Mahindra AppliTrac User manual

MACHINE IDENTIFICATION AND RECORD
OWNER’S NAME - ………………………………………………………………………………………………………………..
ADDRESS - ……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………..
SELLING DEALER CODE - ………………………………………………………………………………………………………
DATE OF DELIVERY - …………………………………………………………………………………………………………….
MACHINE S. No- ………………………………………………………………………………………………………………….
THE WARRANTY ON THIS MACHINE IS VALID ONLY IF THE DETAILS ARE FILLED.
SIGNED AND STAMPED BY THE CUSTOMER.
DEALER’S SIGNATURE AND STAMP

CONTENTS
Introduction -
Safety Precaution -
Mounting instruction & Connecting Hydraulic System -
Operating procedure -
Trouble shooting causes & Remedies -
Maintenance -
Dozer spare Parts catalogue -
Warning -
Service Check List -
Warranty -
SAFETY INSTRUCTIONS

SITE SAFETY
Before you start the machine inspect the working site. You could be killed or injured if the
ground gives way under your machine or if piled material collapses on to it.
SAFETY INSTRUCTION
Carefully read all safety massage in this manual. Learn how to operate the machine and
how to use controls properly. Do not let anyone operate without instruction. Keep your
machine in proper condition. Do not make any modifications to the machine may impair
the function or safety and affect machine life.
LEGAL LIABILITY
You or your company could be legally liable for any damages you may cause to public
utilities. It is your responsibility to make sure that you know the locations of all public
utility cables or pipes on the site, which could be damaged by your machine.
PROTECT PEOPLE
Never allow anyone to walk or work under a raised Dozer or whole in operation. Do not
use the Dozer for a work platform. Do not lift or carry anyone on Dozer or in bucket or
attachment.
CAUTION
You could be electrocuted or badly burned if you get the machine or its attachment too
close to electric power cables.
Before you start using the machine check with local public water supplier, local gas
supplier for any buried pipelines on the site or any other harmful substance burned on the
site.
DANGER
TO avoid body injury, do not stand below the Dozer arm raised condition.
AVOID HIGH PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the skin causing serious injury.
Tighten all connection before applying pressure.
Search for leaks with a piece of cardboard
Protect hands and body from high - pressure fluids.
WARNING

Relieve pressure on system before repairing or adjusting or
disconnecting.
Wear proper hand or eye protection when searching for leaks.
Do not consume hydraulic oil. This is Harmful for human health.
You and others could be killed or injured if you reverse direction
on the move because the change in direction will be sudden and
without warning to others.
Use only the accelerator pedal to control engine speed while
driving. Do not set the speed with hand throttle
Operating on hillside can be dangerous, especially moving across
the slope. If the slop is too steep, your machine could roll over. IF you
must drive across s slope, keep the attachments close the ground.
Loose surface material will change the ground conditions. Do not
drive across a slope of greater than 15 degree.
Do not any welding on piston rods hydraulic cylinders or by
placing the earth on piston rods.
Ensure piston rod not damaged otherwise a small particle will
spoil the seals inside.
Do not push heavy trucks or dumpers with the Dozer it will cause
damage to the Dozer or tractor
Do not block the pump output hose.
Any oil leakages in pipes do not do any welding without removing
the oil inside.
Do not stand under the Dozer up position and do not stand on the
bucket.
DETACH DOZER SAFETY
To help prevent personal injury caused by a falling Dozer always
detach on a hard surface. The Dozer must be equipped with a bucket
when detaching.

MOUNTING INSTRUCTIONS

CONNECTING THE HYDRAULIC SYSTEM

OPERATING PROCEDURE
Joy Stick Operation (Control Lever) …………………………………
Operating Tips …..……………………………………………………………
Loading loose Material ……………………………………………………
Moving the Machine with Full Bucket Load ………………………
Dumping the bucket …………………………………………………………
Detaching the Dozer the From Tractor……………………………
Rear Weight Carrier …………………………………………………………
Water Ballast ……………………………………………………………………
Method of water Ballasting ……………………………………………….
Tyre Pressure ……………………………………………………………………

OPERATING TIPS
It is best to spend a few minutes analyzing the job at the work area.
Set up the work cycle as short as possible less movement leads to the shorted work
cycle that will improve work efficiency.
When the Dozer is used in a specific area mark layout for parking the lorry and put a
ramp with stopper for the tractor to operate with maximum efficiency.
LOADING LOOSE MATERIAL
a) Make sure the bottom of the bucket is in level with the ground.
b) Make use of bucket level indicator provided.
c) Move Dozer control lever to float position and move the machine forward to the pile.
d) When the machine starts to slower, lift the bucket and roll it back.
e) If trained driver is not operating the rear wheel slippage may take place. The rear
wheel slippage can be stopped only by better driving methods. When the rear wheel starts
slipping, the moment the bucket must be rolled back just adequately. Then again tractor can
be moved forward after loading some volume of material again the wheels will try to slip.
Now the bucket is also to be rolled back adequately. This process is to be repeated 3 to 4
times before loading the bucket fully.

RECOMMENDED TYRE PRESSURE
1. Front Tyres - 7.50 x 16, 8 PR
Recommended inflation pressure kPa (kgf/sq.cm)
(i) For field : 25 Lbs
(ii) For Road: 32 Lbs
2. Rear Tyres - 16.9 x 28, 12 PR (without water filling)
Recommended inflation pressure kPa (kgf/sq.cm)
(i) For field : 14 Lbs
(ii) For Road: 18 Lbs

REAR WEIGHT CARRIER
Rear weight carrier is provided to store 1000 to 1300 kg of loose concrete for extended
chassis Dozer.
The more the load the balancing will be better and steering will be easier.
The weight to be filled in 3 point weight carrier is based on tractor 3 point link lifting
capacity. For additional weight add cast weight on the wheel.
WARER BALLAST
It is a must that the tractor rear tyres are water ballasted to add a weight which ensures
better grip during loading of Dozer.(Ref fig. J)
Maintain maximum possible air pressure in the front tyres (30 PSI)
Inflation pressure of water ballasted tyres must be checked frequently as the volume of
air is very less.
METHOD OF WATER BALLASTING
Jack up the tractor to take the load of tyre.
Keep the tyre in such a position so that the valve is at 12 O’clock.
Connect the hydroflation adapter to the valve after removing the valve core.
Use the plunger pump to fill the tyre with 70% water. After filling remove the adapter
and replace valve to inflate to the recommended pressure.
For removing the water, turn the wheel so that the valve is at 6 O’ clock position. Take
off the valve and let the water flow under gravity.
TYRE PRESSURE
Rear – Water Ballasting : 8 to 10 PSI Air
Front recommended pressure for front end Dozer is 35 PSI Air
For construction / Industrial operations jeep tyre can be replaced for better utility
instead of required tractor front tyre.
Cast iron wheel weights are always advisable for better grip in the rear wheels.

TROUBLE SHOOTING CAUSES & REMEDIES

NIPPLE FOR PRESSURE TESTING
GAUGE SHOWING

TROUBLE SHOOTING CAUSES & REMEDIES
Trouble noticed Problem caused & solution
1. Dozer not functioning
2. Dozer
upward movement very slow and
unable to lift with load.
3. Dozer not lifting.
4. Dozer coming down immediately from top
position.
5. Bucket not loading or bucket loaded
comes down & material falls.
6. Hydraulic cylinder not functioning (or) oil
leaking
7. Air sound noticed while operation
8. Rear tyre slips during loading
9.Joystick struck not going to the float
position
10. Oil heats up rapidly within few minutes.
1. Insufficient oil in the reservoir.
If less add oil.
2. Oil is not pumped. Check using pressure
check port of the valve pressure should be
140 BAR.
1. Check piston oil seal &replace it required.
2. Check pump pressure &replace it required.
1. Piston oil seal & arm cylinder damaged.
Replace the same.
2. Pump problem, Check pump pressure.
1. Piston seal of arm cylinder damaged.
Replace the same.
2. Pump problem, Check pump pressure.
1. Piston seal of bucket cylinder damage,
Replace the same the part.
2. Pump problem, Check pump pressure.
Send the same to your authorized service
station or to the company for rectification.
Insufficient oil fills in the tank.
1. Water ballasts the rear wheels.
2. Increase the weight in the rear weight
carrier.
3. Mount cast iron ballast in the rear tyre.
4. Rotate the bucket upwards the moment the
tyre slips.
Remove the bottom plastic cap of the valve,
adjust the screw.

11.Three point linkage functions without
control
12. Dozer operation jerky movement noticed
13. Hoses jumps during operation
1. Check quantity of oil, if less check level
add oil.
2.Problem with the pump, service or replace
3.Oil passages are obstructed, needed to be
replaced
Shut the valve provided in the tractor beneath
the driver seat
Shut the valve provided in the tractor beneath
the driver seat
Shut the valve provided in the tractor beneath
the driver seat

MAINTENANCE

Sr.N
o
Precaution Monitor Check Function
1. Greasing all 26 nipple Every 4 hrs.
2. Breather Daily Clean with pressurized air..
3. Return line filter 500 hrs.
Change if it has lost its quality.
4. Suction strainer 1000 hrs. Clean with diesel and Refit.
5. Hydraulic oil grade 68 1500 hrs. Change if it has lost its quality

ROUTINE MAINTENANCE
1. It is advisable to do daily greasing at all 32 points where grease nipples are provided
for every six hours of operation. And in case of dusty worksite every 3 hours of operation
greasing should be done with a greasing gun. Stop greasing when fresh grease appears at
the joint. If regular greasing is not done as advised, alloy grade pins & bushes may wear
out fast.
2. Check &Clean the hydraulic tank filter, once in 2 months. Change the hydraulic oil
after 1500 hours of operation.
3. If a separate oil tank is provided, suction strainer is to be cleaned once in two months
and to be replaced every 1500 hours of operation.
4. For every 500 hours breather should be changed.

Dozer Spare Parts Catalogue

DOZER ASSEMBLY

CHASSIS ASSEMBLY