FOREWORD
This manual is written for an experienced technician , the information contained
in this manual has been produced to assist you in the correct ,operation and
maintenance of the B17C to B25C.
This Manual is divided into sections with logical sequence.
Every effort has been made to ensure that the information contained in this
manual is correct at the time of publication. BELL EQUIPMENT Co. has a policy
of continuous product development, improvement and design therefore
changes may have occurred that are not included in this manual.
You the user of this manual are urged to strictly comply with the instructions and
warnings that are given in the interest of general safety. Please do not hesitate to
contact your nearest BELL EQUIPMENT Co. service centre or dealer for
additional information.
The address lists on the following pages were correct from the 05 March 2001
R.S.A.
Richards Bay (Head Office):
Carbonode Cell (035) 9079111 Private Bag X20046
Fax : (035) 7973196 EMPANGENI
Email : veronicab@[Link] 3880
Richards Bay (Training):
Carbonode Cell (035) 907 9345 Private Bag X20046
Fax : (035) 797 3196 EMPANGENI
3880
Bloemfontein:
109 Fritz (051) 4327 855 P.O. Box 1878
Stockenstrom Str
Fax: (051) 4323 740 BLOEMFONTEIN
Email : karenm@[Link] 9300
Cape Town:
Milan Street (021) 386 2252 P.O. Box162
Fax : (021) 3862260 EPPINGDUST
Email : stellah@[Link] 7475
Empangeni:
No.1 Irvine Bell Drive (035) 792 6517 P.O. Box 7332
Old Mill Industrial Fax :(035) 792 6516 EMPANGENI
Email : shelleyb@[Link] 3880
East London:
25 Ray Craib (043) 748 6622/3 c/o P.O. Box 3443
Crescent
Beacon Bay Fax : (043) 748 6624 North End
Email : pierred@[Link] PORT ELIZABETH
6001
George:
Pioneer Road (044) 878 0930/1 P.O. Box 1697
Fax : (044) 8780932 GEORGE
Email : karino@[Link] 6530
Johannesburg (Jet Park):
Griffith Road (011) 928 9700 to 22 P.O. Box 25391
Fax : (011) 928 9730 JET PARK
Email : bokkiec@[Link] EAST RAND
1462
Kimberly:
26 South Circular (053) 832 1078/9 P.O. Box 2927
Fax : (053) 832 1135 KIMBERLY
Email : Cornell@[Link] 8300
Kuruman:
8 Acacia Street (053) 712 0698 P.O. Box 1396
Fax : (053) 712 0697 KURUMAN
Email : charld@[Link] 8460
Middleburg:
9 Celcius Street (013) 246 1169 P.O. Box 2821
Fax : (013) 246 1229 MIDDLEBURG
Email : bellmid@[Link] 1050
Nelspruit:
3 Christie Crescent (013) 755 2110/6 P.O. Box 1672
Fax : (013) 755 2117 NELSPRUIT
Email : boeriev@[Link] 1200
Pietermaritzburg:
7 Van Eck Place (033) 3869319 P.O. Box 100436
Fax : (033) 3861837 SCOTSVILLE
Email : carlaf@[Link] 3209
Pongola:
Dewaal Str. 233 (034) 413 1720 P.O. Box 681
Fax : (034) 413 1735 PONGOLA
3170
Port Elizabeth:
349 Kempston Road (041) 451 3202 P.O. Box 3443
Fax : (041) 451 3208 NORTH END
Email : lynneo@[Link] 6056
Port Shepstone:
Shop 5 Industrial Park (039) 685 4124 P.O. Box 560
Fax : (039) 685 5155 PORT SHEPSTONE
4240
Rustenburg:
No. 16 Vanadium (014) 538 1003/4 P.O. Box 3701
Street
Fax : (014) 538 1005 RUSTENBURG
Email : bellrust@[Link] 0300
Springbok:
Drive Inn Avenue (027) 712 1124/30 P.O. Box 618
Fax : (027) 718 1314 SPRINGBOK
Email : laurencedv@[Link] 8240
Tzaneen:
8 Impala Street (015) 307 4812 P.O. Box 2102
Fax : (015) 307 3095 TZANEEN
Email : tinas@[Link] 0850
Umhlali:
Lot 81 (032) 947 0696 P.O. Box 39
Industrial Park Fax : (032) 947 2141 UMHLALI
4390
Vryheid:
Bloekom Street (034) 981 5541 P.O. Box 1221
Fax : (034) 980 9752 VRYHEID
3100
Windhoek:
(264) 612 26021 P.O. Box 12018
37 Lazarett Street Fax : (264) 612 28330 WINDHOEK
NAMIBIA
Wolmaransstad:
(018) 596 2319 C/o P.O. Box 587
80 Kruger Str. Fax : (018) 596 2855 WOLMARANSSTAD
9300
OTHER AFRICA REGIONS
Malawi (BELL Equipment (Malawi) Ltd):
(+265) 783 29310
10/338 Mtendere Fax : (+265) 783 293
Street
Swaziland (BELL Equipment Swaziland):
(+268) 87496 P.O. Box 134
Shop No. 4 Fax : (+268) 87498 Matsapha
SWAZILAND
Zambia (BELL Equipment (Zambia) Ltd):
(+260) 221 8113/121/123 P.O. Box 20367
Plot 4675 Fax :(+260) 221 3516 Chingola Road
Email : bell@[Link] Kitwe
ZAMBIA
Zimbabwe (BELL Zimbabwe):
(+263) 4 661 575 P.O. Box 2980
Stand 186 Fax : (+263) 4 621 026 Harare
Email:bellzimb@[Link] ZIMBABWE
U.S.A.
Garden City (BELL Equipment North America Inc.):
(+1 912) 966-2615
2843 Hwy 80 Fax : (+1 912) 964-1594
Garden city Email : billr@[Link]
GEORGIA
AUSTRALIA
Australia (BELL Equipment Asia Pacific Region):
(+61 8) 9350 5346 P.O. Box 34
12 Granite Place Fax : (+61 8) 9350 437 Welshpool
Email : asiapac@[Link] WESTERN AUSTRALIA
6986
SOUTH EAST ASIA
South East Asia (BELL Equipment (SEA) PTE Ltd):
(09) 65 769 8394# 04-06
Lam Soon Industrial Fax : (09) 65 769 8029
Building
Hillview Avenue Email :
bellsea@[Link]
EUROPE
France (BELL France SARL):
(09) 33 55 589 23 56
Z.A. Rte d’ Argenton sur Fax : (09) 33 55 589 23 24
Creuse
Le-Palestel Email : bell-france@[Link]
FRANCE
UNITED KINGDOM
United Kingdom (BELL Equipment U.K.):
Unit 316B industrial Estate (+44) 128 381 2954
Tutbury Fax : (+44) 128 381 5684
Burton on Trent Email : bell@[Link]
E-mail : techsupport@[Link]
INDEX
SECTION 1 PAGE
ELECTRICAL
Specifications 1
Operator controls and instruments 2-8
Master Display unit ( MFA 10 ) 9
Default displays 10-15
Thresholds and warnings 16-17
Switches 18-20
Range hold switch 21
Battery disconnect switch 22
Ignition switch 23
Start button 24
Battery circuit breaker 25
Gear shift control 26
Air conditioner switch 27-28
General
Electrical earthing connections 29-30
Fault finding 31
Circuit breakers 32
Relays 33
Trouble shooting 34-35
Schematics 36
Earth points 36
Starting and charging 37
Warning lights 38
MFA 10 & Over rev 39
Lighting 40
Turn and hazards 41
Brake lights and exhaust brake 42
Aircon 43
Wipers / washer 44
Cold Start 45
Battery Balancer 46
Range Hold 47
Allison / Bell Allison 48
Electric mirrors 49
Transmission cooler 50
Connector 1 51
Connectors 2 & 3 52
Connectors 4,5,6 & 7 53
Connectors 8,9,10 & 11 54
Connectors 12 , 13 & 14 55
Connectors 15,16,17 & 18 56
Connectors 19,20,21 & 22 57
Connectors 23,24,25 & 26 58
Connectors 27,28,29,30 & 31 59
Connectors 32 – 37 60
SECTION 2
TRANSMISSION
General Description 1
Identification 2
Torque Convertor 2-7
Stall Testing 8-11
Planetary gears and power flows
Planetary gear sets 12
Neutral 17
First 18
Second 19
Third 20
Fourth 21
Fifth 22
Sixth 23
Reverse 24
Hydraulic system Overview
System function 25
Main pressure 26
Solenoid and Regulator valves 26
Clutch application 27
Latching valves 28
Control main circuit 29
Torque convertor circuit 29-31
Exhaust backfill 31
Main pressure regulator 32
Control main regulator 33
Solenoids
Normally open 34
Normally closed 35-36
Hydraulic Schematics (Transmission) Overview 37
Component location (fold out) 37
Neutral (fold out) 38
First (fold out) 39
Second (fold out) 40
Third (fold out) 41
Fourth (fold out) 42
Fifth (fold out) 43
Sixth (fold out) 44
Reverse (fold out) 45
Hydraulic flow operation 46
Torque convertor and lube circuits 46
Convertor flow valve 47
Over drive knock down valve 47-48
Main Pressure 49
Exhaust backfill 50
Electronic control system 51
ECU 52
Pulse width modulation (PWM) 53-54
Upshift clutch control 55-56
Shift selectors 57-59
Vehicle interface module 59
Throttle position sensor and adjustment 60-78
Speed sensors 79
Wiring Harness 80-82
Upshift tests 82-83
Do not shift light (DNS) 84
Auto detect 85-87
Wire check procedures 88-91
Oil level sensor ( Checking the oil level) 92-96
Diagnostic codes 97
Reading and clearing 97-101
Code 13xx 102-103
Code 14xx 104-106
Code 21xx 107-108
Code 22xx 109-110
Code 23xx 111
Code 24xx 112-116
Code 25xx 117-118
Code 26xx 119
Code 32xx 120
Code 33xx 121-122
Code 34xx 123
Code 35xx 124
Code 3600 125
Code 42xx 126-128
Code 44xx 129-130
Code 45xx 131-132
Code 46xx 133
Code 51xx 134-136
Code 52xx 137-138
Code 53xx 139-140
Code 54xx 141-144
Code 55xx 145-146
Code 56xx 147-148
Code 57xx 149-150
Code 61xx 151-152
Code 62xx 153-154
Code 63xx 155
Code 64xx 156-158
Code 66xx 159
Transmission plugs
ECU Black connector 160
ECU Blue connector 161
ECU Grey connector 162
Bulk head 163
Primary shift selector 164
Speed sensor connector 165
Diagnostic plug connector 166
Vehicle inter face wiring connector 167-168
hrottle position Sensor connector 169
Retarder connector 169
Retarder temperature sensor connector 170
Vehicle Inter face module Connector Harness 171
Vehicle Inter face module Connector 172-173
Resistance module 174
General trouble shooting 175-193
Welding on the Vehicle 194
Wiring schematic (fold out) 195
SECTION 3
HYDRAULICS
Location of Hydraulic components 1
Pressure Equivalent tables 2-3
Main pump 4-5
Pressure compensating valve ( Residual ) 6
Pressure compensating valve ( Working ) 6
Pressure compensating valve ( Compensating) 7
Basic load sensing 8-9
Hydraulic components 10
Main pump 10
Emergency steering pump 11
Steering control valve 12
Brake accumulator 13
Check valve 14
Voac Block 15-17
Hydraulic system operation 18
Brake Accumulator charging 18
Steering 19
Normal steering 20
Emergency steering 21
Tipping 22
Priority 23
Hydraulic retarding 24
Voac block ( illustrations) 25
Top view 25
Right view 25
Rear view 26
Front view 26
Bottom view 27
Left view 27
Orbital Steering Valve operation 28-30
Pressure setting procedure 31-43
Hydraulic schematics 44
Hydraulic system component location 45
SECTION 4
PNEUMATICS 1
Compressor 2
Unloader valve 3-6
Park Brake 7-9
Suspension 10
Leveling Vlave 11
Pneumatic system operation
Tip control 12
Exhaust Brake & Hydraulic retarder 13-14
Inter axle lock 15
Air suspension seat 16
Schematics
Location of components 17
Pipe flow Diagram 18
System schematic 19
SECTION 5
DROP–BOX AXLES AND BRAKES
Propshafts 1
Maintenance 1-2
Lubrication 3
Propshaft layout 4
Retaining bolts and lock nut torque check 5
Troubleshooting 6
Dropbox 7
Technical Data 8
Disassembly of Drop box 9-21
Assembly 22-49
Axle Clearance Table 50
Gear Backlash 50
Differentials 51-52
Replacing Seals 53-73
Brakes 74-81
USER COMMENTS FORM
1. Should you as the user of this manual, have any suggestions for improving
the manual, or you find any errors or omissions, then we would like to know.
2. Please complete this form and post it to :
Richards Bay (Training):
Carbonode Cell (035) 907 9345 Private Bag X20046
Fax : (035) 797 3196 EMPANGENI
3880
YOUR COMMENTS OR SUGGESTIONS
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TELEPHONE NUMBER :
LUBRICATING OILS VISCOSITY GRADES
Due to continuous development, Daimler Chrysler engines are constantly
revising their oil recommendations.
To obtain the latest oil recommendations, please refer to our general
service bulletins ( SIB ) on approved consumables or consult your nearest
oil company for their advice.
SERVICE GUIDE
PDI AND 100 HR SERVICE MUST BE DONE ACCORDING TO THE QUALITY
EVALUATION REPORT.
DUE TO THE CONTINUOUS DEVELOPMENT OF THE BELL ADT’S, BELL IS
CONSTANTLY REVISING THE RECOMMENDED SERVICE GUIDE. ANY
CHANGES WILL BE FOUND IN THE BELL SERVICE BULLETINS.
HOW TO READ THE RSG: For example when performing a 500hr service
everything in the 500hr column must be carried including everything in the
previous columns eg.250hr and daily checks. Any additional faults must be
addressed as maintenance problems.
See page 18 for RSG.
RECOMMENDED SERVICE GUIDE
BELL ARTICULATED DUMP TRUCKS
The employees of Bell Equipment take pride in the Equipment we manufacture. Customer:
With the Customer, Customer Service Centre and Bell Equipment working together, VIN (Vehicle Identification Number):
we can continue to improve the quality of our products. BFL Serial Number:
Complete the checklist below using procedures specified in the Operator and Satis- As
a Daily Every Every Every Every Every
Maintenance Manual. factory Required
Unsatis-
r 250 hrs 500 hrs 1000 hrs 2000 hrs 3000 hrs
Details factory
1 Engine
1.1 Adjust the valve clearance x
1.2 Change the primary fuel filter x
1.3 Change the secondary fuel filter x
1.4 Change the oil and filters x
1.5 Change the crankcase breather x
1.6 Change air cleaner secondary filter x
1.7 Change the coolant x
1.8 Check the oil level x
1.9 Check the coolant level x
1.10 Check the coolant specification x
1.11 Check the tension of the drive belts x
1.12 Check the engine compartment components x
1.13 Check the air cleaner primary filter x
1.14 Clean pre-cleaner assembly x
1.15 Drain the primary fuel filter x
1.16 Flush and renew coolant x
1.17 Service injectors on # 300 / #400 engines x
2 Transmission - Allison HD / MD
2.1 Change the filters x
2.2 Change the oil x
2.3 Check the oil level x
3 Transmission - ZF 210
3.1 Change the filters x
3.2 Change the oil x
3.3 Check the oil level x
4 Transfer Case
4.1 Change the oil x
4.2 Check the oil level x
5 Hydraulics
5.1 Change the oil x
5.2 Change the filters x
5.3 Change the breather filter x
5.4 Check the oil level x
6 Axles and Chassis
6.1 Change the oil in differential and final drive x
6.2 Change brake fluid * if applicable x
6.3 Check the oil in differential and final drives x
6.4 Check service brake pads x
6.5 Check park brake pads x
6.6 Check brake fluid level * if applicable x
7 Cab, Pneumatics and Electrical
7.1 Change the air drier filter x
7.2 Check operator contols and instruments x
7.3 Check working lights,reverse buzzer x
7.4 Check electrical connections x
8 Lubrication
8.1 Grease the Hinges x
8.2 Grease the Propshafts x
8.3 Thru drive bearings x
8.4 Grease PTO propshaft x
8.5 Grease all remaining lube points x
9 General Walk Round
9.1 Check for oil,air and fuel leaks x
9.2 Check for loose or damaged components x
9.3 Clean coolers x
Refer bulletin 93/695 regarding water and coolant specification Change intervals can be extended by oil sampling (use kit 261677 for sampling the Allison transmission)
If sulphur content above 0.5% Service between 1200 hrs and 1800 hrs As per bulletin - 99/120
Allison Transmission filters to be changed 1st 1000 hrs service, thereafter every 2000 hrs Every 250 hrs if operated in excessively wet conditions
CUSTOMER SERVICE CENTRE/DEALER SERVICE TECHNICIAN SMR DATE CUSTOMER SERVICE
CENTRE/DEALER NO.
AREA
( )
Rev: Date19/02/2001
