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Contents
1. Load Chart ......................................................................................................................................... 2
2. Specification...................................................................................................................................... 3
3. Safety instructions ............................................................................................................................ 7
4. Know your machine ........................................................................................................................ 36
5. Instruments and controls................................................................................................................ 37
6. Maintenance Schedule ................................................................................................................... 56
7. Maintenance Chart ......................................................................................................................... 82
8. Trouble shooting ............................................................................................................................. 83
9. Electrical Circuit .............................................................................................................................. 96
10. Hydraulic Circuit.......................................................................................................................... 97
11. Pneumatic Circuit with Air Brake ................................................................................................ 98

1
1. Load Chart
Load chart- Hydra 14 Ex

2
 2. Specification
• Max lifting capacity 14T

• Max boom height 11.5m

• Max horizontal reach 7.95m

• Before operating the cranes, tyres to be inflated with recommended pressure

• Lifting capacity is as per ISO : 4573-1982 on a firm & level ground conditions

• Weight of chains, slings & tackles to be considered extra.

Rated Capacity
• 14T @1.6m radius
• 2.5T @7.95m radius

Engine
Make & Model Escorts AE 4. 312C-3A Four cylinder, water

cooled diesel engine, developing 50HP @

2200 RPM or equivalent

Firing order 1-3-4-2

Transmission
Drive Type 2 wheel drive

Heavy duty transmission, developed

especially for crane application. Constant

mesh gearbox coupled with robust

straight drive axle. 8 forward & 2 reverse

speed with high/ Low selector lever

Travel speed Max speed 29Kmpr (Unladen)

Clutch Single plate, heavy duty type

Steering
Type Articulated power steering, hydraulically

controlled through 2 double acting jacks.

Articulation Up to 550

Turning radius 6.5m

3
Hoist mechanism

Hoist Hydraulic winch, 6 fall and rope dia. 13mm

Brakes

Front wheel Pneumatically assisted Hydraulic Brakes

Rear wheel Disc brakes actuated through a slave cylinder

Parking Pneumatic operated, fail safe applicable on front wheel

Hydraulic system

Pump Vane type

Control valve 4 spool control valve with built in pressure relief valve & precision

Control.

Electrical System

Type 12 V single battery, negative earth

Capacities

Fuel Tank 45 ltrs

Hyd. Tank 65 ltrs

Overall Dimensions

Length 10720 mm

Width 2550 mm

Height 3100 mm

Operational weight

11220 kg

4
Boom

Telescoping 3 part hydraulically powered & fully synchronised

Derricking Through double acting jacks

Tyres

Front 11.00 X 20-16PR (4 nos.), inflation pressure 110-115 PSI

Rear 14 X 24-16PR (2 nos.), inflation pressure 29 PSI (Water Ballasted)

Track

Front 1930mm

Rear 1680mm

Safety devices

Overload audio warning system

Safety brake on hoist

Cylinder guard for protection

Rope compensation for auto levelling

Counter balance protection valve in the lift line against hose burst

Visual warning against parking brakes on

Standard accessories

All weather cab.

Front bumper

Lift cylinder guard

Rear view mirror

Reflectors

Turn & reverse lamp

5
Optional Accessories

Fly Jib

Fire Extinguisher

Spark Arrestor

Air condition cabin

Steering Wheel

Safe Load indicator

Over hoist & over load cut off

Heavy duty tyres on rear wheel

Front pneumatic brake

6
3. Safety instructions

1. HAND SIGNAL
2. INSTIBILITY
3. OVEARHEAD POWER CRANE
4. SLINGS,WIRE ROPES & TERMINAL FITTINGS
5. OPERATING INSTRUCTIONS

1. HAND SIGNALS
Signaler should stand in a secure position where he can see the load and can be seen clearly by the
driver. Face the driver if possible. Each signal should be distinct and clear by one signaler only.

7
 HOIST LOWER USE MAIN HOIST USE WHIPLINE
With upper arm With arm and index A hand taps on top of (Auxiliary Hoist)
extended to the side, finger pointing down, the head. Then regular With arm bent at elbow
forearm and index hand and finger make signal and forearm vertical,
finger pointing straight small circles. is given to indicate elbow is tapped with
up, hand and finger desired action. other hand. Then regular
make small signal is used to indicate
circles. desired action.

BOOM UP With arm BOOM DOWN With MOVE SLOWLY SWING

extended horizontally arm extended A hand is placed in front With arm extended
to the side, horizontally to the of the hand that is horizontally, index
thumb points up side, giving the action signal. finger points in
with thumb points down (Hoist slowly shown in direction that boom is
other fingers closed. with example.) to swing.
other fingers closed.

EMERGENCY STOP With

BOOM UP AND LOWER both arms extended
BOOM DOWN AND THE LOAD STOP horizontally to the
RAISE THE LOAD With arm extended side,
With arm extended
With arm extended horizontally to the side horizontally to the palms down, arms
horizontally to the side, palm down, arm are
and thumb pointing up, swung back and
side fingers open and close is swung back and
forth.
and thumb pointing while load movement is forth.
down, fingers open and desired.
close while load
movement is desired.

8
9
 HOIST LOWER TOWER TRAVEL With all TROLLEY TRAVEL With
With upper arm With arm and index fingers pointing up, palm up, fingers
extended to the side, finger pointing down, arm is extended closed, and thumb
forearm and index hand and finger make horizontally out pointing in direction
finger pointing straight small circles. and of
up, back to make a motion, hand is
hand and finger make pushing motion in jerked in direction
small the direction of trolley is to travel.
circles. travel.

STOP DOG EVERYTHING MOVE SLOWLY SWING

With arm extended Hands held together A hand is placed in front With arm extended
horizontally to the at waist level. of the hand that is horizontally, index
side, palm down, arm giving the action signal. finger points in
is swung back and (Hoist slowly shown in direction that boom is
forth. example.) to swing.

EMERGENCY STOP
With both arms extended horizontally to the side,
palms down, arms are swung back and forth.

2. INSTABILITY

10
THE CRANE SHOULD BE ON FIRM LEVEL GROUND FOR CRANING.

If the machine isn’t level or a tyre sinks when slewing, a potentially dangerous overload condition may
develop faster than can be injured with the operator.

MACHINE WORKING UNDER NORMAL ROAD SURFACE

Center of gravity Center Of gravity out of the wheel

inside the wheel
11
• Hook should be placed right over the center of gravity of the load.
• While marching ensure that center of gravity should always fall between the front tyres.

3. OVERHEAD POWER CABLES

WARNING:-
1. Never allow the crane to touch or become too close to overhead power cables fatal accident
can occur without the crane actually touching the cable.
2. When operating near overhead power cables always use a trailing chain from the chassis to
the ground.

ACTION ON THE CONTACT WITH LIVE CABLE

If the crane touches a live cable

1. Do not panic.
2. Stay in the cabin.
3. Tell others to keep clear and not to touch the crane, rope or load.
4. Try to free the crane unaided.
5. If the crane cannot be free, get someone to inform the Electricity Board immediately.
6. Stay in the cab until the electricity supply is shut off.
7. If you must leave the crane, jump well clear of the chassis.

3.1 SAFE DISTANCE RULE

12
When working near overhead Power cables, observe a safe distance. This distance should be
measured along the ground between the chassis and a point vertically below the nearest cable.
Follow the instructions written upon the power cable tower.

WARNING

Increase the safe distance if the cable support pylons are widely spaced. The cable may away in the
wind

13
 While going up the
gradient
always Move in
forward direction as
R the working radius (R)
decreases. Therefore
operation can be
performed safely

While going down the R

gradient
always Move in reverse
direction as the
working radius (R)
decreases. Therefore
operation can be
performed safely

14
 R

Never go down the gradient in forward direction

as in this case the working radius (R) increases.
Therefore the crane can topple

15
 ARTICULATED TO R.H.S. ARTICULATED TO L.H.S.

The load lifting capacity of the crane decreases in articulated condition.

o
Load chart to be derated after 15

16
 Always use D-Shackle

ORIENTATION OF EYE BOLTS

RIGHT
WRONG

Never run a sling through a pair of eye bolts.

Use a pair of shackles instead.

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Correct Orientation-

Load is in the plane of the eye.

load
Load is in plane of eye load

RESULT

RIGHT

WRONG

Eye bolt Incorrect Orientation-

When the load is applied to the eye

in this direction it will bend.

18
Whenever two or more ropes are to be placed over a
hook always use a D-Shackle instead of all rope in one
hook.

19
20
 EFFECT OF CHANGE
OFANGLE ON SLINGS

LOAD ON SLINGS
INCREASES WITH
DECREASE OF
ANGLE ON LOAD
BEING LIFTED
BES GOOD
T

LEAST AVOID
RECOMEND
ED

21
Slinging Methods

22
23
24
4. SLINGS, WIRE ROPES AND TERMINAL FITTINGS
GENERAL

Slings, wire ropes and terminal fittings are vitally important component/parts of the crane. Due to the
arduous duties for which they are used, they suffer from server forms of deterioration and have a
limited life. They should be examined, maintained, and a record made of their condition at regular
and frequent intervals.

REGULATIONS

Depending upon crane location and use, wire ropes, slings and terminal fitting are subject to certain
statutory regulations. These includes the Health and safety at work act, the Factories Act and the
Building, Dock and Ship Building Regulations. It is the legal duty of the person (S) responsible for the
crane that these Regulations are obeyed. The most important provision of these regulations covers
the regular and frequent examination of the wire ropes, slings and terminal fittings by a competent
person.

A register must be kept by the crane user which shows the prescribed particulars with respect the
each such examination.

SLINGS SAFTY PROCEDURES

1. Always examine slings before use for damage and check that the correct shackle pins are
fitted.
2. Never exceed the safe working load of the slings. If in doubt, don’t lift.
3. Avoid shock loadings.
4. Never drop the chain from a height, drag it from under a load or along the ground.
5. Use packing to protect the sling from sharp edges on the load.
6. Never shorten a chain by twisting or knotting.
7. Never use makeshift fasteners or links.
8. Never use badly worn or stretched chain which has no free movement.
9. Ensure that end links rings and shackles ride freely on the crane hook.
10. Avoid placing more than one sling on the crane hook.

25
12. Attached slings to a ring or shackle which can than be placed on the hook.

13. Always secure any unused sling legs.

26
14. Always checked that the load is free before attempting the lift.

15. Always take off your hand from the slings before the lift begins and stand well clear.

16. Remember that the safe working loads decreases as the angle between the sling legs increases.

17. Use drag lines to control the load.

18. Always check that the load is safely landed and properly blocked before unhooking the sling.

19. Store sling where they will not damage nor subjected to corrosion.

20. Never attempt to repair or heat alloy chains.

21. Always use the correct grade of material, size of fittings and attachments for use with the sling
and chain.

5. OPERATING INSTRUCTIONS
Before using the crane:-

Prior to using the crane, check that:

1. The cab windows are clean.

2. There is sufficient pressure in the Air brake system and the low pressure warning light is off.
3. The tyre pressures are correct.
4. The battery electrolyte level IS correct.
5. The cooling system level is ok.
6. All indicators and controls function correctly.

WARNING: THE CRANE MUST NOT BE USE IF ANY DEFECTS ARE FOUND.

Traveling with load suspended:-

Observed the following when traveling with the load suspended:

1. It is recommended that whenever possible the load should be slewed to the front of the
crane for traveling. This will ensure maximum VISIBILITY, SAFETY and TRACTION particularly
for machines with 75% & 85% load rating.
2. Use all crane control gently.
3. Carry the load as near to the ground as possible.

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 LOAD

GAP
GAPDECREASED
DECREASEDFROM
FROM
NORMAL
NORMALCONDITION
CONDITION
Traveling on inclines with load suspended:

It is not recommended that the crane is traveled on inclines with the load suspended. If this is
unavoidable, the following precautions, in addition to those detailed above should be taken.

1. One each occasion, consult a competent person to advice on the feasibility of the operation
and the precautions to be taken.
2. Carry the load on the uphill side of the slope, regardless of the direction of travel.
3. Do not tilt the load except to maintain its uphill position.
4. Take care to ensure that the crane will remain stable when the load is released.

Traveling on the Highway:

Prior to and during highway travel check

1. Travel safely, watch for narrow bridges and low clearances.

2. When maneuvering in confined places, post a signaler to guide you into position.
3. Compliance with bridge load limits.
4. The main hydraulic pump is design for P.T.O system.
5. There is sufficient fuel for the journey.
6. The air brake system pressure is Ok.
7. The tyre pressure is correct.
8. The Battery electrolyte level is correct.
9. The radiator coolant level is correct.
10. All indicator s and controls is functioning correctly.
11. Ensure that the Rear axle is free (Unlock).

NOTE:-Remember that you are responsible for complying with all traffic regulations governing the
movement of the crane on the highway.
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WARNING: THE CRANE MUST NOT BE USED IF ANY DEFECTS ARE FOUND.

Before leaving the crane unattended:

Observed the following procedures

1. Select the parking brake switch to ‘ON’ position.

2. Ensure that the crane is standing on firm level ground.
3. Remove the ignition key.
4. Lock the cabin to prevent unauthorized entry.
5. Secure the hook block.

OPERATING INSTRUCTIONS
General Notes

1. Keep the machine under cover whenever possible & when not in use.
2. Return all hydraulic rams to the closed position when not in use.
3. Ensure that the machine functions are thoroughly checked before commencing work,
especially pertaining the road and crane safety.
4. Should any discrepancies occur in instrument reading, or rapid falls in oil levels be noticed,
investigate immediately and rectify before proceeding.
5. Keep the cabin tidy and free of items for which stowage is provided.
6. Do not use the crane for PILE DRIVING, EXTRACTING OR DRABBING.

Before Craning:

Prior to craning, check that

1. Hook block riving is correct for load to be fitted.

2. Ropes, slings, terminal fittings and anchorages are not worn or damage.
3. The jib is not damage.
4. The cab windows are clean.
5. All indicators and controls function correctly.
6. Tyre pressures are correct for free on wheels craning duties.

WARNING:-THE CRANE MUST NOT BE USE IF ANY DEFECTS ARE FOUND.

29
30
Before lifting

Prior to lifting any load, carry out the following:

1. Ensure that you have an unobstructed view of the load, the signaler and the operating area.
2. Ensure that the operating area is safe and check for any obstacles or hazards which may
impede crane or load movement.
3. Check for overhead power cables and observed the appropriate safety precautions.
4. Note the wind speed and direction. Make adequate allowances as its effect on the load can
be severe. The jib should be retracted and lowered in very high winds.
5. Ensure that the crane is in firm ground, clear of any underground services, hidden culverts or
overhanging jetties which could collapse during craning.
6. Maneuver the crane so that the hook hangs over the center of the crane.
7. Check the load is correctly slung.
8. Never slew load over personnel.
9. Never allow personnel to ride over the load.

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32
33
Lifting

1. Keep your mind on the job and your eyes on the hook block and signaler.
2. Keep the rope tight at all the time.
3. Always leave some rope between the boom head when the boom is set above 0 degree.
4. Lift the load just clear of the ground, check the winch brake and crane stability. If you are in
doubt, stop the lift. Do not take risk, ask your supervisor.
5. Use all control gently; load turn to a minimum especially when lifting heavy loads.
6. Watch the safe load indicator, especially when lifting loads of uncertain weight.
7. Always obey the load warning system.
8. Do not exceed the maximum stated load for the revving, jib length or radius at which the
crane is working.
9. Do not use the travel or slew motions to drag or push loads or obstructions.
10. Do not switch off the engine with a load suspended.
11. Do not attempt any adjustment while the engine is running.

Before Highway Travel

Prior to traveling on the highway:

1. Fully close the jib and stop it over the rear of the machine.
2. Engage the hook block retaining pin.
3. Engage the slew lock pin.
4. Reeve the hook block to at least four falls and pull against the jib head without applying
excessive tension on the rope. Only sufficient pressure needs to be applied to prevent the
hook block swinging freely.

34
Before leaving the crane Unattended:

Observe the following procedure

1. Never leave the crane with the load suspended. If this is unavoidable, someone should be left
in attendance.
2. Ensure that the jib are fully closed and stopped in normal travel order.
3. Remove the ignition key.
4. Lock the door to prevent unauthorized entry.

Wire rope safety procedure:

1. Always wear gloves when handling wire rope.

2. Keep hands off the moving ropes.
3. Never exceed the safe working load of the load or subject it to shock load.
4. Never use a rope that is kinked.
5. Never use a rope that has a knot in any part of it.
6. Never use a rope that has a thimble pulled out of it. Remove from service immediately and
repair.
7. Always use a proper sling; never use the hoist rope for slinging around a load.
8. Always checked that the load is free before attempting a lift.
9. Do not lift a load with a rope that has become cross coiled. Pay out the rope immediately and
inspect it. Discard if seriously damaged or recoil properly on the winch drum.
10. Only use the sheaves and returned blocks supplied with the crane. Undersize or oversize
sheaves, if used, will cause severe rope damage.
11. Check that all rope terminal fittings are correctly assembled and that safety clips are secure.

35
4. Know your machine

Specification

This information contained herein is general in nature and is not intended for specific job application
purpose. The dimension, weight & Capacities shown in specifications are approximate & are subject
to variations within normal manufacturing practices.

ESCORTS policy is one of the continuous improvement.

ESCORTS reserve the right to change product specifications & or equipment at any time without prior
notice & obligation. Illustrations shown in this literature include standard & non-standard terms.

36
 5. Instruments and controls
Before putting the machine into operation, the operator must familiarize himself with the
following instruments / operating controls.

The instrument panel is positioned in front of the operator which provides ready visibility and
accessibility of instrument & controls during operation. Instrument Control is explained below:-

1. Air Pressure gauge 8. Spot Light Switch

2. Engine Oil Pressure gauge 9. Speedo cum - RPM Meter
3. W ater Temperature gauge 10. Fuel Level gauge
4. Ampere Meter 11.Hazard Switch
5. Head light/Park light switch 12. Wiper motor switch
6. LO - HI 13. Horn
7. Indicator Switch 14. Fan

1. Air pressure gauge: The gauge indicates working pressure (0-10kg/Cm2) Range for pneumatic
brakes

Warning: Minimum 6 bar pressure required to apply brake.

2. Engine oil Pressure gauge:-The Engine oil pressure gauge indicates the pressure at which the
engine lubricating oil is circulating through the engine

Warning: Engine oil pressure lies between minimum 2 bar & max 5 bar.

37
3. Water temperature gauge:- The gauge indicates the temperature of the water.

Warning: When water temperature touch red mark stop the engine immediately.

4.Ampere Meter:-This gauge is provided in the Battery charging circuit to indicate the rate at
which the battery is being charged. Movement of Needle towards the +ve will indicates charging
and towards the –ve side will indicate discharging.

5.Head light / Parking light switch:-When we pull head light switch up then head light glows & when
we pull brake switch then this light glows.

38
6.LO-HI lever:- This switch located L.H. Side of the cabin within convenient reach, enable
operator to select the desire road speed.

7.Indicator Switch:-When we turn crane left then left turn indicator will go green & when we turn
crane right then right turn indicator will go green.

LEFT RIGHT

8. Spot light Switch:-When we operate this switch then spot light switch will glow. Mainly this
switch is use during working / driving at night

39
 9.RPM meter:- This will shows the crane RPMx100 at which engine is running.

10. Hour meter:- This will show the crane hour up to 1/100th of a hour

11. Fuel level gauge:-This will show how much fuel is available in the tank.

12. Hazards Switch:- This switch enable the L.H and R.H indicators to be switched on simultaneously,
with the ignition off. The signal light indicates that the switch is being used.

40
13. Wiper Motor Switch:- When we operate this switch then windscreen wiper to be operated.

14. Horn:-This switch is to operate horn. While we operate this switch then horn will blow

HYDRAULIC CONTROL

These are basically hand operated control levers for the complete hydraulic system. These
levers mounted towards R.H. side of the operator within comfortable reach and hand
movement, operate a direction control valve which regulates flow of hydraulic oil to various
hydraulic actuation.
Movement of these control levers result in following movement for the hyd. Actuators.

1. Steering cylinder lever

2. Lift Cylinder Control lever (Boom)
3. Hoist Control Lever
4. Telescopic Cylinder Control Lever

41
 LEFT LOWER OPEN LOWER

Steering Lever Lift control lever Extension Cyl. Lever Winch Lever

RIGHT RAISE CLOSE RAISE

Note: Movement of all levers while in operation must be gradual, especially while operating with
loads. This avoids unnecessary strain on the machines. Lever should not be pushed further to the end
of the stroke

42
43
44
45
46
47
HYDRAULIC SYSTEM

The pump draws oil from the reservoir and feeds it to the Control Valve (Spool type). So long as
the Control Valve spools are in the neutral position. Oil flows freely through the control valve & to
the reservoir. There is no load on the pump, at this stage.

When any · of the control valve spools are operated from the neutral to an operating position
the flow of oil is directed to the Associated c y l i n d e r o r motor to get the
Desired motion. The load on the pump is directly dependent on the pressure developed overcome
the resistance offered by the Load.

Since pump directly coupled to the engine, the flow of oil through the actuators can be directly
controlled by the throttle (accelerator). Hence, higher, engine RPM’s result in faster cycle
timings.

Winch operation is through a hydraulic motor provided with the fail-safe brake system. Moment
the motor spools operated (forward or backward for lowering/lifting loads), the
Brake is automatically released due to pressure developed in the motor feed line.

Remaining hydraulic actuators for performing other functions are:

a) S teering Cylinder - 2 Nos.

b) Main Lift Cylinder·2 Nos.
c) Boom - Extension Cylinder - 1 No.

OIL RESERVOIR
'
Baffles provided in the tank offer better cooling. A strainer provided at the suction inlet prevents
dirt and Contamination from entering the pump. A vent o p e n i n g provided with a larger capacity
air breather. A level pipe provided enables the operator to see the oil level in the tank. A
magnetic plug has also been provided at the bottom to entrap ferrous particles in the tank.

HYDRAULIC PUMP
This is a vane type positive discharge rotary pump, coupled directly to the engine
crankshaft through a coupling, the engine imparts a rotary movement to the rotors of the pump.
The design of the pump forces oil out through the outlet due to the rotary motion of the vanes
in the pump. The pump. Provides constant flow of oil to the desired actuator (through control
valve). The pressure developed in the line depends upon the load connected with the
particular actuator and setting of the relief v a l v e I.e. the pressure developed in the system is a
direct function of the load applied.

48
LIFTING OF LOAD (DERRICKING)
For lifting of load there are 2 lift jack provided on the Machine which operated by lift lever provided
on control valve.
By pulling the lever the lift jack will open and load will lifted.
While pushing the lever the lift jack get closed for lowering of the load
There is a safety in case Engine stopped the load will not all down even some one operate lever.

Boom Telescoping lever is located on RHS of operator seat. 1st part telescoping is by the double acting
hydraulic jack and 2nd part telescoping is with the help of wire ropes & pulleys. Both the sections
extend & retract in synchronization.
The Telescopic speed can be achieved by the engine throttle.
1. For telescoping out, the control lever is pushed forward, thus supplying hydraulic oil under pressure
to the rear end of the cylinder.
2. For telescoping in the control lever is pulled back, thus reversing the hydraulic oil supply to the other
end of the cylinder.

HOISTING
Hoisting is accomplished by a winch mounted on the main boom. The winch is powered by a hydraulic
motor connected to the drum through a planetary gear box 4 fall pulley block arrangement is used to
hoist is controlled directly by means of a hand operated direction control lever. Hoisting speeds can be
controlled directly by engine throttle or by throttling the oil flow to motor from the control valve lever.
A. Raising the Load:
1. Check the load is within the maximum safe specifications for the working radios.
2. With the engine running at low RPM carefully pull back on the hoist/lower lever so as to
take up the load without jerking. Once load is off the ground, the lever can be pulled right
back to raise position.
3. Adjust engine speed with the accelerator pedal, to regulate hoisting speed.
4. When load has been raised to the required to neutral slowly and release pressure on the
accelerator pedal.

B. Lowering the Load:

1. With the engine idling, carefully push the hoist raise, lower lever, forward to lower the load.
Avoid jerky control valve movement.
2. Adjust position of accelerator to acquire required lowering speed level, allow the hoist
control to return to neutral and release pressure on accelerator pedal.

Caution
1. Avoid stopping the load suddenly as this imposes unnecessary strain on the crane.
2. Avoid travelling at over 4 Km/h with the load hoisted.
3. Always lower the load to the ground before shutting down the engine or leaving the crane
unattended.
4. While lowering the hoisted load, avoid lowering the boom since it may increase the load
overhang
Beyond the safe load radius & thus include instability

49
A. Winch Fail Safe Brakes

There are two types of safety devices (winch braking system} which have been used for the Hydraulic
Winch
i} Dynamic braking for hyd. motor.
ii) Internal mechanical wet disc fail safe brakes

i) Dynamic Braking
The oil supply to the motor is fed through a counter balance valve, generally a standard device for
applying brakes to hydraulic motors

ii) Mech. Fall Sate Brakes

This is a wet disc type brake normally in the applied position with the help of springs which actuate the
piston. As oil is fed to the winch motor it releases the brakes, alternatively when there is a loss of
pressure in the line either by a pipe failure or by bringing the control lever to neutral position, this
automatically applies the brakes, thus ensuring fail safe braking system

1. BRAKES
The crane is provide with pneumatically assisted hydraulic brake son the front & rear
(traction)
Wheels. Both systems are operating through a common foot pedal & have been synchronized
to
Provide best result
The braking system not only retains the inherent ruggedness and dependability of the mechanical
braking system, but also incorporates the numerous advantage of the pneumatic system as well
as the reliability & positive action of the hydraulic system. The following are some of the high lights
of brake on the crane
The braking is through a pressurized reservoir of air so that braking force is available to the service
brakes even when the engine is shutoff.
Pneumatic assistance provided for reduced pedal effort which reduces operator's fatigue.
Synchronizing of the front & rear brakes enables application of the rear brakes a fraction of a
second before the front brakes, thus providing additional safety.
Parking brakes are applied on the wheels simultaneously by a single lever which will hold the
crane stationary. Application is through a cable mechanism which will lock the brakes in the
applied position as & when desired.
The system meets all SAE requirements for braking for this category of equipment.

50
2. AIR RESERVOIR
The function of reservoir is to store compressed air so that there will always be an ample supply
available for immediate use in brake operation. It also provides storage for sufficient compressed
air to permit several brake applications even after the engine has stopped.
Another function of reservoir is to provide place where the air, heated during compression,
may cool oil, water vapor condense.
The total reservoir volume (15ltrs)

PARKING BRAKE

This lever is used for parking brakes, Pulling the l e v e r l o c k s t h e b r a k e s i n t h e “Brake

Applied “position
Parking Brake is meant for keeping the machine stationary in parking conditions.

Caution : Never use this as service brake

Brake Applied

Parking Brake

Brake Released

51
Electric system
DESCRIPTION
The following components essentially constitute the electrical system i.e. starting and
lighting.

I) 12 Volt Battery ii) Alternator iii) Starter

In order to have trouble free starting of the engine and maximum availability of machine
for
Use.it is always advisable to pay attention towards the maintenance of electrical system.
Following few points if adhered to will avoid problems of the system

BATTERY:
When the atmospheric temperature is below the freezing point special attention should
given to hydrometer readings of the battery. A specific gravity of 1.270 to 1.215 at 80" F
is
considered satisfactory for continued use. Specific gravity readings without corrections
for
temperature are practically meaningless. For each 10 degrees that the temperature of
electrolyte is above 80 deg. F add 4 points to hydrometer reading and for each 10 degrees
below 800 F subtract. 4 points to get true specific gravity

For example· if hydrometer reading is 1.250 and electrolyte temperature is 200F, (600 below
800 F ) 1.250 minus 24 points equals 1.22.6- the true specific gravity.

If corrected readings are below 1 . 2 1 5 the battery’s not receiving sufficient charge. This
might
Indicate that the alternator or alternator regulator requires attentio n . If these units prove.
Satisfactory inspect system for short circuit and for loose or corroded connections.
In zero weather 1hero is danger of battery freezing.
If specific gravity 1.100 it will freeze at 10 F battery with .a specific gravity of 1.220 will
freeze
at 31 below zero F. During freezing weather. Any addition of water to cells should be made
after engine is started at beginning of an operating period to make certain that water.
And electrolyte solution will be thoroughly mixed. Otherwise it may freeze. The filter caps
must be kept fight at all times and top of the battery kept clean and dry.

Check the level of electrolyte in the battery after every week of operation or as often as
Operating conditions prov., it necessary Maintain level of solution 10mm above plates of
battery
by addition of clean distilled water. Keep battery and cable terminals tight & cleaned.

To prevent possibility of electric short circui t . Always disconnect 1he battery. Before
Attempting any repair or while cleaning.

52
 If corrosion occurs, clean battery posts and terminals with a strong soda solution and coat
terminals lightly with petroleum jelly before connecting them again. The petroleum jelly
will prevent further corrosion.

In case the battery run down is fast, check for:

1. Loose or corroded wire connections.
2. Broken wires.
3. Womb generator brushes.
4. Oily Alternator brushes or commutator.
5. Fan belt loose.
6. Faulty voltage regulator

PRECAUTION:
1. Do not bring lighted matches or on open flame of any kind within the
proximity of battery cen.
2. Keep the battery dean by sing a stiff bristle brush. If terminals are corroded
of if the battery is acid Slackest, wash with hot water or soda solution. Vent
plugs are open.
3. Ensure tightness of all battery connections.
4. In the event of long storage of machine, it is advisable to remove the
battery and keep it In a cool dry covered place.
5. It is advisable to get the battery trickle charged at least once a month if the
machine is kept idle for a long period.

Testing and adjustment of the alternator should not be attempted without dependable
testing
equipment. Therefore it is recommended that these units be taken to a dependable
electrical
repair shop when service is required.

Warning
Whenever the Alternator has been removed for repairs or replacement, or when Alternator
regulator
leads have been disconnected and reconnected, the alternator must be polarized. It causes
current
to flow in normal direction through the field coils and will prevent vibration, arcing, burning
and
sticking of regulator points.

53
Caution
Never operate the starter motor for more than 10 Seconds at a time. If the engine does
not start in first instance, wait for 2-3 minutes before making next-attempt for starting.
The cause and rectify the same, If
the starter fails to crank the engine , check the following parts

1. Broken wires or loose connections.

2. Faulty starting switch.
3. Exhausted battery.
4. Worn out pinion_ teeth.
5. Damaged winding

Note :Put Off all the lights while using the starter to avoid heavy damage of battery
power

54
CLUTCH PEDAL FREE PLAY
• The clutch pedal free play is to be maintained to 3/4"or 20mm.The play can be adjusted by
adjusting the cable linkage.
• Ensure Proper lubrication on cables for ease operation.
Wheel Assembly

To assure maximum life and satisfactory performance, Inspect tyres once every day and keep them
properly inflated.
Recommended tyre pressure are:
Front tyres 110 PSI
Rear tyres 35 PSI

Over inflation results is rapid wear at the center of the tread1tread cracking, excessive strain
on the side walls, beads and rims and tyre failures due to sudden application of brakes.
Under inflation causes rapid wear on outer edges of the tread and excessive internal heat
due to flexing which may result in blowouts. Never release built-up pressure in tyre, such
as encountered extremely hot days. Pressure built up on a hot days actually protects the
tyres by avoiding excessive side wall flexing and heat which are both detrimental to tyre
life. Venting lyres will also result in under inflation when the tyre cools
mis alignment of the tyres also cause rapid & uneven wear of tyres.

Tyres should always be kept free from oil, plant & grease, because they are very harmful
to
life of tyres. During long storage of machine the wheels should be jacked up so that tyres
do not touch the ground. This is to avoid wear on bottom portion of tyres due to constant
weight of machine acting downwards

Replacement of split rim rear tires:

1. Remove the wheel rim assembly by loosening eight central nuts retaining the wheel rim
with Wheel reduction gear hub.
2. Loosen wheel weight clamping bolts.
3. Deflate the tyres.
4. Loosen l16 nuts holding the two halves of split rims.
5. Part of the two halves using a tie rod lever.
6. Replace tyre, inflate the tube a little and refit the two split halves using a torque
wrench adjusted to specified torque.
7. Tighten wheel weight clamping bolts.
8. Mount the wheel rim assembly on wheel reduction hub

55
6. Maintenance Schedule
PERIODICAL LUBRICATION SCHEDULE
Lubrication is an essential part of preventive maintenance, controlling to a great
extent the useful life of the unit. Different lubricants are needed and some
components
in the unit require more frequent lubrication than others. Therefore it is important that
the instructions regarding types Of lubricants and the frequency of their application,
as given In this manual, be explicitly followed. Periodic lubrication of the moving
parts reduces to a minimum the possibility of Mechanical failures.

To prevent minor Irregularities from developing into serious condition that might involve
shut- down and major repair several other services or Inspections are recommended for
the same intervals as the periodic lubrication. The purpose of these service or
inspections which require
only few minutes to assure the uninterrupted operation of the unit by reveling the
need for
adjustment cause by normal wear. The need for same minor adjustment if neglected,
could
result in failure and shutdown. Refer to the periodical maintenance schedule and the
lubrication.

IMPORTANT

Thoroughly clean all lubrication fittings, caps, filter and level plugs, and their
surroundings surfaces before servicing. Prevent dirt from entering the lubricant.
The lubricant should be wam (operating temperature) when draining at oil change
intervals. The intervals given in this guide are based on normal operation. Perform
these services, inspections etc. more often (as necessary} for operation under abnormal
and severe conditions.
When checking oil level of systems equipped with a gauge rod having "Operating
Range" mark the system has adequate oil for safe operation when the oil level is
anywhere within the "Operating range" mark the system has adequate oil for safe
operation w h e n t h e oil level is anywhere within the "Operating Range” marks.

Daily Every 10 Hrs. Operation

56
 • Check Radiator Water Level Check Engine
Oil
• Level Check Hydraulic Oil Level Check Fuel
Level
• Check Air Cleaner Choke Indicator
• Clean Pre Air Cleaner

Weekly (Every 50 Hrs.)

• Change Engine Oil & Filter (New Engine)
• Clean Air Filter Element, if indicator shows red band.
• Grease all points
• Check Axle oil Level
• Check Battery Electrolyte Level
• Drain Air Pressure from the Air Reservoir
• Check Tyre Pressure
• Check Winch Oil Level
• Check for leakage of Fuel/Engine Oil, Hyd. Oil and Rectify.

Note: - Only 3 cleaning of outer filter element allowed. After 3 cleaning

both Inner & outer elements to be replaced. Never clean Inner Element

Every Three Months (5OOHrs)

• Change Engine Oil & Filter

• Change Hyd. return Filter
• Change Fuel Filter Element
• Check Front Wheel Bearing
• Clean Radiator
• Replace Air Filter
• Check tappet clearance(inlet valve 0.30mm & exhaust valve 0.40)

Every Year (1000Hrs)

• Change Engine Oil & Filter
• Change Fuel Filter Elements
• Change Hyd. Oil &Hydraulic oil filter
• Change Air filter elements
• Change Axle Oil
• Change Fan belt
• Change Winch Gear Box Oil
• Check Front Wheel Bearing & replace Grease
• Check Battery Electrolyte Level
• Drain Air Pressure from the Air Reservoir
• Check Tyre Pressure
• Check tappet clearance(inlet valve 0.30mm & exhaust valve 0.40)
MAINTENANCE OF HYDRAULIC SYSTEM
it is crucial that complete hydraulic system be maintained in tip top condition, since all the
57
actives being performed by the crane are hydraulically controlled. For this it is important
that the following points be strictly adhered to:

1. OIL USED
Use the hydraulic oil specified by the manufacturers only. Any c h a n g e in make/grade/
Viscosity of oil substituted by the user will have adverse effect on the performance of the
Machine. Different oils have different activities some of which may be harmful to the oil seals
used throughout the hydraulic circuit. Different oils also have different lubricating properties,
which could result in excessive temperature rise. This is very h a r m f u l for various hydraulic
Components.

Other oils have varying viscosity characteristics at different temperatures.

This will again result in improper performance of the machine if the recommended oils
are not used.

2. FILTRATION
Oils should always be procured from standard sources so that the soluble impurities are
kept within allowable limits.
To remove the insoluble impurities the hydraulic oil must always be poured in through
a 20 G sieve before adding to the tank. The machine must never be left with the
filler cap of the hydraulic tank removed.
Abrasive sand particles can cause a great deal of harm to tile hydraulic pump and motor.

3. INTERNAL LEAKAGE IN HYDRAULIC DISTRIBUTOR

After a long use the spools may get worn out & oil m a y leak past them. To diagnose the
Internal leakage through the distributor valve, proceed as follows:
A. Raise Boom about 2 meters above the ground level
B. Shut off the engine and disconnect oil line from the distributor valve to the reservoir.
If oil is leaking through the disconnected line, it indicates internal leakage & may
call for change of control valve

4. INTERNAL LEAKAGE IN HYDRAULIC JACKS

During the course of use of the equipment, these cylinders may develop internal leakage
due to normal wear on the seats etc,. The internal leakage will reduce the sensitivity
and lifting capacity of the equipment. It is therefore necessary to check the cylinder
for internal leakage as follows:

Check the internal leakage in lift cylinder:

1. Lower the boom to the lowest position.
2. Disconnect the pipe connecting the full bore end chamber of the main lift cylinder.
3. Operate the main cylinder "lift" lever, further to forward position for a few seconds,
Till the relief valve blows.
4. In case of internal leakage in the cylinder oil will flow out from the disconnected end of the
58
Chamber.
5. Repeat the same procedure to check the leakage from other cylinder in case, any internal
leakage is observed the jack should be dismantled according to proper laid down procedure.
all the hyd. seals replaced and reassembled. Special care must be taken
against any ingress of dirt/abrasive particles.

Note: Before removing the cylinders for repair drain hydraulic oil from the reservoir.
Be sure the boom is lowered fully and that engine is stopped before disconnecting the
hydraulic hoses.

5. FILTER
A fine filter is provided in the return line of the main hydraulic circuit. The entire
amount of oil going to reservoir gets filtered here.

Filter element should be changed at the intervals mentioned in the periodical

maintenance schedule.

For removal of filter element unscrew the 4 screws. Filter body along with the
element and replace with new element.

6. RESERVOIR
A hydraulic reservoir has been provided to cater for hydraulic circuits. Baffle plate
is welded inside the reservoir to avoid turbulent flow of oil.

7. OIL LINES AND HOSES

Check all oil lines and connections periodically for leaks and dents. Oil leaks in pressure
lines can be located by carefully inspecting the external area of the system.

To check for air leaks in suction lines or pump shaft packing open top plate of oil reservoir
while under operation and check for foaming. Presence of air bubbles in oil indicates intake
of air from suction.

This can damage the pump in shorter period. When tightening connections two wrenches
should
always be used to prevent twisting or breaking tubing. Dented tubing should be replaced as
the
restriction causes oil foaming and faulty crane operation.

Wash oil lines with clean solvent to remove dirt from inside and outside before installing on
crane.

CAUTION

Do not tighten fittings too tight. Make them just enough to eliminate leaks.
Regular attention to the maintenance of the hydraulic system will result in increased
efficiency
59
and longer life
Following points need special attention.
1. Repair hydraulic oil leaks promptly to avoid loss of oil and possible damage to the system.
2. A leaking or damaged hose must immediately be replaced by a new one.
3. Bleed air from the system any time a hydraulic hose is removed, a tube
disconnected
or the system is opened to the atmosphere. After reassembly, bleed the system by
running
the engine and operating the Distributor Valve levers (with no load in the boom) a
couple of
times. After bleeding the system, shut off the engine and close the hydraulic jacks.
Check
oil levels and add fresh oil in necessary.

Maintenance of Brake System

BRAKE ADJUSTMENT

REAR
This primary setting is followed by testing simultaneously braking of both wheels, performed
at a stand, or over a smooth surface during the machine riding. The brake which acts with
delay on pressing of the brake pedal, has the control rod due for shortening in length, by
screwing it further into fork end piece. After adjustment tighten lock nut firmly

FRONT
To adjust the front brakes;
1. Jack up the front wheels.
2. Unlock nut of the adjusting cam on one wheel
3. Rotate the cam till the wheels are fully jammed.
4. Slowly rotate the cam in the opposite direction till the wheels are just free.
5. Lock the cam by locking nut.
Repeat the same for adjusting brakes on 2nd wheel. Check the oil level in the master
cylinder. Bleed the brake system.

4. BRAKE FLUID FILLING

The level of brake fluid in the container should be checked from time to time and topped
up if

necessary. Only the recommended brake fluid should be used for dependable operation

60
conditions. Do not overfill mixing of different brands of fluids in the system should be

avoided.

If the brake pedal gats spongy, this may be due to air in the braking system. This defect
can be
Rectified by bleeding the system.

Whenever any repairs or disconnecting of any brake pipe is done, it is imperative to bleed
the
system to any air trapped in it.

It is vital that the absolute cleanliness is maintained throughout tile entire bleeding
operation.
All equipment to be used must be entirely free from petrol, Kerosene or any form of
mineral
Oil, as mineral oil contamination spread rapidly in the braking $system, causing a dangerous
deterioration of the rubber seals.

During filling operation, keep the following points in mind:

1. Ensure that the fluid level in the container do not fall low enough to cause air to be
drawn
Into the system.
2. Never, under any circumstances, use the fluid which has been bled from the system.

Maintenance
1. Remove filter cap & fill the brake fluid container with fresh brake fluid upto indicated level.

2, Remove the dust cap from the left front wheel cylinder bleed screw and clean it thoroughly.
Attach the bleeder tube to the bleed screw and place the other end of the tube in a
clean glass jar containing sufficient brake fluid to submerge end of the tube.

61
3. Pump the brake p e d a l twice/thrice slowly throughout its stroke and b y holding the p e dal,

loosen the bleed screw and watch the air bubbles in the glass jar.

4. Re-tighten the bleed screw and ·release the brake pedal. Repeat the same operation until
air bubbles cease to appear at the end of the bleed lube allowing only fluid to flow.
5. Repeat the same procedure from s t e p 1 to 4 for front tight wheel cylinder, & rear left
and right slave cylinder.

6. If the pedal feel is spongy even after initially bleeding the brakes should be vigorously

pumped and then the bleeding operation repeated.

7. Fill the brake fluid container up to indicated level.

Note:
While doing bleeding brake system, the engine should be running and also the parking
brake should be released.
The performance of the high compression Diesel Engine depends upon the supply of clean fuel in
the form of a fine spray to the engine cylinder. This is achieved through precision parts such as
the fuel Injection pump and injection nozzles aided by the filtering system, The working parts are
manufactured to extremely dose tolerances.
lf particles of devein the finest are allowed to flow in between these precision working parts
wear takes place rapidly and consequently the pump is unable to develop the required pressure
for spraying the fuel into the cylinder. A high rate of fuel injection equipment wear is
attributable to dirt and foreign matter in the fuel. Many replacement expenses can be saved and
engine reliability enhanced if meticulous care is taken while handling engine fuel.
Only high speed diesel should be used as fuel for the engine. An inferior fuel will prove
expensive
in the long run.

LUBRICATING SYSYTEM
The lubricating oil is used in the engine to reduce friction at the bearing surfaces by providing
a
film of oil between them. It also keeps temperature of the moving surfaces with in limits. The
effective film can be maintained between the surfaces only if the recommended grade of oil is used.

The system of lubrication. Comprises of pressure feeds to main & big end bearings to No. 2

62
camshaft bearing rocker shaft & auxiliary drive. The pump draws oil through the strainer,
from the sump and delivers it by an internal drilling with in the crankcase to the oil relief valve
cover fitted on tho Side of the cylinder block. From the oil pressure relief valve cover, the oil
flows through an external pipe t o the full flow lubricating oil filter.

At the outlet from this filter, the flow passes along a further pipe to the pressure
rail.
The out union on the filter Is drilled to allow for the connection of the oil pressure
gauge
pipe. The pressure rail is an internal passage within the crank case.

Holes drilled In the crankcase webs, lead from this pressure rail to the crankshaft
carry the oil to the big end bearings. Surplus oil is returned to the sump.

An oil seal prevents oil from leaking along the crankshaft at its rear end, and any oil
thrown from this seal returns by a passage to the sump. Two oil feeds are taken from
the oil filter head One pipe carries oil at full pressure to the auxiliary drive body.
The other pipe carries oil to the lower of the two drillings in the camshaft tunnel
on the centre line of no. 2 camshaft bearing.
As the camshaft revolves, oil is picked up and carried round in the narrow slot
machined on no.2 camshaft journal until it escapes through the upper drilling in the
camshaft tunnel. Tile oil then flows through the pipe to the cylinder head where as an
other pipe conveys It to the hollow rocker shaft which feeds oil to the rocker bushes etc.

The overflow of oil from the rocker shaft from the head into camshaft tunnel
and from the front of the tunnel on to the timing gear and drive sprockets and
then returns to the pump.

63
64
65
66
TIPS 0 N FUEL S A V I N G

1. Know your engine

Your manual will tell you everything you need to know about the maintenance and
Operation of your Engine. Research shows t h a t a badly maintained E n g i n e
Wastes u p t o 25% of precious diesel.
2. Stop diesel leaks

Check your Engine daily. A leak of one drop per second can cost you
600 liters per year.

3. Turn your engine off, when you stop

An idling Engine wastes more than 1 liter of diesel every hour.

4. Dirt-your engine's worst enemy

Good air filtration is important since Crane often operate in dusty conditions.
Research proves that unfiltered air wears out cylinder bores 45 time faster and
piston rings 115 times faster than normal.

Good fuel filtration is important, too. Dirty fuel endangers the engine too.

Use quality fuel filters and replace them as recommended

Remember:

- When in doubt, check with your dealer.

Remember:

Inspect joints in

-Fuel tank, -Fuel injectors,

-Fuel pump,- Fuel lines

Remember:

- Keep your battery, dynamo and self-starter in top running condition.

If they are faulty they can force you to idle.

Remember:

- do not replace both fuel filters simultaneously.

- Clean air cleaner regularly
DIESEL STORAGE AND HANDLING

67
 The Funnel for pouring the diesel
should have close mesh gauze.
Cans and funnel should be kept
clean and dry and covered up
when not in use.

The barrels should be kept well

sheltered and the contents given
ample time to settle before any
diesel is withdrawn.

A tap should be screwed into the

hole on one end of the barrel,
which should be placed tilted away
from the tap. It will be necessary to
loosen the second plug for drawing
the diesel and to tighten it
afterwards.

The barrel should not be

completely drained, but refilled
while there is still 5-10 litres diesel
in it.

HOW TO GET TOP PERFORMANCE FROM YOUR ENGINE

ENGINE MAINTENANCE
Ensure daily and periodic maintenance as per given schedule in this manual

• Always operate the engine at rated speed as specified in the operator manual for
maximum work output.

Do's
• Ensure protective caps on all openings.
• Ensure proper lubrication.
• Ensure leak proof joints for oil & air. Check periodically.
• Ensure specified grade of lubricating oil.
• Run engine at idle RPM for approx 1min. Before stopping
& after starting.
• Check air & oil filter condition regularly to the manufacturer's specification.
• Ensure that engine maintenance intervals are adhered to.

68
Don'ts
• Do not add any additives in lubricating oil & fuel unless until specified.
• Do not run the vehicle I engine at idle for long periods (more t1
20- 30mins).
• Do not park your machine in moist or wet place.

AIR CLEANER
• Check Vacuum Indicator & clean filter element when the indicator shows red band. Change Air
Filter
After every 600 hours(As per service schedule).
HOW TO GET TOP PERFORMANCE FROM YOUR ENG INE
ENGINE OIL

• Check engine oil level daily. Oil level between "Min" & "Max" is safe and there is no need to
add more oil. Top up oil level if oil level is close to "Min" mark. Use only recommended grade
of oil (20w40).
Note:- Top of engine oil is to be done only in case of leakage or seepage from the engine
and contact dealer or service engineer for corrective actions.

FAN BELT TENSION

• Maintain proper(% or 12mm) fan belt tension. Loose fan belt leads to slippage and causes
engine
overheating and the battery does not get charged also.

GREASING AND LUBRICATION

• Grease all greasing points every 50 hrs. Or weekly

DIESEL FUEL

Before handling fuel, filling tanks, etc., observe the following:

• Under no circumstances, should gasoline, gasohol, or diesel hol (a mixture of diesel fuel and
alcohol) be added to diesel fuel because of increased fire or explosion risks. In addition,
in a closed container, such as a fuel tank, they are more explosive than pure gasoline.
Do not use these blends. Additionally, diesel hol is not approved due to possible inadequate
lubrication of the fuel injection system.

• Clean the filler cap area. Fill the fuel tank at the end of each day to reduce overnight condensation.

• Never remove the filler cap or refuel with the engine running.

• Keep control of the fuel filling pipe nozzle and do not smoke when filling the tank.

• Do not fill tank to capacity. Allow room for expansion and wipe up spilled fuel immediately.
• If the original fuel tank cap is lost or damaged, replace it with an approved cap and tighten
securely. A non approved cap may not be safe.
69
 • Diesel fuel with a Sulphur content above 1.3% is not recommended.
• Precautions should be taken to ensure that stored fuel is kept free of dirt, water, etc.

• Fuel s h o u l d be sto red in black iron t a n k s , not galvanized tanks, as the galvanized

coating will react with the fuel and form compounds that will contaminate the injection pump

and injectors.

• Bulk storage tanks should be installed away from direct sunlight and angled slightly so that
the outlet pipe is at the higher end. In this way sediment in the tank settle away from the
outlet pipe.

• To facilitate moisture and sediment removal, a drain plug should be provided at the lowest
point (at the opposite end to the outlet pipe). If there is no filter on the o u t l e t p i p e , t h e n
a funnel with a fine mesh

DAILY MAINTENENCE
This section gives full details of the service procedures necessary to maintain your Engine
at peak efficiency while the lubrication and maintenance chart on next page provides a ready
Reference to these requirements.
In addition to the regular service operations listed, the following items should be checked
every 10 hours or daily.

• Fuel in fuel tank

• Engine oil level

• Air cleaner

At the first 50 hours service, ensure that the following additional service operations are
carried out

• Change engine oil & filter.

• Check and adjust fan belt tension.

NOTE: Ensure that the Machine is on level ground and that all rams are extended, where applicable
before checking oil levels. See in latter pages for additional amount that may be added to the rear
axle and for oil capacities and grades. To prevent contamination when changing oils, filters, etc.
always clean the area around the filter, level and drain plugs, dipsticks a n d filters. Before
connecting remote cylinders, ensure that oil contained within t11em is clean, has not degenerated
due to long storage and is of the correct grade.

Cylinder head bolt torque

Cylinder head bolts tightening sequence 4 cylinders

70
• Cylinder Head Bolts tightening torque

• First stage 10-11 Kgm/Second stage 14-15 Kgm

IMPORTANT

Warm up the engine

• Tighten the cylinder head Bolts in the above shown sequence, in two stages and upto
recommended
torque using a calibrated torque wrench of reliable make.

• Do not over tighten the bolts.

• Warm up the engine and re-torque the cylinder head bolts in the same sequence, if cylinder
head
gasket is replaced.

LUBRICATION & MAINTENANCE

Most operation is done, as a habit, between 1600-1800 engine RPM where engine power

71
 and work output is low and results in performance dissatisfaction.
Although hourly and timely engine maintenance is given in the following pages of your
"Operator's Manual" to get top notch performance, yet we list down a few 'MAINTENANCE
AND OPERATION TIPS" to get top notch performance,

SOME FACTS
• ESC0RTS engines are rated at 2200 RPM for maximum
power output

Engine oil level

Before checking the oil level, stop the engine and wait for a short period to allow the
oil to drain back into the sump, Check the oil level by means of the dipstick, if necessary,
remove the filler plug and top up with fresh Oil to the upper mark on the dipstick. Do not
overfill,
dipstick in between "Min" and "Max" marks.

EVERY 10 HOURS OR DAILY (Whichever occurs first carry out the following checks

Engine Oil Level

1 . Filler Cap
2. Dip Stick

There is no need to top up. Add oil when level comes to near Min" mark.

IMPORTANT:
More often when operating in dusty conditions. In extreme Conditions, it may be necessary
to service the Pre cleaner two or three times each day.

Dry Air Cleaner Dust Collector

A rubber dust collector protrudes beneath the dry air cleaner body periodically pinch the dust

72
 collector which will open and discl1arge any accumulated dust

14. Dry Air Cleaner

1. Dust Collector

Air Cleaner Outer Element

Extract the outer element after removing the retaining wing· nut. Clean the element by
Tapping on the palm. Do not beat the element against
a hard Surface as the element may be damaged or
distorted. Alternatively, compressed a i r not

exceeding 3 0 lbf/in2 (2 <g/ cm2 ) may be used.

Insert the air line nozzle inside the element and blow
the dust from inside to outside. Blow loose particles
from the outside of the element by holding the
nozzle at least Gin. (150 mm) front the element.
Clean the inside of the air cleaner casing with damp
lint free cloth. Re-install the outer element ensuring
that the rubber sealing ring on the end is secure.
NOTE: Do not remove or disturb the inner element. The Inner element
should be serviced only by an Authorized Dealer

FUEL FILTERS

Loosen the bleed screw in turn and loosen the drain plug to allow contaminated fuel to drain.
Repeat more frequently during conditions of high condensation.

After draining the fuel filters tighten the drain plugs and bleed the injection system

1. Filter retaining bolts

2. Bleeding Screw

EVERY 500 HOURS carry out the preceding checks plus the following :

The following text depicts the normal 500 hour engine oil and filter change period.
73
However, engines operating in temperatures below 12"C (1O"F) or in arduous conditions
should have the oil changed every 150 hours of operation.
(The oil filter need only be changed at the normal 500 hours service interval).
In some countries, locally available diesel may have a high sulphur content, in which case
the oil change period should be adjusted, as follows:
Diesel fuel sulphur content below 0.5%- normal oil change period applies.
Diesel fuel sulphur content between 0.5 and 1.0% reduce oil change period to half the normal
Diesel fuel sulphur content between 1.0 and 1.3% reduce oil change period to one quarter the normal
The use of diesel fuel with sulphur content above 1.3% is not recommended.

Engine Oil and Filter

Warm up the engine to operating temperature. Stop the engine, remove the drain plug and
collect

the oil in a suitable container. Unscrew and discard the oil filter. Clean the area around the filter.

Smear clean engine oil Around the rubber seal of a new. filter and install on the Engine. Screw up

until the faces just meet, then tighten it further 3/4 of a turn. Do not over tighten

1. Oil Filter

Replace the drain plug; remove the filler plug and refill the engine with recommended new oil.

Replace the filler plug. Run the engine for a minute or so, to circulate the oil, then stop the engine.

Wait for a short period to allow the oil to drain back to sump, and then check the oil level by means
of dipstick.

Add clean oil, as necessary, until the oil reaches the upper 'Max' mark on the dipstick.

74
1. Filler Plug

2. Dipstick

STARTER PINION:
Disconnect the cable from the battery earth terminal and the battery cables from the starter motor
and solenoid. Extract the three securing bolts and remove the starter motor.
Examine the starter pinion for clutch dust contamination and, if necessary, brush clean with a solution
of 75% paraffin (kerosene and 25% lubricating oil. This mixture will provide sufficient lubrication for
the pinion until the next
600 hours service

Fan belt tension

1. Alternator adjusting link bolt
2. Alternator mounting bolts

Fan/Alternator Belt Tension

Belt tension is correct when the belt can be deflected 0.50-0.75 in. (13 -19
mm).
To adjust, remove the guard, slacken the mounting bolts and adjusting link
bolt. Move the alternator to retention the belt. Do not over tension the belt.
Tighten the mounting bolts.

75
Fuel Filter (Primary)

Close the fuel tank shut-off valve by turning in a clockwise direction.

Clean the filter assembly with a clean, lint-free cloth. Unscrew the central retaining bolt. Remove the
primary filter element and bowl. Discard the filter element

Using clean fuel, wash out the filter bowl. Install a new filter element and gaskets and re-install the
bowl. Open the fuel shut off valve and Bleed the system.

Using clean fuel, wash out filter bowl. Install a new filter element and gaskets and re-install the bowl.

Open the fuel shut-off valve and bleed the system. Given in latter pages.

Bleeding the Fuel System

Loosen the air vent screw on filter assembly.
Loosen priming pump knob and actuate the pump until fuel comes out without air bubble from vent
screw on filter assembly.
Tighten the vent screw.
Loosen all the high pressure pipes at injector end. Energize the solenoid switch (Switch 'ON' the
ignition). Crank the engine while depressing the accelerator pedal Cleaned or replaced, as necessary

Injectors & pipe connections

1. Injector
2. Injector tube
3. Over flow tube

Alternator Brushes

Change the alternator brushes and clean the brush box. It is recommended that only an Authorized Dealer
should carry out this service.

76
EVERY 1500 HOURS carry out the preceding checks plus the following:
Fuel injector tips
CAUTION: The fuel oil in the injection system is pressurized and can penetrate human skin with
fatal results. Unqualified persons should not carry out adjustments of fuel injection equipment.
Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks.
Wear eye protection.
Stop t/Je engine and relieve pressure before connecting or disconnecting fines. Tighten all
connections before starting the engine or pressurizing fines.
If any fluid is injected into the skin, obtain medical attention immediately or gangrene may result.
IMPORTANT: Before loosening or disconnecting any part of the fuel injection system, thoroughly
clean the a r e a to be worked on Alternator Service Precautions

To avoid damage to the alternator charging system, service precautions should be observed, as
follows:
• NEVER make or break any of the charging circuit connections, including the battery, when the
engine is running.
• NEVER short any of the charging components to earth.
• ALWAYS d i s c o n n e c t the battery earth terminal when installing or removing the alternator.
• D 0 NOT use a slave battery of higher than 12 volts nominal voltage.
• ALWAYS disconnect the battery earth cable when charging the battery in the tractor using a
battery charger.
• ALWAYS observe conduct polarity when installing a battery or using a slave battery to jump-
start the engine.
A L WAY S disconnect the battery earth cable before carrying out arc welding on the tractor or
on any implement attached to the tractor.
EVERY 2500 HOURS carry out the preceding checks plus the following:
Fuel Injection Pump-Oil
Change the fuel injection pump oil after every 2500 hours. It is recommended that only an
Authorized Dealer carry out this service.
EVERY 3000 HOURS carry out the preceding checks plus the following:
Fuel Injectors
Repeat the service as described in operation 48. If required, replace the injectors. Regular
maintenance of the injectors is not necessary. The injector need nozzles maintenance if:
• Engine difficult to start or will not start.
• Engine will not develop enough power.
• Engine misfires or runs erratically.
• High fuel consumption
• Visible black exhaust smoke
• Engine knocks or vibrates excessively
• Excessive engine temperature

WARNING: Wear eye protection w h e n charging the Battery or starting the tractor with a
slave battery.
77
MAINTENANCE OF WINCH ROPE, RETRACT ROPE, EXTRACT ROPE ARRANGEMENT

WINCH ROPE ARRANGEMENT

PROCEDURE FOR REPLACEMENT OF WINCH WIRE ROPE

• Unwind all the wire rope from the drum.

• Remove the wire rope clamp from winch

78
 PROCEDURE FOR FITMENT OF WINCH WIRE ROPE

• Extend the boom fully before fitment of rope.

• One end of the wire rope is crimped (In the form of loop for anchoring on jib Head)
whereas other end is free
• Fit crimped end of the jib head of the boom
• Take pass it over the compensation pulley fitted on top of lind extension such
that the rope remains betwe en the pulley guide & pulley. This guide will
help in directing the rope towards outside.
• Take this end further on the angular pulley fitted on the top of 1st extension
in away that rope remains between pulley & its guide.
• Further take this end of the rope & anchor it on the winch drum
• Reeve the rope on the winch drum through winch hydraulic lever.

RETRACT ROPE ARRANGEMENT

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PROCEDURE FOR FITMENT OF RETRACT ROPE

• Fix the wire rope from center on lind extension keeping the stud end on left hand side
and pull the rope in rear.
• Insert lind extension in 1st extension & pull the wire rope from rear & insert it on retract
pulley & clamp the two rope ends with angular pulley bracket.
• Insert the assembled 1st & lind in Main Boom and pull the stud & free end from the cut
on Main Boom, Fix the free end by wedge & socket provided on the RH side of Main
Boom and stud end by M12 nut on

EXTRACT ROPE ARRANGEMENT

PROCEDURE FOR FITMENT OF RETRACT ROPE

• Fix the wire rope from center on lind extension and pull the rope in front.

• Insert lind extension in 1st extension & the wire rope on top of extension
pulley
• Insert the assembled 1st & lind in Main Boom and insert the stud of the wire
rope in the hole of the bracket welded at the Main Boom rear end

• Tighten the stud by M16 Nuts.

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 ADJUSTING RETRACT AND EXTENSION ROPES
• Run winch rope down approx. 600mm with boom fully retracted.

• Tighten retract rope adjusting stud (1 off) on front of Main Boom until
2nd Extension is fully retracted.

• With the fall block reeved on four part and the engine set at 1500rpm - Winch up until the
winch motor hydraulically stalls, causing the fall block on the head of the extension. This will
induce the maximum tension in the retract rope and equalize the tension in both ends.
The 2nd extension should move out - Measure the gap between the section of the 1st
Extension and the stiffening collar of the 2nd extension. This should measure 13-16mm.
When the retract rope is correctly tensioned. If the measured gap is more. Repeat steps 1-3
Tighten Retract Rope at Step 2.

• Tighten Extension Rope Adjusting Stud (2 off) on rear of main boom until the 2nd
Extension just start to move out. Check if both ropes are now equally tensioned.

• Repeat the above exercise again after 75 Hrs.

81
7. Maintenance Chart

82
 8. Trouble shooting

Trouble shooting is an organized study of a problem, then a planned procedure for investigating and
correcting the problem. Anyo ne familiar with constructional details & operating principles of a
particular equipment/components, can trouble shoot the failure without much difficulty.

The serviceman responds to a complaint by getting the full story from the operator, by observing the
machine a n d making necessary investigation a n d test which will reveal about the cause of failure
The first act of the trouble shooting is to understand the problem v e r y precisely. For this
purpose following questions are suggested to diagnose the trouble property.

A) OPERATING CONDITIONS:
1 Did any unusual noise precede the failure?
2) Was the crane under specified load or over loaded?
3) Did any unusual dusty or smoky conditiOf1 persist for long time ?
4) Did oil pressure or oil temperature very?
5) What were weather conditions?
6) How was trouble first noticed?
7) What w a s the consumption rate f o r fuel or lubricant?
8) What was the condition of exhaust?
9) Was t h e e n g i n e starting & shutdown satisfactory?
1O)Old the engine run at Idle for long period.
11)Was there any smoke f ro m any part other than exhaust?

B) OBSERVATIONS
1) Is the crane clean on dirty?
2) Is there any leakage of oil, or fuel, externally visible?

3) Are there any nuts, bolts, screws found lose?

4) Are there any modifications done on the crane by removal or replacement or parts ?
5) IS there any misalignment or wrong adjustment?
6) Is there damage of parts due to accident?
7) Is there any part fouling?
8) Is there any symptom of burning or overhauling or a part?

CAUSES

12. EXCESSIVE LUBRICATING OIL CONSUMPTION:

1. External oil leaks.
2. Wrong grade of oil used.
3. Valve guide worn out.
4. Oil rings stuck in piston ring grooves.
5. Pistons, rings, liners, worn out.
6. Engine overheating.

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REMEDIES

1. Check leakage and rectify.

2. Drain the oil and refill with proper grade of oil.
3. Replace the valve guide.
4. Replace affected parts.
5. Replace affected parts.
6. Clean Air Cleaner, intak6 system & fill with fresh oil.
7. Clean Radiator lines.
CAUSES

13. NO OR LOW LUBRICATING OIL PRESSURE:

1. Pressure gauge defective.
2. Oil lines loose/broken inside.
3. Wrong grade of oil used.
4. Insufficient oil in the crankcase.
5. Cooling system defective.
6. Main or connecting rod or crankshaft bearings worn out.
7. Lub. Oil pump defective.
8. Lub. Oil pump suction strainer chocked.
9. Oil pressure valve defective.

REMEDIES
1. Replace oil pressure gauge.
2. Repair or replace affected parts.
3. Drain oil and refill with the proper grade of oil.
4. Fill crankcase to proper level.
5. Rectify cooling system.
6. Replace affected bearings.
7. Repair or replace the pump.
8. Clean strainer.

CAUSES

14. EXCESSIVE LUBRICATING OIL PRESSURE:

1. Pressure gauge defective.

2. Pump defective.
3. Wrong grade of oil used.
4. Oil pressure valve sticking.

REMEDIES

1. Check & replace pressure gauge.

2. Repair / replace pump.
3. Drain and refill with proper grade of oil.
4. Clean / Replace relief valve.

84
CAUSES

15. CLUTCH OPERATING HARD OR STICKY:

1. Clutch not adjusted properly.
2. Clutch linkage or pedal fouling.
3. Clutch linkage parts rusty.
4. Release bearing failure.

REMEDIES

1. Adjust the clutch.

2. Rectify.
3. Clean & lubricates the joints. Check clevis pin for free rotation.
4. Replace the bearing.

CAUSES

16. CLUTCH SLIPPING:

1. Clutch out of adjustment.
2. Worn clutch plate.
3. Spring tension poor.

REMEDIES

1. Adjust clutch.
2. Replace clutch plate.
3. Replace springs.

CAUSES
17. GEARS NOT ENGAGING/SLIPPING;
1. Clutch not disengaging.
2. Fork / lever / shaft bent.
3. Interlock jammed.
4. Springs broken or lost tension.
5. Worn gear teeth.
6. Fork lock loose

REMEDIES

1. Adjust the clutch.

2. Replace or repair fork/lever/shaft.
3. Rectify.
4. Replace springs or add washer.
5. Replace gears.
6. Tighten the lock.
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CAUSES

18 UNUSUAL SOUND FROM GEAR BOX;

1. Incorrect lubricants & level too low.
2. Worn or broken gear teeth.
3. Worn bearings.

REMEDIES

1. Fill with recommended grade of oil and check for leakage.

2. Replace gears.
3. Replace bearings.

CAUSES

19. DIFFERENTIAL NOSILY:

1. Incorrect lubricants & level too low.
2. Worn broken gear teeth.
3. Crown wheel & pinion unmatched or not properly adjusted.

REMEDIES

1. Check level, use recommended oil and check for leakages.

2. Replace worn out parts.
3. Adjust back lash/replace with matched.

CAUSES

20. DIFFERENTIAL OVERHEATS:

1. Incorrect lubricants or level too low.

2. Bearing adjusted too light.
3. Excessive wear on gear.

REMEDIES

1. Check level fill with correct recommended grade oil

2. Re-adjust properly.
3. Check gears for excessive wearing scoring replace if
necessary.
CAUSES

21. NOISE IN REDUCTION HOUSING:

1. Incorrect lubricants & low oil level
2. Bearings worn out.
3. Gear & pinion teeth worn out/broken.
4. Splines on axle / wheel shaft worn out.
86
REMEDIES

1. Check level. Fill recommended grade of oil & check for leakage.
2. Replace bearings.
3. Replace worn out / broken parts.
4. Replace worn out parts.

22. BRAKES NOT EFFECTIVE:

Type of fault

1. A brake pedal hard to operate Possible causes

a) Reservoir drain plug open.

b) Trailer brakes shut of left open

Recommended action

Make a complete check of pipelines, hoses, connections.

Reservoir and trailer couplings.

1. Compressed leakage.
Fault in air
Compressor such as:

I) Detective of worn compressor.

ii) Leaking delivery valve.

iii) Leaking inlet valve

iv) Defective unloader valve
v) Leakage at tyre inflator

Recommended action

Service the Compressor Unload Valve tyre inflator as per manufacturer recommended

2. Wheel brakes or pedal

Possible causes

a) Brake pedal, relay lever or brakes shoe binding

b) Glazed linings
c) Grease or brake fluid on linings.

d) Corrosion in master cylinder.

e) Restriction or damage to hydraulic lines to wheel cylinders.

87
Recommended action

a) Inspect pedal linkages or shoe assemblies for tightness.

b) Reline shoes or clean linings and adjust brake.

c) Inspect master cylinder.

d) Check operation of wheel cylinders / slave cylinders

3. Hydraulic System Trouble

Possible causes

a) Corrosion in wheel cylinder / slave cylinders.

b) Residual check valve not opening in master cylinder.
c) Incorrect brake fluid.

Recommended action

Inspects wheel cylinders / slave cylinders

Remove master cylinder outer connections and inspect valves.
Flush out system and refill with correct fluid.

B. Brakes fall to release

1. Wheel Brakes or pedal trouble

Possible causes

a) Shoe linkage seized.

b) Weak or broken shoe return spring.
c) Brake pedal or linkage binding
d) weak of broken pedal return spring.
e)Broke linkage incorrectly adjusted. Preventing servo- returning to 'off' position.

Recommended action

Check brake assemblies for seizing and weak or broken springs

Check pedal and linkage for correct alignment and freedom movement.
Lubricate pedal pivot and linkage.
Adjust brake linkage so that both pedal and servo are in 'off position.

2. Hydraulic system Trouble

Possible causes
a) Faulty adjustment of slave Cylinder push rod.
b) Faulty adjustment of slave Cylinder push rod.
c) Corrosion in master cylinder.
d) Restriction of damage to hydraulic lines to wheel cylinder / slave cylinder.
e) Corrosion in wheel cylinder.
88
Recommended action

a) Check that the servo output rod stand out in correct If not adjust by internal
b) Inspect master cylinder.
b) Check operation of wheel cylinder / slave cylinders and inspect pipes.
c) Inspect wheel cylinder / slave cylinder.

Type of Fault

Possible causes

1) Incorrect brake fluid.

a) Lever assembly not functioning correctly
b) Exhaust valve sticky
c) Release breather filter obstructed.
d) Power piston not returning due to dirt corrosion or lack lubrication.
e) Reaction piston not returning due to dirt or lack of lubrication due to dirt or lack permanently
set.
f) Power piston or Reaction piston springs. Or broken or permanently set.

Recommended action

Flush out system and refill with correct fluid.

Remove lever housing and check lever operation.
Check exhaust valve.
Remove power piston examine & re lubricate
Examine spring & if faulty replace

C. BRAKE PEDAL HAS EXCESSIVE TRAVEL:

Possible causes

1. Wheel brakes or Pedal Trouble.

a) Brake shoe in need of adjustment.

b) Excessive wear in brake pedal linkage.

c) Shoe linkage seized.

d) Cracked drums of distorted brake shoe.

Recommended action

Adjust brake clearance

Inspect pedal and linkage

Examine brake assemblies

89
2. Hydraulic system trouble

Possible causes

a) Low fluid level in master cylinder level

b) Air in system

c) Defective seals in master cylinder

d) Leakage in pipe lines to wheel cylinders

e) Defective seals in wheel cylinders/slave cylinders

f) Incorrect brake fluid

Recommended action

Check level of fluid and top up to correct level

Bleed the system

Examine master cylinder

Inspect pipe and fitting for loose connections replenish fluid

Check seals in wheel cylinder/cylinder slave

Flush out system and refill with correct fluid.

D. BRAKES GRAB:

1. Wheel Brakes or pedal Trouble

Possible causes

a) Grease or brake fluid on lining.

b) Broken Shoe return
c) Pedal linkage binding
d) Distorted brake shoos
e) Brakes out of adjustment

f) Pedal linkage binding

g) Loose brake flange plate
h) Slake hub bearing

90
RECOMMENDED ACTION

a) Reline shoe or clean lining

b) Examine brake assemblies and brake drum
c) Adjust brake as necessary
d) Check and lubricate pedal linkage
e) Examine brake assemblies

2. Hydraulic System Trouble

Possible cause
a) Leakage of fluid at wheel cylinder / slave cylinder.
b) Defective seals in wheels cylinder/slave cylinder.
Recommended action
a) Examine assemblies
b) Inspect wheels cylinders/slave cylinders.

23 Vehicle dragging to either side

Causes
a) Brake unequally adjusted
b) Worn out lining
c) Tyre pressure unequal
d) Defective wheel brake cylinder slave cylinder
e) Brake shoe return spring damage

Remedies
a) Adjust brake properly
b) Replace lining
c) Inflate all the tyres to recommended pressure
d) Replace defective parts
e) Replace defective parts

24 Unequal steering turns on two side

Causes
a) Steering geometry distributed
b) Stoppers not set properly
c) unequal Tyre Pressure

Remedies
a) Check & rectify
b) Check & rectify
c) Inflate all the tyres to the recommended pressure

91
25 Steering wrong direction
Causes
a) Incorrect plumbing of steering unit to steering lines

Remedies
a) Check steering line plumbing

26 Hydraulic response poor

Causes
a) Cold hydraulic oil
b) Oil of high viscosity
c) Insufficient engine speed
d) Air leak in suction line
e) Pump worn out
f) Oil leaking past O-rings & seal actuators
g) Oil leaking Past distributor
h) Restriction in Suction line
i) Clogged breather in hydraulic oil reservoir
j) mechanical linkage joints jammed
k) Load exceeding specify lift capacity
l) checked or partially clogged in strainer in oil reservoir

Remedies
a) Allow hyd. Oil to warm up the slow engine speed
b) Use recommended oil
c) Press foot accelerator to increase speed
d) Check & Rectify add hyd. Oil if necessary
e) Get pump repair/ replaced
f) Check & replaced affected parts
g) Get distributor valve repaired/ replaced
h) Check clean & reassemble suction line strainer & hyd. oil filter
i) Clean breather
j) Clean & lubricate
K) Reduce load
l) Remove, clean & refit

27 Hydraulic system not responding

Causes
a) Insufficient oil in reservoir
b) Foreign matter lodged under seat of relief valve or in line check valve
c) Insufficient relief valve pressure

92
d) Pump badly worn out & damaged
e) Broken Oil line
f) Obstruction in oil lines & valves
g) Worn distributor valve
h) Pump gears worn out
i) Pump shaft, key or propeller shaft sheared

Remedies
a) Add oil
b) Check & clean relief valve
c) Get relief valve reset to recommended pressure
d) Get pump repaired/ replaced
e) Check for leakage and repair oil lines
f) Check flow of through the hyd. Circuit and remove obstruction
g) Get distributed valve repaired or replaced
h) Check for dirt or metal chips. Clean the parts through and replace the affected parts. Flush with
hyd. Oil if necessary
i) Check and replace affected parts

28 Boom fails to hold up

Causes
a) Leaking or broken oil lines from distributor valve to lo lift cylinders
b) Internal leakage in cyl. Past O-rings & seals
c) Internal leakage past distributed spool

Remedies
a) Check for leaks, tighten or replace lines.
b) Check & replace affected parts.
c) Get distributor spool repaired/ replaced

29 Hydraulic oil overheating

Causes
a) Operator holds distributor valve open to long causing relief valve to open
b) Incorrect relief valve pressure setting
c) Incorrect grade of oil used
d) Dirty oil
e) Insufficient oil in hydraulic reservoir
f) Dirty breather on hydraulic oil reservoir
g) Suction line restricted
h) Worn pump valve or cylinder
i) Air in the system

93
Remedies
a) Release control handle when not in use
b) Get relief valve reset to recommended oil pressure
c) Use recommended oil
d) Drain & relief with recommended oil
e) Fill tank to proper level
f) Clean or replace breather
g) Clean suction line /strainer
h) Replaced affected parts
i) Check hydraulic system suction lines

30. Oil Foaming

Causes
a) Kink or dent in oil lines
b) Worn seal on the pump shaft
c) Incorrect grade of oil
d) Low oil level in reservoir
e) Oil contaminated with water

Remedies
a) Replace oil lines
b) Get pump repaired or replace
c) Use recommended oil.
d) Add recommended oil to proper level
e) Drain hydraulic oil & refill recommended oil

31. Noisy hydraulic operation

Causes
a) Partially dogged suction line
b) Sludge & dirt in pump
c) Reservoir breather clogged
d) Oil viscosity high
e) Pump worn out
f) Low hydraulic oil level
g) Engine speed too high
h) Air in system

Remedies
a) Remove & clean suction line between reservoir & pump
b) Get the pump cleaned thoroughly
c) Remove breather cap, flush & clean

94
d) Use recommended oil
e) Check & repair/ replace the pump
f) Add hydraulic oil to proper level
g) Always maintain the recommended speed
h) Check hydraulic system for air leaks in the suction lines

32. Steering response poor on one of the side

Causes
a) Internal leakage in steering jack
b) Piston rod bend
c) Blocked hose/ pipe lines
d) Flow cum pressure relief valve defective

Remedies
a) Check & replace
b) Replace jack
c) Clean/ replace
d) Rectify/ replace the assembly

95
9. Electrical Circuit

96
10. Hydraulic Circuit

97
11. Pneumatic Circuit with Air Brake

98
99