Illustrated factory Service Manual for BELL Articulated Dump Trucks Models B18D 6X4, B18D 6X6, B20D 6X4, B20D 6X6, B25D 6X6 and B30D 6X6.
This manual will assist you in diagnosing, analyses, testing, and repair for your articulated dump truck.
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Covered Models:
B18D 6X4 (MK 6)
B18D 6X6 (MK 6)
B20D 6X4 (MK 6)
B20D 6X6 (MK 6)
B25D 6X6 (MK 6)
B30D 6X6 (MK 6)
Format: PDF, 410 pages
Language: English
Publication Date: 01 Mar 2010
Table of Contents:
SAFETY 17
Specification 17
General 17
Safety Features 17
Material Safety Data Sheet (MSDS) 18
Unauthorised Modifications of ROPS and FOPS 18
Loosening or Removal Of ROPS and FOPS 18
Noise Emission Levels 18
Safety Regulations 19
General Safety 19
TYRE INFORMATION 30
Tyres and Rims 30
Tyre Pressures - General 30
Tyre Pressures - Inflation Pressure, Hot vs. Cold 30
OPERATIONAL CHECK-OUT PROCEDURE 35
Operational Check 35
Ignition Button Pressed ONCE, Engine OFF 35
Ignition Button Pressed (Second Stage), Engine Start 36
Engine Stop Button Pressed 38
ENGINE 39
Engine (OM 906 LA Shown) 39
Diagnose Engine Malfunctions 43
Adjustments 45
Display Menu Tachometer (B20D Shown) 45
Slow and Fast Idle Adjustment 45
Valve Clearance Adjustment 45
Exhaust Brake Adjustment 46
Oil Pump Pressure Test 52
ELECTRICAL SYSTEM 55
Schematics 55
Electrical Schematic Symbols 55
Electrical Schematics 56
Earth Connections 79
Fuse and Relay Layout 79
ADM-Mercedes ECU Inputs and Outputs 93
Connectors 97
Multiple Wire Colours 97
Wire Colour 97
Relay 97
Connectors 97
Engine Fault Codes (ADM) 129
Engine Fault Codes (PLD-MR) 133
CCU, MDU & OEU Fault Codes 149
Default Display 167
Accessing Service Mode 169
Main Menu 170
Specifications and Tests 198
On Board Weighing (OBW) Troubleshooting Guide 204
TRANSMISSION ZF 6 HP 592 C PLUS 209
General Descriptions 209
Stall Speeds 213
Planetary Gears and Power Flows 214
Hydraulic System 220
Valve Schematic 1 221
Retarder Lever 226
ZF Gear Shift Control 227
Internal Solenoids 229
Renewing Sensors 232
External Solenoids 239
Diagnostic Codes 239
Transmission Control Unit Error Codes 248
PNEUMATIC SYSTEM 267
Pneumatic System Schematic 267
Pneumatic System Operation 268
Fault Finding 272
Adjustments and Tests 274
Pneumatic System Main Pressure Test and Adjustment 274
Park Brake Pressure Test 274
Park Brake Adjustment 275
HYDRAULIC SYSTEM 279
Hydraulic System Circuit Symbols 279
Hydraulic Schematic B18D and B20D Without Wet Disc Brakes 280
Hydraulic Schematic B25D and B30D Without Wet Disc Brakes 281
Hydraulic Schematic B30D With Wet Disc Brakes 282
Articulated Dump Truck Hydraulic System Operation 283
Main Hydraulic Pump Operation 285
Main Hydraulic Pump Load Sense Operation 286
Steering Valve Operation 288
Secondary Steering Pump Operation 290
Hydraulic System Manifold (Front View) 293
Hydraulic System Manifold (Rear View) 294
Hydraulic System Manifold (Right View) 295
Manifold Schematic 296
General Description 297
Service Brake System Operation 298
Steering And Secondary Steering System Operation 299
Bin Operation 300
Diagnostic Procedure 303
Tests and Adjustments 312
Digital Thermometer Installation 312
Digital Analogue Pressure/Temperature Analyser Installation 312
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy 313
Hydraulic System Warm-Up Procedure 313
Setting Hydraulic Pressure 314
Activate the Hydraulic Pressure Setup Mode: 315
Calibrate the Bin Position Sensors: 315
Set the Emergency Steering Pump Pressures 315
Set the Emergency Steering Pump Residual Pressure 315
Set the Emergency Steering Pump Compensating Pressure: 316
Set the Main Pump Residual Pressures B18/B30 317
Set the Main Pump Compensating Pressure B18/B30 317
Set the Steering Pressure 319
Set the Brake Circuit Pressures: 319
Accumulator Charge Pressure Check and Re-charge Procedure 321
Set the Bin Tip Pilot Pressure 322
Cycle Time Test 323
HEATING, VENTILATION AND AIR CONDITIONING 325
Air Conditioning System Cycle Of Operation 325
Heater Core Operation 326
Tests 331
Operational Checks 331
R134A Air Conditioning System Test 332
Air Freeze Control Switch Test 334
Air Compressor Clutch Test 334
Air High/Low Pressure Switch Test 334
Air Expansion Valve Test 335
Expansion Valve Bench Test 336
Refrigerant Leak Test 337
SERVICING, SCHEDULES & LUBRICATION CHART 341
Hydraulic System Overview 341
De-pressurising the Hydraulic System 341
Engine Oil 342
Service Schedules 347
HOURS SERVICE AND CHECKS 355
Service Instructions 355
HOURS SERVICE AND CHECKS 359
Service Instructions 359
Change Engine Oil And Replace Filter 359
Check Engine Air Intake System 359
Drain the Racor Fuel Filter 359
Check for oil leaks 360
Tilt and lower the cab 360
Loosen Cab Mounting Bolts Front And Rear Left Hand Side 360
Lower The Cab 361
The Transmission Fluid Level 361
Dipstick Check - Transmission Fluid COLD (Cold Check) 361
Dipstick Check - Transmission Fluid HOT (Hot Check) 362
Check Park Brake Pad Wear 363
Check Service Brake Pad Wear 363
Check The Transfer Case Fluid Level 364
Check Front Axle Suspension Struts 364
General Check Drive Line & Suspension Fasteners 365
Transfer Case Breather (Located under the Hydraulic Reservoir) 365
Transmission Breather And Axle Breathers 365
Middle Axle Breather 365
Rear Axle Breather 366
Inspect, Clean And Replace Cab Air Filter 366
Check Batteries, Clean And Tighten Terminals 367
Check Electrical Connectors, Harnesses And Looms 367
Check Work Lights, Reverse Buzzer And Horns 367
Record & Delete Fault Codes On The MDU 367
Check The Operator Controls And Instruments 368
Grease All Grease Points 368
Lubricate Bin Pivots 368
Articulation Joints, Oscillation Tube Through Drive Shaft Bearing Front And Steering Cylinders Rear Pivot Points 368
Oscillation Tube And Oscillation Tube Through Drive Shaft Bearing Rear 368
Grease Tailgate Pivot Points (If Equipped) 369
Check Hydraulic Oil Level 369
Service Brake Accumulator Routine Test 369
Replace Hydraulic Reservoir Breather 369
Grease Prop Shaft Slip Joint 370
Check Bin Shock Pad Clearance 370
Bin Pad Spacing (Field spacing only) 371
Clean Headlights 372
HOURS SERVICE AND CHECKS 373
Service Instructions 373
Adjust Engine Valve Clearance 373
Replace Primary Fuel Filter (Water Separator) 373
Replace Secondary Fuel Filter 373
Replace Crankcase Breather Filter 373
Remove Tappet Cover 373
Remove Tappet Cover 373
Change the Primary Filter Element 374
Check Coolant Condition 375
Check The Fan Belt Condition 375
Replace Hydraulic Oil Return Filter 376
Check Axle Oil Level 377
Check Final Drive Oil Levels 377
HOURS SERVICE AND CHECKS 379
Service Instructions 379
Change the Secondary Filter Element 379
Change Transmission Oil 379
Drain Transmission Oil Cooler 379
Replace Transmission Oil Filters 380
Fill Transmission 380
Change Transfer Case Oil 380
Change Axle Oil 381
Change Final Drive Oil 382
Check Service Brake Disc Thickness 382
Check Front Hubs 382
Replace Pneumatic System Dryer Filter 383
HOURS SERVICE AND CHECKS 385
Service Instructions 385
Change jockey pulley bearing (Tensioner Pulley) 385
Remove Idler Pulley Assembly 385
Change Aircon Pulley Assembly 386
Change all axle driveline cross and rollers 386
Replace The Suction Screen 386
HOURS SERVICE AND CHECKS 387
Service Instructions 387
Replace Fan Belt 387
Change Hydraulic Oil 387
Fill Hydraulic Tank 388
Change Pneumatic Block Breather Filters 388
AS REQUIRED SERVICE 389
Introduction 389
Service Instructions 389
Check the Engine Compartment Components 389
Clean/Replace Primer Pump Fuel Screen 390
Prime fuel system 390
Change Engine Coolant 391
Clean Cooling System 392
Check for Oil and Fuel Leaks 392
Clean the Air Cleaner Pre-cleaner Bowls 392
Clean Air Conditioning Filters 392
Grease Hinges 392
Check And Clean Coolers 392
Hydraulic Oil Cleanliness Sampling Procedure 392
MISCELLANEOUS SERVICE AND CHECKS 395
Service Instructions 395
Inspect Serpentine Belt 395
Change Wheels 395
Using Battery Charger 395
Replace Batteries 396
Replace Front Turn Signal Bulb, Headlight Bulb and Front Park Light Bulb 396
Replace Front Turn Signal Bulb 397
Replace Headlight Bulb 397
Replace Front Park Light Bulb 397
Reassemble Headlight Assembly 397
Adjust Headlights 397
Replace Backup Light and Work Light (If Equipped) 398
Replace Tail and Brake Light and Rear Turn Signal Light 398
Replace Dome Light Bulb and Circuit Breaker Compartment Light Bulb 398
STORAGE AND PRESERVATION 399
Introduction 399
General 399
Category 1 - Laid up for up to 12 months 399
Category 2 - Laid up for 12 to 36 months 400
Category 3- Laid up for up more than 36 months 400
TROUBLE SHOOTING 401
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