BELL B18D 6X4, B18D 6X6, B20D 6X4, B20D 6X6, B25D 6X6 and B30D 6X6 (MK 6) Articulated Dump Trucks Service Manual (874115)

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