BELL B18D 6X4, B18D 6X6, B20D 6X4, B25D 6X6, B25DN 6X6 and B30D 6X6 MK7 Articulated Dump Trucks Service Manual (872329)

Illustrated factory Service Manual for BELL Articulated Dump Trucks Models B18D 6X4, B18D 6X6, B20D 6X4, B25D 6X6, B25DN 6X6 and B30D 6X6.

This manual will assist you in diagnosing, analyses, testing, and repair for your articulated dump truck.
You can use a Windows, Mac, or Android device to view this manual. You only need to have a PDF reader installed.

Covered Models:
   B18D 6X4 (Mk 7)
   B18D 6X6 (Mk 7)
   B20D 6X4 (Mk 7)
   B25D 6X6 (Mk 7)
   B25DN 6X6 (Mk 7)
   B30D 6X6 (Mk 7)

Format: PDF, 495 pages
Language: English
Publication Date: 01 Jun 2012
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
      SCR 44
      SCR - Components 44
      The Metering device 45
      Display Menu Tachometer (B20D Shown) 53
      Slow and Fast Idle Adjustment 53
      Valve Clearance Adjustment 53
      Exhaust Brake Adjustment 54
      Oil Pump Pressure Test 60
   ELECTRICAL SYSTEM 63
      Schematics 63
      Electrical Schematic Symbols 63
      Electrical Schematics 64
      Earth Connections 91
      Fuse and Relay Layout 91
      ADM-Mercedes ECU Inputs and Outputs 105
   a. ELECTRICAL SYSTEM - Connectors 111
      Connectors 111
   b. Fault Codes & MDU Fault Display 153
      Engine Fault Codes (ADM) 153
      Engine Fault Codes (PLD-MR) 162
      CCU, MDU & OEU Fault Codes 178
   c. MDU Menu Structure 193
      General Description 239
      MDU3 Menu Structure 193
      Default Display 196
      Accessing Service Mode 198
      Main Menu 199
      Specifications and Tests 229
   TRANSMISSION 239
      Planetary Gears Sets 244
      Transmission Cross Sectional Diagram 246
      Power Flow 247
      Functional Description Hydraulic System 248
      General Description 254
      Speed Sensors 257
      Control Module 257
      Wiring Harnesses 258
      Autodetect Feature 261
      Hydraulic Circuits 263
      Neutral to Drive Transition 265
      st Range Operation 265
      st Range to 2nd Range Transition 266
      Torque Converter And Lube Pressure Circuits 277
      Exhaust Backfill Pressure 277
      Definitions And Abbreviations 278
      Identification of Potential Circuit Problems 293
      Oil Level Sensor (OLS) 284
      Diagnostic Code Memory 286
   TRANSMISSION ZF 6 HP 592 C PLUS 295
      General Descriptions 295
      Stall Speeds 299
      Stall Speeds (Blu@dvantage) 299
      Planetary Gears and Power Flows 300
      Hydraulic System 306
      Valve Schematic 1 307
      Retarder Lever 312
      ZF Gear Shift Control 313
      Internal Solenoids 315
      Renewing Sensors 318
      External Solenoids 325
      Diagnostic Codes 325
      Transmission Control Unit Error Codes 334
   PNEUMATIC SYSTEM 353
      Pneumatic System Schematic 353
      Pneumatic System Operation 355
      Fault Finding 360
      Adjustments and Tests 362
      Pneumatic System Main Pressure Test and Adjustment 362
      Park Brake Pressure Test 362
      Park Brake Adjustment 363
   HYDRAULIC SYSTEM 367
      Hydraulic System Circuit Symbols 367
      Hydraulic Schematic B18D and B20D Without Wet Disc Brakes 368
      Hydraulic Schematic B25D and B30D Without Wet Disc Brakes 369
      Hydraulic Schematic B30D With Wet Disc Brakes 370
      Articulated Dump Truck Hydraulic System Operation 371
      Main Hydraulic Pump Operation 373
      Main Hydraulic Pump Load Sense Operation 374
      Steering Valve Operation 376
      Secondary Steering Pump Operation 378
      Hydraulic System Manifold (Front View) 381
      Hydraulic System Manifold (Rear View) 382
      Hydraulic System Manifold (Right View) 383
      Manifold Schematic 384
      General Description 385
      Service Brake System Operation 386
      Steering And Secondary Steering System Operation 387
      Bin Operation 388
      Diagnostic Procedure 391
      Tests and Adjustments 400
      Digital Thermometer Installation 400
      Digital Analogue Pressure/Temperature Analyser Installation 400
      Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy 401
      Hydraulic System Warm-Up Procedure 401
      Setting Hydraulic Pressure 402
      Activate the Hydraulic Pressure Setup Mode: 403
      Calibrate the Bin Position Sensors: 403
      Set the Emergency Steering Pump Pressures 403
      Set the Emergency Steering Pump Residual Pressure 403
      Set the Emergency Steering Pump Compensating Pressure: 404
      Set the Main Pump Residual Pressures B18/B30 405
      Set the Main Pump Compensating Pressure B18/B30 405
      Set the Steering Pressure 407
      Set the Brake Circuit Pressures: 407
      Accumulator Charge Pressure Check and Re-charge Procedure 409
      Set the Bin Tip Pilot Pressure 410
      Cycle Time Test 411
   HEATING, VENTILATION AND AIR CONDITIONING 413
      Air Conditioning System Cycle Of Operation 413
      Heater Core Operation 414
      Tests 419
      Operational Checks 419
      R134A Air Conditioning System Test 420
      Air Freeze Control Switch Test 422
      Air Compressor Clutch Test 422
      Air High/Low Pressure Switch Test 422
      Air Expansion Valve Test 423
      Expansion Valve Bench Test 424
      Refrigerant Leak Test 425
   SERVICING, SCHEDULES & LUBRICATION CHART 429
      Hydraulic System Overview 429
      De-pressurising the Hydraulic System 429
      Engine Oil 430
      Service Schedules - Pg 1 of 2 435
      Service Schedules - Pg 2 of 2 436
   HOURS SERVICE AND CHECKS 441
      Service Instructions 441
   HOURS SERVICE AND CHECKS 445
      Service Instructions 445
      Change Engine Oil And Replace Filter 445
      Check Engine Air Intake System 445
      Drain the Racor Fuel Filter 445
      Check for oil leaks 446
      Tilt and lower the cab 446
      Loosen Cab Mounting Bolts Front And Rear Left Hand Side 446
      Lower The Cab 447
      The Transmission Fluid Level 447
      Dipstick Check - Transmission Fluid COLD (Cold Check) 447
      Dipstick Check - Transmission Fluid HOT (Hot Check) 448
      Check Park Brake Pad Wear 449
      Check Service Brake Pad Wear 449
      Check The Transfer Case Fluid Level 450
      Check Front Axle Suspension Struts 450
      General Check Drive Line & Suspension Fasteners 451
      Transfer Case Breather (Located under the Hydraulic Reservoir) 451
      Transmission Breather And Axle Breathers 451
      Middle Axle Breather 451
      Rear Axle Breather 452
      Inspect, Clean And Replace Cab Air Filter 452
      Check Batteries, Clean And Tighten Terminals 453
      Check Electrical Connectors, Harnesses And Looms 453
      Check Work Lights, Reverse Buzzer And Horns 453
      Record & Delete Fault Codes On The MDU 453
      Check The Operator Controls And Instruments 454
      Grease All Grease Points 454
      Lubricate Bin Pivots 454
      Articulation Joints, Oscillation Tube Through Drive Shaft Bearing Front And Steering Cylinders Rear Pivot Points 454
      Oscillation Tube And Oscillation Tube Through Drive Shaft Bearing Rear 454
      Grease Tailgate Pivot Points (If Equipped) 455
      Check Hydraulic Oil Level 455
      Service Brake Accumulator Routine Test 455
      Replace Hydraulic Reservoir Breather 455
      Grease Prop Shaft Slip Joint 456
      Check Bin Shock Pad Clearance 456
      Bin Pad Spacing (Field spacing only) 457
      Clean Headlights 458
   HOURS SERVICE AND CHECKS 459
      Service Instructions 459
      Adjust Engine Valve Clearance 459
      Replace Primary Fuel Filter (Water Separator) 459
      Replace Secondary Fuel Filter 459
      Replace Crankcase Breather Filter 459
      Remove Tappet Cover 459
      Remove Tappet Cover 459
      Change the Primary Filter Element 460
      Check Coolant Condition 461
      Check The Fan Belt Condition 461
      Replace Hydraulic Oil Return Filter 462
      Check Axle Oil Level 463
      Check Final Drive Oil Levels 463
   HOURS SERVICE AND CHECKS 465
      Service Instructions 465
      Change the Secondary Filter Element 465
      Change Transmission Oil 465
      Drain Transmission Oil Cooler 465
      Replace Transmission Oil Filters 466
      Fill Transmission 466
      Change Transfer Case Oil 466
      Change Axle Oil 467
      Change Final Drive Oil 468
      Check Service Brake Disc Thickness 468
      Check Front Hubs 468
      Replace Pneumatic System Dryer Filter 469
      SCR Pump Module Accumulator Test & Pressure 469
   HOURS SERVICE AND CHECKS 471
      Service Instructions 471
      Change jockey pulley bearing (Tensioner Pulley) 471
      Remove Idler Pulley Assembly 471
      Change Aircon Pulley Assembly 472
      Change all axle driveline cross and rollers 472
      Replace The Suction Screen 472
   HOURS SERVICE AND CHECKS 473
      Service Instructions 473
      Replace Fan Belt 473
      Change Hydraulic Oil 473
      Fill Hydraulic Tank 474
      Change Pneumatic Block Breather Filters 474
   AS REQUIRED SERVICE 475
      Introduction 475
      Service Instructions 475
      Check the Engine Compartment Components 475
      Clean/Replace Primer Pump Fuel Screen 476
      Prime fuel system 476
      Change Engine Coolant 477
      Clean Cooling System 478
      Check for Oil and Fuel Leaks 478
      Clean the Air Cleaner Pre-cleaner Bowls 478
      Clean Air Conditioning Filters 478
      Grease Hinges 478
      Check And Clean Coolers 478
      Hydraulic Oil Cleanliness Sampling Procedure 478
   MISCELLANEOUS SERVICE AND CHECKS 481
      Service Instructions 481
      Inspect Serpentine Belt 481
      Change Wheels 481
      Using Battery Charger 481
      Replace Batteries 482
      Replace Front Turn Signal Bulb, Headlight Bulb and Front Park Light Bulb 482
      Replace Front Turn Signal Bulb 483
      Replace Headlight Bulb 483
      Replace Front Park Light Bulb 483
      Reassemble Headlight Assembly 483
      Adjust Headlights 483
      Replace Backup Light and Work Light (If Equipped) 484
      Replace Tail and Brake Light and Rear Turn Signal Light 484
      Replace Dome Light Bulb and Circuit Breaker Compartment Light Bulb 484
   STORAGE AND PRESERVATION 485
      Introduction 485
      General 485
      Category 1 - Laid up for up to 12 months 485
      Category 2 - Laid up for 12 to 36 months 486
      Category 3- Laid up for up more than 36 months 486
   TROUBLE SHOOTING 487