-) 78.714
STATIC DIMENSIONS OF EQPT
Overall length.	:	10000 mm.
Overall width.	:	2990 mm.
Overall height.	:	3060 mm.
Sprocket centre to idler centre. (Track length)	:	3445 mm.
Track gauge.	:	2380 mm.
Minimum ground clearance.	:	554 mm.
Ground contact area.	:	50697 cm2
Operating weight	:	22800 kg.
BACKHOE BUCKETS
Bucket capacity.  (SAE/ISO heaped)	:	1.00 Cum.
Bucket capacity  Struck.	:	0.76 Cum.
Bucket width without side cutters.	:	1155 mm.
Bucket width with side cutters.	:	1250 mm.
Bucket mass without side cutters. (with teeth)	:	918 kg.
Bucket mass with side cutters. (with teeth)	:	952 kg.
No. of bucket teeth.	:	04 Nos.
WORKING RANGE (Arm length 2.5 mtr)
Maximum digging height.	:	8970 mm.
Maximum digging depth.	:	6170 mm.
Maximum vertical wall digging depth.	:	4970 mm.
Maximum dumping height.	:	6200 mm.
Maximum digging reach at ground level.	:	9510 mm.
Bucket digging force.	:	125 kN (12700 kg).
Arm crowd force.	:	120 kN (12270 kg).

Appendix ‘D’

RECOMMENDED LUBRICANTS WITH FILLING CAPACITY AND PERIODICITY

S/No	Item	Viscosity Grade	Grade of Lubricant		Filling Capacity	Periodicity for change
			BEML STD	IOC
a)	Engine. BS6D105-1	CF4 15W 40	C6002-30	Servo premium CF4 15W40	17.5 ltrs	Initial Eng oil and oil filter element change at 250 Hrs and thereafter every 250 hrs.
b)	Swing Machinery case. (Swing Drive)	SAE 30 CD	C6002-03	Servo Ultra KB 30	9.3 ltrs	Oil change after every 1000 hrs.
c)	Final drive case.	SAE 30 CD	C6002-03	Servo Ultra KB 30	3.7 ltrs (on each side)	Oil change after every 2000 hrs.
d)	Hydraulic system.	SAE 30 CD	C6002-03	Servo Ultra KB 30	150 ltrs	Hydraulic oil filter element change after every 250 hrs and Hydraulic oil change after every 2000 Hrs.
e)	Coolant.	-	-	-	35 ltrs	Coolant change once in a year.
f)	Grease .	Molex Grease	C6003-02	Servo Molex Grease	-
g)	Fuel Tank.	HSD	C6002-01	-	280 ltrs
h)	Fuel pre-filter and fine filter.	-	-	-	-	Initial fuel pre-filter and fine filter element change at 250 Hrs and thereafter every 250 hrs.
j)	Air Cleaner.  (Element Assy)	-	-	-	-	When required.
k)	Hydraulic oil tank Strainer.	-	-	-	-	After every 2000 Hrs, if found damaged.

Note:

Never mix two different brands of oil.

Do not mix one brand of Coolant/Antifreeze with a different brand.

   _______