GMI-252

DIRECTOR GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION NO. 252

ON OPERATION AND MAINTENANCE OF

MOTOR GRADER MAKE BEML MODEL BG 605

INTRODUCTION:

(a)     Motor Grader make BEML model BG 605 mounted on axle wheel type under carriage powered by BEML make BS6D125-1 (BS-III) model, 4 stroke, 6 cylinder, water cooled, Turbo charged, inline, direct injection diesel engine developing 145 HP (108 kW) at 1800 rpm.

(b)  This GMI gives the technical specification and know how on the operation, maintenance and repair procedure of Motor Grader make BEML model BG 605 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 Motor Grader make BEML model BG 605 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 instructions are issued as guidelines for general, preventive maintenance schedule and lubrication of Motor Grader make BEML model BG 605 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 – Do’s and Don’ts.	Appendix ‘A’
b)	Periodic Maintenance schedule.	Appendix ‘B’
c)	Technical Specification.	Appendix ‘C’
d)	Recommended Lubricants with filling capacityand periodicity for change.	Appendix ‘D’

                                                                                                   Sd/-

                                                                                                (Deepak Kumar)

                                                                                                EE (E&M) NFSG

                                                                                                Joint Director (Tech)

                                                                                                For Dir Gen Border Roads

                                                                                                           

                                                                                                 Appendix ‘A’

OPERATING PROCEDURE - DO’s & DON’Ts

GENERAL

1.      Initial warming up of Engine before putting on load.

2.      Check for abnormal noise/blow-by/smoke color.

3.      Avoid prolonged low idling and high idling of engine.

4.      Before stopping the engine, put in low idle and check for leakage.

5.      Frequent monitoring of dashboard gauges while operating the equipment to avoid engine damage.

6.      Avoid lugging and sudden acceleration.

7.      Attend to any minor problems without postponing, particularly with respect to leaks & fire hazards.

8.      Sufficient care should be taken when the equipment is going down the gradient since there is a chance of engine being over driven (run) by the drive line, which will cause major damage to engine.

9.      The engine should be started periodically (at least once in a month) when the equipment is in storage.

10.     In case the engine is stored for long period, charge turbocharger and lube oil system with fresh oil and do cold cranking before starting the engine.

11.     Use proper clamps for hose connections.

12.   Whenever drive line (engine mounted assembly) is disturbed, check crankshaft endplay after re-assembly.

13.     Check engine anti vibration mounts for cracks periodically and replace if necessary.

14.     Disconnect electrical system (negative terminals of alternator, starter and battery) while carrying out any welding on equipment. This is to avoid failure of electrical/electronic components.

15.     Oil pressure and water pressure gauges are most important as far as engine is concerned and maintain the same is good condition.

16.     Always carry out daily inspection and maintenance correctly. Check for leakage for fuel/lubricant/coolant and for loose or broken or missing parts.

17.     Before starting the engine, make sure that all control levers are in “NEUTRAL”.

18.     Check the level of the fuel, lubricants and cooling water.

19.     Run the engine at the low idling (at least 3 minutes) to cool the engine slowly and then stop the engine.

 AIR INTAKE SYSTEM

1.     Clean element only when required (ref dust indicator) to increase service life of the element.

2.    Do not clean inner element. Clean only the outer element upto 6 times max. Make use of the stickers marked from 1-6 on the metal portion by removing each sticker whenever that numbered cleaning is completed (For example, if you are cleaning for the 2^nd time, remove the sticker numbered 2 & so on).

3.     While changing the outer element change the inner element also as a set.

4.   Use correct air jet and avoid excess air pressure (recommended is 2 to 5 kg/cm²) while cleaning the element.

5.     After cleaning the outer element check for puncture of filter paper, if damage is noticed, change as a set.

6.   Check the rubber hoses and elbows for proper clamping, tightness of clamps, surface cracks, aging, puncture etc periodically.

7.   When dust indicator is changed (due to damage) ensure correct specification. Engine should not be operated with broken dust indicator. A plug should be fitted till a new dust indicator is fitted.

8.   If equipment is operating in a remote area where compressed air facility is not available for element cleaning, then a dedicated air cleaner element may be provided as stand-by. Always keep in mind that the inner element also has to be replaced after 6 cleaning of the outer element ie. both the elements together.

9.   Any lapses in ‘Air Intake System’ maintenance or noncompliance shortens the engine life by way of accelerated wear of cylinder liner, piston, piston rings & bearings and also results in faster deterioration of engine lube oil.

LUBE OIL SYSTEM

1.      Use correct engine oil grade and class as per recommendations and ambient temperature.

2.      Do not mix different brands, grades and classes of oils.

3.      Change the engine oil and cartridge, if the engine is stored for longer period (more than 6 months) before starting.

4.      Always drain oil (during oil change) when it is warm.

5.      Check for debris/metal particles in the old cartridges. If present, investigate.

6.      Check the condition of seal of new cartridge before fitting.

7.     Sudden stoppage of engine will damage the Turbocharger, therefore run the engine at low idle for few minutes before stopping.

8.      Check the oil level using the dip stick gauge. If the oil level lies between the H & L mark on the gauge, then the oil quantity is normal. The oil level shall be checked when the eqpt/engine is in the horizontal position.

FUEL SYSTEM

1.      Maintain storage & equipment fuel tank in clean condition.

2.     Fuel tank lid to be always secured and strainer to be used in the filter pipe. Never use cotton waste for cleaning the fuel tank.

3.      Always check for fuel leakage, hose condition and clamping.

4.      Avoid by-passing the water separator.

5.      Do not over tighten the banjo bolt (with strainer) at the FIP feed pump inlet to avoid collapse.

6.      Do not add any additional strainer or filter on the suction side of FIP.

7.      Check for debris/metal particles in the old cartridges. If present, check the condition of fuel in the tank.

8.      Check the condition of seal of new cartridge before fitting.

9.      Frequent usage of drain cock of water separator may lead to leakage of fuel & air lock, as a result of poor sealing. Therefore, drain water when float reaches the red line.

COOLING SYSTEM

1.      Radiator cap is always to be fitted to avoid dust collection, coolant loss and system pressure loss.

2.    Clean/wash radiator fins periodically. Do not use sharp tools for cleaning tubes/fins as it may puncture them.

3.      It is advisable to change the hoses and fan belts periodically since abrupt failure of these items will lead to engine seizure.

4.      Always change fan belts in sets.

5.    When the coolant temperature goes beyond limits, it is advisable to run the engine at medium speed without load for further investigation.

6.      Change the coolant at least once in a year.

7.      Rapid raise of coolant temperature beyond 75⁰ C indicates that the thermostats are stuck.

8.    Radiator (top tank) should not be filled upto the mouth. It should be filled only up to the filler neck. The empty space is meant for coolant expansion and de-aeration.

9.     When radiator is hot, do not remove the cap, boiling water may spurt out.

MISCELLANEOUS

1.      Before starting the engine, confirm that all control levers are in “NEUTRAL” or “HOLD”.

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

3.    The equipment should always be operated at a speed where it can be correctly controlled. Avoid speeding, sudden starting, sudden braking and sudden turning.

4.      Do not control the equipment speed by pressing the brake as it will overheat the brake lining.

5.      Always be aware of the operating capacity of the equipment. Using the equipment to do work beyond its capacity will not only damage the equipment but may even cause unexpected accidents.

6.    The equipment condition can be judged from many factors. Changes in the gauges, sound, vibration, exhaust gas colour or response of the control levers can indicate the occurrence of some disorder. If any defect noticed, park the equipment in a safe place and take appropriate action.

7.     When parking the equipment after discontinuing work, put the gear shift lever in to “NEUTRAL” position, apply the brake lock, lower the blade to the ground and put all safety levers in to “LOCK” position. Never leave the operator’s seat without switching the engine off.

8.     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 equipment to roll over or slip sideways.

9.   When going down a slope, use the engine as brake. If this is not enough to control the speed of the equipment, use the service brake as well. Never move down in a slope with the gear shift lever in “NEUTRAL” or with clutch disengaged.

10.    As far as possible, avoid turning the equipment on a slope. It may cause the equipment to roll over or slip sideways.

11.     Before going up or down a slope, select a travelling speed most suited to slope. Do not change gear on slope.

12.   If the engine stalls on slope, first use the brake to stop the equipment, then return the gear lever “NEUTRAL” before starting the engine again.

13.   When operating in snow, even sight slopes can cause unexpected side slipping, so in such places, operate with extreme caution. Never use the service brake to stop suddenly on slopes. Lowering the working eqpt (Blade) is a far more effective way of stopping.

14.     When washing the equipment, be careful not to throw water on the Alternator and Breathers.

15.   Drain water collected in the fuel system so as to avoid frozen of water at night during cold weather operation.

16.   When operating on uneven ground, drive at as low a speed as possible and avoid sudden changes in direction.

Appendix ‘B’

PERIODIC MAINTENANCE SCHEDULE

Maintenance work

Service intervals in hours

Remarks

ENGINE

Daily

100

250

500

750

1000

1250

1500

Check Engine oil level and top up if necessary.

*

Engine oil change.

* Initial

*

*

*

*

*

After every 250 Hrs run.

Engine oil filter change .(Bypass filter)

* Initial

*

*

*

*

*

Centrifugal oil filter change .(if applicable)

* Initial

*

*

*

*

*

Clean Engine Breather element/Crankcase breather cleaning.

*

*

*

*

*

*

After every 250 Hrs run.

Replace Engine Breather hose.

After every 2000 Hrs.

Check Eng vibration damper for crack/ leakage/breakage.

After every 2000 Hrs.

Check and adjust Engine valve clearance.

* Initial

After every 2000 Hrs also.

Check & Adjust Injector adjusting screw.

* Initial

After every 2000 Hrs also.

Check & Re-tighten Injector mounting bolt.

After every 2000 Hrs.

Check leakage for water, oil  and fuel.

*

COOLING SYSTEM

Check coolant level and top up if necessary.

*

Check water pump, fan drive/Hyd pump assy and Air Compr, if applicable.

*

After every 4000 Hrs also.

Check fan/Hyd pump Alternator belt tension .

*

*

*

*

*

*

*

Check & Clean Radiator fins.

*

*

*

*

*

*

After every 250 Hrs run

Change Corrosion Resistor cartridge. (If applicable)

*

*

*

After every 500 Hrs run.

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

As and when required/once a year.

FUEL SYSTEM

Drain water and sediment from fuel tank.

*

Replace Fuel pre-filter and fine filter. (full flow filter)

* Initial

*

*

*

*

*

After every 250 Hrs. (50 Hrs for high altitude area)

Inspect float position of  Water separator & drain water.

*

Maintenance work

Service intervals in hours

Remarks

Daily

100

250

500

750

1000

1250

1500

Drain water. (Water separator)

As and when required.

Drain sediments from fuel filter.

*

*

*

*

*

*

Check fuel level & top up if necessary.

*

Clean fuel tank bottom strainer.

*

*

*

*

*

*

Replace when damaged.

AIR INTAKE

Check intake and exhaust manifold & retighten.

After every 4000 Hrs.

Check Dust indicator & clean Air cleaner element. (only outer)

*

Check Axial & Radial play in Turbocharger.

After every 2000 Hrs.

Check Turbocharger fasteners & re-tighten .

*

After every 1000 Hrs.

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

As and when required.

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/before start of winter.

Check & re-tighten electrical wiring.

*

Check performance of  Alternator and Starter Motor.

After every 2000 Hrs.

TRANSMISSION CASE

Check oil level and top up if necessary.

*

*

*

*

*

*

After every 250 Hrs.

Change oil.

* Initial

*

After every 1000 Hrs.

Transmission oil filter.

*

*

*

After every 500 Hrs.

FINAL DRIVE CASE

Check oil level and top up if necessary.

*

*

*

*

*

*

Change oil.

* Initial

*

After every 1000 Hrs.

HYDRAULIC SYSTEM

Check Hyd oil level and top up if necessary.

*

*

*

*

*

*

Hydraulic oil change.

* Initial

*

After every 1000 Hrs.

Hydraulic oil filter .

* Initial

*

After every 1000 Hrs.

TANDEM CASE

Change oil.

* Initial

*

After every 1000 Hrs.

Maintenance work

Service intervals in hours

Remarks.

Daily

100

250

500

750

1000

1250

1500

Check oil level & top up if necessary.

*

*

*

*

*

*

GEAR CASE OF BLADE ROTATING SYSTEM

Change oil.

* Initial

*

After every 1000 Hrs.

Check level & top up if necessary.

*

*

*

*

*

*

OTHERS

Check and adjust Service Brake.

*

*

*

*

*

*

Check stroke of Parking brake lever.

*

*

*

*

*

*

Check & retighten wheel hub nut.

*

*

*

*

*

*

Check Ball joint clearance, pitman arm ball joint clearance .

*

*

*

*

*

*

Check circle guide clearance.

*

*

*

After every 500 Hrs.

Check Vacuum pressure.

*

Check & adjust Tyre pressure.

*

Check & adjust parking brake lever.

*

Check & adjust braking pedal and braking ability.

*

Check & adjust steering wheel play.

*

Check brake fluid level and top up if necessary.

*

Check tightness of nuts and bolts.

*

Check looseness of drawbar front ball joint .

After every 1000 Hrs run.

Drain oil from float tank.

Check front bearing clearance.

Check and adjust Toe-in.

GREASING

Circle pinion gear and blade guide rail.

After every 50 Hrs.

Front axle centre pin, Leaning cylinder pins &  rod ends, Knuckle bracket king pin, Tie rod, Scarifier ball joints & cylinder pin, Drawbar ball joint, Blade lift cylinder yoke & ball joints, Bank control guide & lock pin, Draw bar side shift cylinder ball joints, Steering cylinder pin.

After every 250 Hrs.

Drive shaft.

After every 1000 Hrs.

Front wheel bearing.

After every 2000 Hrs.

                                                                                                                                          
                                                                                                                                                    Appendix ‘C’

                                               TECHNICAL SPECIFICATION

Description	:	Motor Grader BEML BG 605
ENGINE
Model.	:	BS6D 125-1 BEML
Type.	:	6 Cylinder inline, diesel, 4 stroke, Water cooled, turbo charged.
Cylinder Bore x stroke.	:	125 mm x 150 mm.
Flywheel Horse power/Net power.	:	145 HP (108 kW)  @ 1800 rpm.
Maximum Torque.	:	73.5 Kgm @ 1200 rpm .
Piston displacement.	:	11040 cc (11.040 l).
Firing Order.	:	1-5-3-6-2-4.
High idling speed.	:	2000 – 2100 rpm .
Low idling speed.	:	650 – 700 rpm.
Dry weight.	:	1170 Kgs.
Turbo charger.	:	KKK (TEL).
Valve Clearance at Cold.	:	Inlet – 0.33 mm. Exhaust – 0.71 mm .
ELECTRICAL SYSTEM
Battery.	:	12 V 200 AH Qty – 02 Nos.
Alternator .	:	24 Volt, 25 Amp.
Starting Motor.	:	24 Volt, 7.5 kW.
WHEELS
Tyre.	:	13.00 x 24 – 12 PR.
Rim.	:	8.00TG x 24 SDC.
Tyre pressure.	:	Front - 2.45 Kg/cm2 Rear - 2.45 Kg/cm2
WORK EQPT AND HYDRAULIC CONTROL
Control Valve.	:	7 – Spool type with safety valv.e
Maximum Oil pressure.	:	175 kg/cm2
Oil pump discharge.	:	2 x 39 ltr/min.
Oil motor discharge.	:	78 ltr/min.
Blade length x height x thickness.	:	3710 x 620 x 19 mm.
MISCELLANEOUS
Standard steering wheel play.	:	10 to 12 mm.
Standard brake pedal play.	:	5 to 15 mm.
Braking ability.	:	Braking distance 14 mtr or below at initial speed of 35 Kmph.
PERFORMANCE
Travel Speed
Forward .	:	Ist -   3.5 km/hr
		2nd -  6.3 km/hr
		3rd -  10.5 km/hr
		4th -  14.5 km/hr
		5th -  26.1 km/hr
		6th -  43.6 km/hr
Reverse.	:	Ist -   4.1 km/hr
		2nd -  7.4 km/hr
		3rd -  12.4 km/hr
		4th -  17.2 km/hr
		5th -  30.9 km/hr
		6th -  51.6 km/hr
Gradeability	:	240
Max Drawbar pull	:	7280 kg
Minimum Turning Radius	:	10.4 mtr
Overturn angle	:	350
STATIC DIMENSIONS OF EQPT
Overall length	:	8415 mm
Overall width	:	2375 mm
Overall height (top of exhaust pipe)	:	3200 mm
Wheel base	:	6000 mm
Tread, front	:	1970 mm
Tread, rear	:	2000 mm
Ground clearance	:	330 mm
Operating weight	:	12650 kg
Weight on front axle	:	3550 kg
Weight on rear axle	:	9100 kg

Appendix ‘D’

RECOMMENDED LUBRICANTS WITH FILLING CAPACITY AND PERIODICITY FOR CHANGE

S/No	Item	Kind of fluid	Viscosity Grade	IOC Grade	Filling Capacity	Periodicity for change
a)	Engine oil pan	Engine oil	SAE 30	Servo Ultra KB30 / Servo Premium CF4 15W40	30 ltrs	Initial oil and oil filter element change at 250 Hrs and thereafter every 250 hrs
b)	Transmission Case	Engine oil	SAE 30	Servo Ultra KB30	36 ltrs	Initial oil change at 250 Hrs & thereafter every 1000 hrs
c)	Blade Circle (Rotating system) Gear case	Engine oil	SAE 30	Servo Ultra KB30	4 ltrs	Initial oil change at 250 Hrs & thereafter every 1000 hrs
d)	Tandem case (each)	Engine oil	SAE 10W	Servo Ultra 10W	36 ltrs	Initial oil change at 250 Hrs & thereafter every 1000 hrs
e)	Hydraulic system	Hyd oil	SAE 10W	Servo Ultra 10W	27 ltrs	Initial oil change at 250 Hrs & thereafter every 1000 Hrs
f)	Final drive case	Gear oil	SAE 90	Servo Ultra KB30	24 ltrs	Initial oil change at 250 Hrs & thereafter every 1000 hrs
g)	Brake fluid tank	Brake Fluid	SAE J-17031	-	0.800 ltrs
h)	Hydromaster Vacuum Cyl oil	-	-	-	0.060 ltrs	Apply oil after every 500 Hrs/once in a six months
j)	Cooling system	Water	-	-	55 ltrs	Coolant change once in a year/As & when required
k)	Fuel Tank	Diesel fuel	-	-	250 ltrs
l)	Eng oil filter (Bypass filter)	-	-	-	-	Initial oil change at 250 Hrs & thereafter every 250 Hrs
m)	Fuel filter	-	-	-	-	Initial 250 Hrs & thereafter every 250 Hrs
n)	Full flow filter					Initial 250 Hrs & thereafter every 250 Hrs
o)	Air Cleaner  (Element Assy)	-	-	-	-	When required
p)	Hydraulic filter	-	-	-	-	Initial oil change at 250 Hrs & thereafter every 1000 Hrs
q)	Transmission oil filter	-	-	-	-	After every 500 Hrs
r)	Corrosion Resistor (if applicable)	-	-	-	-	After every 500 Hrs
s)	Fuel tank bottom Strainer	-	-	-	-	When damaged replace with new one
t)	Crankcase Breather element	-	-	-	-	Initial change at 250 Hrs & thereafter every 250Hrs
f)	Grease	-	Molex Grease	Servo Molex Grease	-

Note:

(a)        Never mix two different brands of oil.

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

(c)    50 Hrs, 250 Hrs and 500 Hrs maintenance are also to be carried out at the time of 1000 Hrs maintenance.

                                                                        ________