BELL B35D 6X6, B40D 6X4 Supertruck, B40D 6X6, B45D 6X6 and B50D 6X6 (MK 6) Articulated Dump Trucks Service Manual (874116)

Illustrated factory Service Manual for BELL Articulated Dump Trucks Models B35D 6X6, B40D 6X4 Supertruck, B40D 6X6, B45D 6X6 and B50D 6X6.

This manual will assist you in diagnosing, analyses, testing, and repair for your articulated dump truck.
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Covered Models:
   B35D 6X6 (MK 6)
   B40D 6X4 Supertruck (MK 6)
   B40D 6X6 (MK 6)
   B45D 6X6 (MK 6)
   B50D 6X6 (MK 6)

Format: PDF, 420 pages
Language: English
Publication Date: 01 Apr 2010
Table of Contents:
   SAFETY 15
      Specification 15
      General 15
      Safety Features 15
      Material Safety Data Sheet (MSDS) 16
      Unauthorised Modifications of ROPS and FOPS 16
      Loosening or Removal Of ROPS and FOPS 16
      Noise Emission Levels 16
      Safety Regulations 17
      General Safety 17
   TYRE INFORMATION 28
      Tyres and Rims 28
      Tyre Pressures - General 28
      Tyre Pressures - Inflation Pressure, Hot vs. Cold 29
   OPERATIONAL CHECK-OUT PROCEDURE 33
      Operational Check 33
      Ignition Button Pressed ONCE, Engine OFF 33
      Ignition Button Pressed (Second Stage), Engine Start 34
      Engine Stop Button Pressed 36
   ENGINE 37
      Engine Description 37
      Diagnose Engine Malfunctions 41
      Adjustments 43
      Valve Clearance Adjustment 43
      Exhaust Brake Adjustment 44
      Tests 45
      Cylinder Compression Test 45
      Fuel Pump Pressure Test 45
   ELECTRICAL SYSTEM 49
      Schematics 49
      Electrical Schematic Symbols 49
      Electrical Schematics 50
      Earth Connections 73
      Fuse and Relay Layout 73
      ADM-Mercedes ECU Inputs and Outputs 90
      Connectors 94
      Multiple Wire Colours 94
      Wire Colour 94
      Relay 95
      Connectors 95
      Engine Fault Codes (ADM) 129
      Engine Fault Codes (PLD-MR) 133
      CCU, MDU and OEU Fault Codes 149
      Default Display 160
      Accessing Service Mode 162
      Main Menu 163
      Specifications and Tests 191
      On Board Weighing (OBW) Troubleshooting Guide 198
   TRANSMISSION 203
      General Description 203
      Planetary Gears Sets 208
      Functional Description Hydraulic System 212
      Speed Sensors 221
      Control Module 221
      Autodetect Feature 225
      Neutral to Drive Transition 229
      st Range Operation 229
      st Range to 2nd Range Transition 230
      Torque Converter And Lube Pressure Circuits 241
      Exhaust Backfill Pressure 241
      Definitions And Abbreviations 242
      Oil Level Sensor (OLS) 248
      Identification of Potential Circuit Problems 257
   PNEUMATIC SYSTEM 259
      Pneumatic System Schematic 259
      Adjustments and Tests 268
      Pneumatic System Main Pressure Test and Adjustment 268
      Park Brake Pressure Test 268
      Park Brake Adjustment 269
      Grammar Seat Functional Test 271
   HYDRAULIC SYSTEM 273
      Hydraulic System Circuit Symbols 273
      Hydraulic Schematic B35D and B40D 274
      Hydraulic Schematic B35D and B40D Wet Disc Brake with Adaptive Suspension 275
      Hydraulic Schematic B35D Dry Disc Brake with Adaptive Suspension 276
      Hydraulic Schematic B50D 277
      Hydraulic System Operation 279
      General Description 296
      Service Brake System Operation 296
      Steering And Secondary Steering System Operation 298
      Fan Drive System 298
      Bin Operation 299
      Tests and Adjustments 311
      Digital Thermometer Installation 311
      Digital Analogue Pressure / Temperature Analyser Installation 311
      Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy 311
      Hydraulic System Warm-Up Procedure 312
      Setting Hydraulic Pressure 313
      Activate the Hydraulic Pressure Setup Mode: 313
      Calibrate the Bin Position Sensors: 314
      Set the Emergency Steering Pump Pressures 314
      Set the Emergency Steering Pump Residual Pressure 314
      Set the Emergency Steering Pump Compensating Pressure: 315
      Set the Main Pump Residual Pressures B35/B40 315
      Set the Main Pump Residual Pressures B45/B50 316
      Set the Main Pump Compensating Pressure B35/B40 317
      Set the Main Pump Compensating Pressure B45/B50 319
      Set the Steering Pressure B35/B40 320
      Set the Steering Pressure B45/B50 321
      Set the Brake Circuit Pressures: 321
      Accumulator Charge Pressure Check and Re-charge Procedure 323
      Set the Bin Tip Pilot Pressure 324
      Set the Bin Up Pressure Limiting Pressure 325
      Set the Fan Drive Pressures B35/B40 325
      Set the Fan Drive Pressures B45/B50 327
      Suspension Calibration Procedure B45/B50D Only 328
      Calibrate the Articulation Sensor 329
      Calibrate the Height Sensors 329
      Cycle Time Test 330
   HEATING, VENTILATION AND AIR CONDITIONING 331
      Air Conditioning System Cycle Of Operation 331
      Heater Core Operation 332
      Tests 337
      Operational Checks 337
      R134A Air Conditioning System Test 338
      Air Freeze Control Switch Test 340
      Air Compressor Clutch Test 340
      Air High/Low Pressure Switch Test 340
      Air Expansion Valve Test 341
      Expansion Valve Bench Test 342
      Refrigerant Leak Test 343
   SERVICE SCHEDULES and LUBRICATION CHART 347
      Hydraulic System Overview 347
      De-pressurising the Hydraulic System 347
      Engine Oil 349
      Service Schedules 354
   HOURS SERVICE AND CHECKS 361
      Service Instructions 361
      Change Engine Oil And Replace Filter 361
      Lower And Raise The Belly Plate 361
      Replace Primary Fuel Filter (Water Separator) 362
      Replace Secondary Fuel Filter 363
      Replace Fuel Depth Filter B50D Only 363
   HOURS SERVICE AND CHECKS 367
      Service Instructions 367
      Change Engine Oil And Replace Filter 367
      Check Engine Air Intake System 367
      Drain the Primary Fuel Filter 367
      Check The Coolant Level 367
      Replace Fuel Tank Breather Filter 368
      Replace Both Fan Belts 368
      Check Tyre Pressures 368
      Tilt and Lower the Cab 368
      Check Transmission Fluid Level 370
      Check Park Brake Pad Wear 371
      Check Service Brake Pad Wear (Dry Brakes) 372
      Check Transfer Case Fluid Level 372
      Check Front Axle Suspension Struts B35D and B40D 372
      Check Bin Shock Pad Clearance 373
      General Check Drive Line and Suspension Fasteners 373
      Inspect, Clean And Replace Cab Air Filter 374
      Check Electrical Connectors, Harnesses And Looms 375
      Check Work Lights, Reverse Buzzer 375
      Record and Delete Fault Codes On MDU Display 375
      Check Operator Controls And Instruments 375
      Check The Air Conditioner Receiver Air Drier Site Glass 375
      Grease All Lubrication Points 375
      Check Grease Level Of Auto Greasing System 376
      Check Hydraulic Oil Level 377
      Replace Hydraulic Reservoir Breather B50D 378
      Clean Hydraulic/Transmission Cooler Fan 378
      Replace Hydraulic Reservoir Breather B35D and B40D 379
      Clean Headlights 379
   HOURS SERVICE AND CHECKS 381
      Service Instructions 381
      Adjust Engine Valve Clearance 381
      Replace Fuel Depth Filter (B50D Only) 381
      Replace Primary Fuel Filter (Water Separator) 381
      Replace Secondary Fuel Filter 381
      Replace Fuel Tank Breather Filter (B50D Only) 381
      Change Primary Air Filter Element 381
      Check Coolant Conditioner In Radiator 382
      Check The Fan Belt Condition B35D and B40D Only 382
      Clean Crankcase Breather Filter 382
      Drain Transmission Oil Cooler 383
      Replace Transmission Filters 383
      Change The Transfer Case Filter 384
      Replace Hydraulic Reservoir Breather 384
      Check Condition Of All Drive Shafts 385
      Check Axle Oil Level B35D and B40D Only 385
      Check Final Drive Oil Levels B35D and B40D Only 385
   HOURS SERVICE AND CHECKS 387
      Service Instructions 387
      Change the Secondary Air Filter Element 387
      Change Transfer Case Oil 387
      Change Axle Oil 388
      Change Final Drive Oil 388
      Check Service Brake Disc Thickness 389
      Check Transfer Case Breather 389
      Check Transmission Breather and Axle Breathers 389
      Replace Transmission Oil 390
      Replace Wet Disc Brake Cooler Oil And Filter 391
      Replace Wet Disc Brake Cooling Oil Filter 391
      Check Wet Disc Brake Cooling Oil Reservoir (B40D) Only 392
      Replace Pneumatic System Drier Filter 392
      Change Axle Oil (B35D and B50D With Bell Wet Brakes) 393
   HOURS SERVICE AND CHECKS 395
      Service Instructions 395
      Change Jockey Pulley Bearing (Tensioner Pulley) 395
      Change The Air Conditioner Pulley Assembly 395
      Change All Axle Driveline Cross and Rollers 395
      Replace Suction Screen 395
   HOURS SERVICE AND CHECKS 397
      Service Instructions 397
      Replace Fan Belt B35D and B40D Only 397
      Change Hydraulic Oil 398
      Change Pneumatic Block Breather Filters 398
   AS REQUIRED SERVICE 399
      Introduction 399
      Service Instructions 399
      Check the Engine Compartment Components 399
      Clean/Replace Primer Pump Fuel Screen 400
      Change Engine Coolant 400
      Clean Cooling System 401
      Check for Oil and Fuel Leaks 401
      Clean the Air Cleaner Pre-cleaner Bowls B35D and B40D Shown 402
      Clean Air Conditioning Filters 402
      Grease Hinges 402
      Check And Clean All Coolers 402
      Hydraulic Oil Cleanliness Sampling Procedure 402
   MISCELLANEOUS SERVICE AND CHECKS 403
      Service Instructions 403
      Inspect Serpentine Belt 403
      Change Wheels 403
      Using Battery Charger 403
      Replace Batteries 404
      Replace Front Turn Signal Bulb, Headlight Bulb and Front Park Light Bulb 404
      Adjust Headlights 405
      Maintenance of Automatic Grease System 407
   STORAGE AND PRESERVATION 409
      Introduction 409
      General 409
      Category 1 - Laid up for up to 12 months 409
      Category 2 - Laid up for 12 to 36 months 410
      Category 3- Laid up for up more than 36 months 410
   TROUBLE SHOOTING 411