Bell B40C 6X6 Operator's Manual
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Bell B40C 6X6 Operator's Manual

Articulated dump truck
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B40C 6X6
ARTICULATED DUMP TRUCK
OPERATORS MANUAL
Document Part Number 870984-01

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Summary of Contents for Bell B40C 6X6

  • Page 1 B40C 6X6 ARTICULATED DUMP TRUCK OPERATORS MANUAL Document Part Number 870984-01...
  • Page 3 The safe operation of your BELL EQUIPMENT machine is very important to prevent any personal injury and/or damage. This manual must be read and fully understood before operating or carrying out any maintenance on your BELL EQUIPMENT machine. This manual must be kept in the cab of the machine at all times. SAFETY SYMBOL The following symbol is used for all safety messages.
  • Page 5 B40C 6X6 ADT OPERATORS MANUAL This manual is applicable to: B40C 6X6 (408844.00 & 408844.01) Document Part Number 870984-01 Issue : MARCH 1999 Technical Documentation BELL EQUIPMENT COMPANY Richards Bay...
  • Page 6 IMPORTANT Due to BELL EQUIPMENT ‘s policy of continuous product improvement, the information contained in this manual was correct up to the time of printing (issue date of manual). Any changes after this date will only be included in the next update of this manual.
  • Page 7 BELL EQUIPMENT Co. has a policy of continuous product development, improvement and design. BELL EQUIPMENT Co. reserves the right to change, amend and update the design of its product at any time without prior notice. With this policy, changes may have occurred that are not included in this manual.
  • Page 8 Airport Industria Fax : (021) 386 2260 EPPINGDUST CAPE TOWN email : carmenb@bell.co.za 7475 7525 EMPANGENI: No.1 Irvine Bell Drive (0351) 787 1366 P.O. Box 198 Old Mill Industrial Fax : (0351) 787 0740 EMPANGENI EMPANGENI email : shelleyb@bell.co.za 3880...
  • Page 9 Griffith Road (011) 928 9700 to 22 P.O. Box 25391 JET PARK Fax : (011) 928 9730 EAST RAND 1459 email : bokkiec@dc.bell.co.za 1462 KIMBERLEY: 26 South Circular (053) 832 1078/9 P.O. Box 2927 KIMBERLEY Fax : (053) 832 1135...
  • Page 10 134 Patterson Road (041) 541 721/2 P.O. Box 3443 NORTH END Fax : (041) 542 060 NORTH END 6056 email : lynneo@bell.co.za 6056 PORT SHEPSTONE Shop 5 Industrial Park (039) 685 4124 P.O. Box 560 Cnr. Main Harding and Fax : (039) 685 5155...
  • Page 11 P.O. Box 2980 Willowvale Road Fax : (+263) 4 621 026 Harare Willowvale email:bellzimb@iafricaonline.co.zwZIMBABWE ZIMBABWE U.S.A. GARDEN CITY (BELL EQUIPMENT NORTH AMERICA INC.): 2843 Hwy 80 (+1 912) 966-2615 Garden City Fax : (+1 912) 964-1594 GEORGIA email : billr@bellequipment.com GA 31408...
  • Page 12 WESTERN AUSTRALIA email : asiapac@bell.net.au WESTERN AUSTRALIA 6106 6986 SOUTH EAST ASIA SOUTH EAST ASIA (BELL EQUIPMENT (SEA) PTE Ltd): Lam Soon Industrial Building (09) 65 769 8394 Unite # 04-06 Fax : (09) 65 769 8029 63 Hillview Avenue email : bellsea@magix.com.sg...

  • Page 13: Table Of Contents

    TABLE OF CONTENTS USER’S COMMENT FORM ......... . i ABBREVIATION LIST .
  • Page 14 Gear Shifting ..........33 Retarder .
  • Page 15 Install the Articulation Safety Lock Bar ........50 Lower and Raise the Belly Plate .
  • Page 16 Introduction ..........89 Service Instructions.

  • Page 17: User's Comment Form

    Please complete a facsimile of this form and hand it in to your nearest BELL EQUIPMENT Product Support Rep- resentative or post it directly to your nearest BELL EQUIPMENT Branch . Addresses are given at the beginning of this manual.
  • Page 18 870984-01 June 1, 1999...

  • Page 19: Abbreviation List

    ABBREVIATION LIST The table below lists the abbreviations used in this manual: Abbreviation Meaning Abbreviation Meaning °C kilowat degrees Celcius °F pound degrees Farenheit Liquid Crystal Display ampere Light Emitting Diode Atlantis Diesel Engines metre Articulated Dump Truck cubic metre ampere hours Neutral circuit breaker...
  • Page 20 870984-01 June 1, 1999...

  • Page 21: Safety

    (if equipped with an air conditioner). BELL EQUIPMENT USA Inc. will provide, at no cost, Material Safety Data Sheets which are applicable to its product line. Simply request them from your local BELL EQUIPMENT dealer.
  • Page 22 Keep Riders Off the Machine Do not allow unauthorised personnel on the machine. Prepare for Emergencies Keep a first aid kit and fire extinguishers handy and know how to use them. Inspect and have your extinguisher serviced as recommended on its instruction plate. Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone.
  • Page 23 If acid is swallowed: • Drink large amounts of water or milk. • Then drink milk of magnesia, beaten eggs, or vegetable oil. • Get medical attention immediately. Wear Protective Clothing Wear a hard hat, protective glasses and other protective equipment as required by the job conditions. Do not wear loose clothing or jewellery that can catch on controls or other parts of the machine.
  • Page 24 Tyre Information Welding or heating of the rim components, external fire or excessive use of brakes can cause overheating of the tyres, which could cause a tyre explosion. This explosion can propel the tyre, rim and final drive components approximately 500 metres from the machine, which may cause personal injury or death and/or property damage.

  • Page 25: Safety Decals

    SAFETY DECALS There are several safety decals on your BELL EQUIPMENT machine. Their exact location and description of the hazard are reviewed in this section. Please take the time to familiarise yourself with these safety decals. Keep the decals clean by using a soft cloth, water, and soap. Do not use solvent, gasoline, etc. You must replace a decal if it is damaged, missing or cannot be read.
  • Page 26 TYRE PRESSURE B40C 6x6 CAUTION FRONT MIDDLE REAR MAKE MODEL SIZE BRIDGESTONE 29.5 R25 2 BATTERY ISOLATOR MICHELIN XADN/XADT 29.5 R25 ISOLATE BATTERY BEFORE WELDING 204608 203318 PAYLOAD: 23 000 kg (50 600 lbs) PAYLOAD: 36 500 kg (80 468 lbs) Located at the battery isolator switch.
  • Page 27 WARNING TORQUE ALL WHEEL NUTS TO 650Nm (480 lb-ft) AFTER THE FIRST 5 HOURS OF OPERATION AND THEN AFTER 50 HOURS. REPEAT THIS PROCEDURE IF THE WHEELS ARE CHANGED. 204976 Located in the following positions: One on the small, left side window. One on the fuel tank.
  • Page 28 WARNING This vehicle is equipped with a transmission shift inhibitor system. Neutral to drive shift Located on the air conditioner. ranges are automatically prevented at high engine speeds. After completing neutral PTO operation, reduce engine speed to below 900 rpm to allow neutral to range shift. 204962 Located on the side window.

  • Page 29: Bulletins

    BULLETINS Record the relevant information from the Technical Documentation Bulletins, Service Bulletins and Parts Bulle- tins into this manual as follows: Ensure the manual number (87——) reflected in the bulletin is the same as the 87—— number at the bottom of the main content pages.
  • Page 30 TECHNICAL DOCUMENTATION BULLETIN RECORD INSERTED BY BULLETIN NO. SUBJECT NAME SIGNATURE DATE 870984-01 June 1, 1999...

  • Page 31: Chapter 1. Specifications

    Model· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·...
  • Page 32 Electrical System Voltage · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 24 V Battery type ·...

  • Page 33: Machine Dimensions

    Machine Dimensions The dimensions for the B40C are as follows:- ° 5 806 (20') B40C ° 619 (2') 1 527 (5') 1 950 (6' 5") 4 474 (14' 8") 2 721 (8' 11") 10 671 (35') 3 234 (10' 7") 2 600 (8' 6") 3 380 (11' 1") Inside Turning Radius...
  • Page 34 Recommended Fuel, Lubricants and Coolant Additives The following chart details the recommended fuel, lubricants and coolant additives. BELL RECOMMENDED LUBRICANT CHART B35C AND B40C ARTICULATED DUMP TRUCK Recommended Lubricant Viscosities for use at Ambient Temperatures from -40 C (-40 F) to 50 C (122 F)
  • Page 35 Discretion must be used when torqueing into a shallow hole or into soft or brittle materials. Always adhere to engine / gearbox / BELL Equipment etc. manufacturer's specified torques. Nuts should be of the same grade as the corresponding bolt or screw.
  • Page 36 IMPERIAL SIZES - BS GRADES BS Grade T Manufacturer's Manufacturer's BS Grade A Mark Mark Coarse Coarse 55 tsi (849 Mpa) 28 tsi (432 Mpa) Grade Grade or Fine or Fine BS Grade S BS Grade V Manufacturer's Manufacturer's Mark Mark Coarse Coarse...

  • Page 37: Chapter 2. Operator's Controls And Instruments

    CHAPTER 2. OPERATOR’S CONTROLS AND INSTRUMENTS Introduction This chapter details the layout and operation of the controls and instruments in the B40C. All operator controls and instruments for the machine are located in the cab. The following figure details the layout of the main controls and instruments in the cab. Cels.
  • Page 38 The following figure details the controls and instruments on the left side instrument panel. WARNING TO CHANGE DROP BOX RATIO 1. STOP MACHINE 2. SELECT NEUTRAL 3. SELECT HIGH OR LOW RANGE 4. SELECT REVERSE THEN SELECT FORWARD GEAR 204990 S005103 Inter axle differential lock control Headlight switch...
  • Page 39 The following figure details the controls and instruments on the main instrument panel. Cels. Cels. 80 100 120 Dia 53 Dia 53 Dia 82 x100 km/h REV/MIN r/min Dia 56 X100 Dia 53 n/min 204073 S005038 Tachometer 12. Park brake warning indicator Speedometer 13.
  • Page 40 The following figure details the controls and instruments on the right side instrument panels. Hobbs QUARTZ HOURS Dia 61 X100 S005040 Hour meter (SMR meter) Start button Air pressure gauge Battery charge warning indicator Ignition switch Cold start warning indicator 870984-01 June 1, 1999...

  • Page 41: Controls And Instruments

    The gauge measures the pneumatic system pres- Controls and Instruments sure. Gauges System pressure is 930 kPa (134 psi). Hour Meter (SMR Meter) Note: The accelerator pedal is not operational until the air pressure has reached normal operating pres- sure 930 kPa (134 psi). The red needle indicates the pressure in the front pneumatic circuit.
  • Page 42 The gauge monitors the temperature of the engine Tachometer and Speedometer coolant in degrees Celsius ( The normal operating temperature is 90 C (194 If overheating occurs stop the machine and allow the engine to idle until the temperature returns to nor- Dia 82 mal.

  • Page 43: Warning Indicators

    The hydraulic tank is pressurised by the pneumatic Engine Oil Pressure Gauge system and is protected by a pressure relief valve set at 70 kPa (10 psi). Warning Indicators When the ignition switch is turned to the ON (I) posi- tion the following indicators will either flash or remain illuminated until the engine has been started:- •...
  • Page 44 ‹ CAUTION Park Brake Warning Indicator When the transmission oil temperature indicator illuminates the machine must be stopped imme- diately or serious damage will be caused to the transmission. S005059 Transmission Oil Pressure Warning The park brake warning indicator (1) is located on Indicator the main instrument panel .
  • Page 45 Battery Charge Warning Indicator Low Coolant Level Warning Indicator S005063 The low coolant level warning indicator (1) is located on the main instrument panel. S005045 The indicator illuminates to indicate when the cool- The battery charge warning indicator is located on ant level in the radiator is low, an audible buzzer will the right side instrument panel.
  • Page 46 Emergency Steering Warning Indicator Bin Up Warning Indicator n/min S005056 S005061 The emergency steering warning indicator (1) is lo- The bin up warning indicator is located on the main cated on the main instrument panel. instrument panel. The indicator will illuminate when there is an engine The indicator will illuminate when the bin is raised.

  • Page 47: Switches

    Turn Indicators Switches Windscreen Wiper/Washer Switch S005062 The left (1) and right (2) turn indicators are located on the main instrument panel. The indicators flash when the turn indicator lever is moved to indicate a turn. Main Beam Indicator S002112 The windscreen wiper/washer switch (1) is a rocker n/min switch located on the left control panel .
  • Page 48 Interior Light Switch Low Range Selector Switch S002110 S005068 The interior light switch (1) is a rocker switch located The low range selector switch (1) is located on the on the left instrument panel. left control panel. Note: The switch has two positions:- ‹...
  • Page 49 The switch is used to operate the beacon on the roof Air Conditioner of the cab. Note: The switch has two positions:- The first position (normal) is rotating beacon OFF. The second position (switch in the down position) is rotating beacon ON. Ignition Switch and Start Button F000414 S005046...

  • Page 50: Controls

    Battery Disconnect Switch Controls Steering Wheel F001638 Note: An emergency steering system is standard on all machines. The steering wheel is turned clockwise or counter F000415 clockwise to make the machine articulate to right or The battery disconnect switch is located in the bat- to the left.
  • Page 51 ‹ CAUTION Indicators and Headlight Control The inter axle differential lock control must not be engaged while the machine wheels are spin- ning. ‹ CAUTION The inter axle differential lock control must only be used when the ground conditions are very poor and must not be used on graded or tar roads.
  • Page 52 To release the park brake, pull the lever up and Note: The engine speed cannot be increased until the air pressure has reached normal operating pres- move it forward to the RELEASE position. sure. ‹ CAUTION Note: When the accelerator is released the engine When releasing the park brake, wait for the sys- retarder function will be activated automatically.
  • Page 53 When the switch is OFF the transmission is in the Push Button Shift Selector and Range normal automatic operating mode. Hold Switch Note: Shift cycling or “gear hunting” on certain uphill The machine is equipped with an automatic gearbox applications can be eliminated by correct use of the with the push button selector located to the left of the range hold switch.

  • Page 54: Operator's Seat

    Back Rest Angle Adjustment Operator’s Seat The operator’s seat is fully adjustable to suit the op- erator’s individual height, weight and reach. F000730 The backrest adjustment knob (1) is located on the left of the seat. Turn the knob to obtain the required angle of the back rest.
  • Page 55 Weight Adjustment Arm Rest Adjustment The arm rest may be lifted to allow easier access to the seat and then lowered for driver comfort. F000733 The weight adjustment lever (1) is located on the right side of the seat. F000731 Use the adjustment lever to obtain the most comfort- To adjust the angle of the arm rests, turn the knob able driving position.

  • Page 56: Trainer Seat

    Releasing Miscellaneous Press down the red button on the fixed clasp. Bonnet Catch Release Lever The seat belt is spring-loaded to return to its stowage position. Ensure that it returns fully and is not twisted. ‹ WARNING Always wear a seat belt when operating the ma- chine.
  • Page 57 Ashtray Controlled Traction Differential (CTD) Switch ‹ CAUTION The CTD locks must not be engaged when the machine is moving. ‹ CAUTION The CTD locks must only be used when the ter- rain is poor and must not be used on tar or graded surfaces.
  • Page 58 24V Utility Socket/Cigarette Lighter 12V Utility Socket F002116 F002115 The cigarette lighter is used in the 24V utility socket. The 12V utility socket is located on the right of the The socket is located on the right, below the dash- cab, above the air conditioner unit.

  • Page 59: Chapter 3. Procedures Before Starting

    Daily or 10 Hourly The 100 hour service MUST ONLY be done by Service Checks in Chapter 9. BELL EQUIPMENT Service Personnel. The service decal located on the side of the cab lists the scheduled service needs (maintenance sched- ule) and is useful for locating the items.
  • Page 60 Raise the bonnet and check the condition of the Inspect the suspension air bags, shock absorb- lifting strut, pivots and restraining straps. ers and verify that the axle restraint cable is in place. Check the transmission oil level. Check that the steering cylinders are secure. Check the condition and tension of the alternator belts.

  • Page 61: Chapter 4. Operating Instructions

    CHAPTER 4. OPERATING INSTRUCTIONS ‹ CAUTION Read and understand all of the operator related chapters in this manual before performing any of the following procedures and obey all Warnings and Cautions contained in the sections. Refer to the detailed procedures in the relevant chapter. S005046 Insert the machine key into the ignition switch Safety Rules...

  • Page 62: Starting The Engine In Cold Weather

    Starting the Engine in Cold Shutting Down the Engine Weather Stop the machine in the straight ahead position. Refer to Service Brakes for the correct proce- ‹ CAUTION dure for stopping the machine. Allow the engine to idle for at least half a minute. Apply the park brake and select N on the gear Thereafter operate the machine at less than full selector.

  • Page 63: Gear Shifting

    Check that there are no personnel on or around the Reverse Selection machine before driving the machine. Sound the horn Select R on the gear selector. before moving off Release the park brake. Check the steering and brake functions and confirm Release the service brake and increase the en- that the reverse alarm sounds when reverse is se- gine speed (rpm).

  • Page 64: Operating With Inter-Axle Differential Locks

    OFF (O) position. Note: If the inter axle differential lock is no longer ef- Shut down the engine. fective the LOW range function of the drop box must be selected. Contact your BELL Product Support Represen- tative. 870984-01 June 1, 1999...

  • Page 65: Operating With Controlled Traction Differential (Ctd) Lock

    To select LOW range the following must be done: Operating with Controlled Stop the machine. Traction Differential (CTD) Lock Select neutral (N) ‹ CAUTION Move the range selector switch to the LOW Do not engage the CTD lock while the machine is range position (down).

  • Page 66: Lowering The Bin

    Lowering the Bin To lower the bin the following must be done: n/min Move the tip control lever towards the front of the S005056 cab and hold in position until the bin is fully low- When the emergency steering system is activated ered the emergency steering indicator (1) will illuminate.

  • Page 67: Chapter 5. Operating Techniques

    CHAPTER 5. OPERATING TECHNIQUES The following information details suggested tech- niques to obtain the safest and most efficient use of The transmission will initially attain 1st gear your machine. when D is selected. As machine speed in- creases, transmission will upshift automatically through each gear.

  • Page 68: Gear Pre-Selection

    Use this gear when pulling through mud and GEAR The range hold switch (next to the shift deep snow, when manoeuvring in tight spaces selector) allows the operator to hold the (RANGE) or while driving up /down grades. transmission in a gear of his choice to HOLD improve cycle time in abnormal operat- 1st gear provides the machine with maximum...

  • Page 69: Transport Operation

    Transport Operation Downhill Operation When operating the machine in ideal conditions (e.g. When driving downhill the exhaust brake and retar- level graded surfaces) normal driving and gear se- der must be utilised to assist the service brakes and lection must be used. to reduce brake pad wear.

  • Page 70: Off-Road Operation

    If engine-governed speed is exceeded, the transmis- Steer the machine so that it is straight. The operator sion will upshift automatically to the next gear. must have clear and unobstructed vision through his rear view mirrors. If the machine is articulated and not in the straight ahead position the operator may Off-road Operation find it difficult to observe the spotter and the loading...

  • Page 71: Stuck Machine

    ‹ WARNING ‹ CAUTION Do not operate the bin tip lever unless the trans- Do not make N to D or directional shift changes mission is in Neutral (or dumping in 1st or when the engine speed is above idle. Also if the Reverse).
  • Page 72 870984-01 June 1, 1999...

  • Page 73: Chapter 6. Recovery And Transportation

    Safety Rules ity is required for towing on gradients and poor ground conditions Always consult your BELL EQUIPMENT Product ‹ CAUTION Support Representative before towing a disabled machine. Failure to lift the wheels off the road or discon-...

  • Page 74: Towing A Machine With Operable Engine

    Towing a Machine with Operable Towing a Machine with Inoperable Engine Steering System If the steering system has no fault and the engine Use these procedure in conjunction with relevant can be run, an operator must steer the machine. Engine Operative or Engine Inoperative Towing Pro- cedures detailed previously.

  • Page 75: Machine Lifting Points

    Machine Lifting Points The following figure details the machine lifting points: Note: Ensure that the articulation bar is installed. CRANE B40C CRANE 870984-01 June 1, 1999...
  • Page 76 Note: The crane must be moved slowly to prevent Lifting the Machine excessive swinging of the lifted machine Note: The machine lifting points are indicated in red Move the machine over the transporting vehi- on the machine. cles trailer slowly. When lifting the machine the following must be done: When the machine is directly over the transport- ing vehicle’s trailer lower the machine onto the...

  • Page 77: Machine Tie-Down Points

    Machine Tie-down Points The following figure indicates the machine tie-down points: B40C X000475 Note: Ensure that the articulation safety lock bar is Driving the Machine onto a installed. Transporting Vehicle To drive the machine onto the transporting vehicle Transporting the following must be done: Transporting the Machine on Position the transporting vehicle’s trailer against the loading ramp.
  • Page 78 870984-01 June 1, 1999...

  • Page 79: Chapter 7. Pre-Service Instructions

    REMOVED BY THE PERSON SERVICING THE MACHINE BELL B40C COLD BELL MACHINES ARE FITTED WITH EITHER 1 OR 2 ARTICULATION LOCKS S005010 Park the machine in the straight ahead position and 4. Install wheel chocks to ensure that the machine...

  • Page 80: Install The Bin Prop

    Install the Bin Prop Install the Articulation Safety Lock Bar ‹ WARNING When the bin is raised to perform maintenance The following procedures must be used to install the tasks, the bin prop must be installed. articulation safety lock bar: 1.

  • Page 81: Lower And Raise The Belly Plate

    Lower and Raise the Belly Plate To Tilt the Cab To perform some maintenance tasks it is necessary The machine’s cab is hinged so that it may be tilted to lower the belly plate for access. for access to the hydraulics and transmission sys- tem below.
  • Page 82 F000383 When the cab is raised fully insert the cab prop to 3. Loosen the locking bolt. prevent accidental lowering. 4. Remove the locking bolts on the rear mechani- ‹ WARNING cal lock. Do not work under the raised cab unless the cab 5.

  • Page 83: Rules When Servicing

    All lifting devices, for example slings and ratchet take the following steps: blocks, must comply with national regulations for lift- ing devices. BELL EQUIPMENT COMPANY will not • Move the machine away from the danger area. accept any responsibility if any lifting devices, tools •...
  • Page 84 Keep the work place clean. Oil and/or water on the leak could result. If a leak is suspected, do not try floor makes it slippery. to refill the system. Contact your BELL EQUIPMENT Representative . Oil and/or water in close proximity to electrical equip-...

  • Page 85: Chapter 8. Maintenance Schedules

    CHAPTER 8. MAINTENANCE SCHEDULES Preventative maintenance is very important. It includes lubrication, checks and adjustments which the operator can perform. Procedures which require BELL EQUIPMENT Product Support to perform are noted in the in- structions. Most of these service measures are simple to carry out and do not need any detailed explanation. The instruc- tions which require specific procedures are detailed in this Chapter.
  • Page 86 Maintenance Schedule in Running Hours Details Daily Every Every Every Every 1 000 2 000 Req. ENGINE (continued) Check the drive belts Check the air cleaner assembly Check the air cleaner service indicator Check the fuel tank and filler cap Check the accelerator throttle linkage and TPS attach- ment to the accelerator lever TRANSMISSION...
  • Page 87 Maintenance Schedule in Running Hours Details Daily Every Every Every Every 1 000 2 000 Req. AXLES, CHASSIS AND DRIVESHAFTS Check the service brake pads Check the park/emergency brake pads Check the oscillation through drive Check the tyres Change the oil in the differentials Change the oil in the final drive Check the final drive oil level Check and clean the axle breather...
  • Page 88 Maintenance Schedule in Running Hours Details Daily Every Every Every Every 1 000 2 000 Req. CAB, PNEUMATICS AND ELECTRICAL (continued) Check the windscreen and windows Check the seats and seat belts LUBRICATION Grease at the lubrication points * Torque all wheel nuts to 650 N⋅m (ft lb) after the first 5 hours of operation and again after 50 hours of opera- tion.

  • Page 89: Chapter 9. Daily Or 10 Hourly Service Checks

    CHAPTER 9. DAILY OR 10 HOURLY SERVICE CHECKS Introduction It is recommended that the daily or 10 hourly service checks be performed by qualified service personnel. Depending upon the working conditions, it may not be necessary to carry out some of the tasks listed in this chapter on a daily basis.
  • Page 90 Check the Coolant Level Check the Engine Compartment Components ‹ WARNING Perform a general, visual check on the engine and Check the coolant level when the engine is cold. components in the engine compartment as follows: Whenever the cap on the expansion tank needs to be removed, remember that the system may 1.
  • Page 91 f002024 Check the alternator (1) for damage and secu- rity. f002016 f002019 6. Check the starter motor (1) for damage and se- Check for Oil and Fuel Leaks curity. 1. Perform a visual inspection for oil and fuel leaks on and around the engine and components in- side the engine compartment.
  • Page 92 3. Check that the cables and wires are fastened in Check the Fan Cowling the correct position and no chafing can occur when the machine is in use. 4. Check all the electrical connections in the en- gine compartment to ensure that they are secure.

  • Page 93: Transmission

    Check the Air Cleaner Assembly Transmission Check the Transmission Dipstick F002012 1. Check the air cleaner assembly for damage to the air cleaner (1) and pre-cleaner (2). F000875 2. Check the rubber elbow (3), connecting pipes, clamps and mounting bolts for security and 1.
  • Page 94 10. If the fluid level is not within the “Cold Full and Dipstick Check - Transmission Fluid COLD Cold Add” band, add or drain transmission fluid (Cold Check) as necessary to bring it within the band. ‹ CAUTION ‹ CAUTION DO NOT start the engine until the presence of The fluid level rises as the fluid temperature in- transmission fluid has been confirmed.
  • Page 95 Push-button Check - (Electronic Note: The fluid level check may be delayed until the following conditions are met: Transmission Fluid Level Check) • The fluid temperature is above 65°C (149°F) The electronic method of checking the transmission and below 104°C (220°F). fluid level incorporates a fluid level sensor to display the fluid level on the shift selector.

  • Page 96: Transfer Case (Drop Box)

    Check the Rubber Mountings and Note: Report sensor failure or any problem you are having difficulty correcting to your nearest BELL Mounting Bolts, Hoses and EQUIPMENT representative. Connections 5. To exit the fluid level display mode, press any 1.

  • Page 97: Hydraulics

    Hydraulics Check the Hydraulic Fluid Level 1. Ensure that the bin is in the lowered position. F002121 Check the Steering Cylinders, Hoses and Connections f000265 2. The fluid level must just show in the upper sight glass when cold. 3. If necessary replenish the fluid in the hydraulic tank.

  • Page 98: Axles, Chassis And Driveshafts

    Note: If there has been a failure in the transmission 1. Check the service brake pad wear indicator. cooling system, the cooler must be removed and tested. Contact BELL EQUIPMENT Product Sup- • When the ends of the sliding blocks (1 and 2) are port.

  • Page 99: Pneumatic System

    Check the Air Reservoirs ‹ Warning The pressures on the decal are cold inflation op- erating and shipping pressures and will vary according to application. Consult your tyre sup- plier if in doubt. TYRE PRESSURE B40C 6x6 FRONT MIDDLE REAR MAKE MODEL SIZE BRIDGESTONE 29.5 R25 2...

  • Page 100: Seats

    Trainer Seat and Seat Belt 1. Ensure that the seat is clean and undamaged and that the seat is mounted securely. 2. Functionally test the seat belt adjustments. 3. Ensure that the seat belt is undamaged and is mounted securely. ‹...
  • Page 101 Check all Exterior Lights, Reverse Buzzer and Horn Two people are needed to perform this check. One person inside the cab to control the switches and the other outside to ensure all the lights are working. Re- fer to Operator Controls and Instruments, Chapter 2.

  • Page 102: Climate Control

    Check the Alternator 1. Check that the battery charge light is not indicat- ing a low charge. Refer to Operator Controls and Instruments, Chapter 2. Check the Starter Motor 1. Carry out a functional test of the starter motor Refer to Operator Controls and Instruments, Chapter 2, for starting the engine.
  • Page 103 Grease Points The following figure details the points that must be greased daily on the B40C. There are two banks of grease points located on the machine: On the rear chassis. On the right side of the articulation joint. The rear chassis grease point lubricates the rear thru drive bearing and the front and rear oscillation bearings. The right side grease point lubricates the front thru drive gearing and the upper and lower articulation pins.
  • Page 104 870984-01 June 1, 1999...

  • Page 105: Chapter 10. First 100 Hours Service

    Introduction Note: The seal may stick to the sump, ensure that it is removed. The 100 hours service must be performed by BELL 4. Allow the oil to drain into the container. EQUIPMENT Product Support service personnel. 5. Clean the drain plug and check for damage to the thread.
  • Page 106 10. Fill the oil filter bowl with oil. Refer to Specifica- Clean the Fuel Screen tions, Chapter 1 for recommended fuels, lubricants and coolant. ‹ CAUTION It is important to fill the oil filters with oil before fitting. This ensures lubrication directly after starting the engine.
  • Page 107 5. Gently rinse the fuel screen reservoir and all the components. 6. Fill the reservoir with clean fuel. 7. Assemble the fuel screen, sealing ring and spring to the reservoir. 8. Install the fuel screen assembly securely. 9. Operate the hand priming pump to ensure that the reservoir is full.
  • Page 108 11. Start the engine and check for leaks at the sec- ondary fuel filter head. Check the Anti-freeze/Corrosion Inhibitors Refer BELL EQUIPMENT Product Support. Adjust the Engine Valve Clearance Refer to the ADE Engine Repair Manual for the pro- cedures.
  • Page 109 1. Check the accelerator throttle linkage (1) and the throttle position linkage (2) for damage and security. Contact BELL EQUIPMENT Product Support to ad- just the linkages. F000973 1. Loosen the adjusting bolts (1) and (2) and manually move the air conditioner compressor forward on the bracket (3) to apply tension to the drive belts.

  • Page 110: Transmission

    (a small amount of condensation is normal dur- 7. Install the seals onto the filter covers. operation). Report transmission fluid 8. Install the filters and secure with the filter covers. contamination to BELL EQUIPMENT Produc t Support. 870984-01 June 1, 1999...

  • Page 111: Transfer Case (Drop Box)

    5. Remove the oil fill plug (1) from the drop box. ‹ CAUTION 6. Remove the oil level fitting (3) from the drop box. Only BELL EQUIPMENT filters are to be used. 7. Refill the drop box with clean oil, through the fill BELL EQUIPMENT filters have the correct mi- hole (1) until the oil flows from the level hole (3) cron filtration rating for the hydraulic system.

  • Page 112: Axles, Differentials And Driveshafts

    1. Clean the axle housing around the level/filler plug. 4. Rotate each of the wheels so that the word BELL can be read in the horizontal position. 2. Remove the level/filler plug from the axle hous- ing. 5. Remove the fill plug (1), and fill each of the final drives with clean oil through the fill hole, until the 3.

  • Page 113: Chassis

    Check and Clean the Axle Breather Check the Axles and Components 1. Check the axle mounting bolts for security. Note: The procedure is the same for all the axle breathers 2. Ensure that the suspension air bags, shock ab- sorbers and the restraint cable are secure and not damaged.
  • Page 114 870984-01 June 1, 1999...

  • Page 115: Chapter 11. 250 Hours Service

    CHAPTER 11. 250 HOURS SERVICE Introduction Transmission The 250 hours service must be performed when the Check and Clean the Transmission machine has operated for 250 hours and the service Breather must be repeated every 250 hours thereafter. The transmission breather must be checked daily in Every 250 hours service must be performed by quali- adverse working conditions.

  • Page 116: Axles, Chassis And Driveshafts

    Hours Service. After the machine has been in service for over 500 hours, an oil sample should be analysed every 250 hours. Refer to BELL EQUIPMENT Product Sup- port. Check and Clean the Axle Breather The procedure is detailed in...
  • Page 117 4. Refit the internal filter onto the bottom of the air conditioner and re-clip securely into place. The air conditioner unit requires specialised servic- ing annually. Contact BELL EQUIPMENT Product Support. F000410 1. Unclip the air conditioner internal filter and re- move it from the bottom of the air conditioner.
  • Page 118 870984-01 June 1, 1999...

  • Page 119: Chapter 12. 500 Hours Service

    CHAPTER 12. 500 HOURS SERVICE Introduction 2. Discard the breather filter. 3. Install the new breather filter. The 500 hours service must be performed when the machine has operated for 500 hours and the service 4. Tighten the filter hand tight, then a further 90°. must be repeated every 500 hours thereafter.
  • Page 120 870984-01 June 1, 1999...

  • Page 121: Chapter 13. 1 000 Hours Service

    CHAPTER 13. 1 000 HOURS SERVICE Introduction 4. Manouevre the new drive belts between the vis- cous hub and the fan. The 1 000 hours service must be performed when 5. Fit the drive belts to the air conditioner compres- the machine has operated for 1 000 hours and the sor pulley and the engine pulley.

  • Page 122: Transmission

    4. Fit a new filter cartridge to the filter head with a Transmission new O-ring. Smear a little oil on the new O-ring before fitting Change the Transmission Fluid and Filters 5. Tighten the air drier filter cartridge by hand and then one half turn further.

  • Page 123: Chapter 14. 2 000 Hours Service

    CHAPTER 14. 2 000 HOURS SERVICE Introduction The 2 000 hours service must be performed when the machine has operated for 2 000 hours and the service must be repeated every 2 000 hours thereaf- ter. Every 2 000 hours service must be performed by qualified service personnel.

  • Page 124: Hydraulics

    Hydraulics Change the Hydraulic Fluid S000450 7. Fit a 1 inch NPT nipple (1) and suitable hose (3) onto the valve. f000340 8. Open the drain valve (2) and drain the hydraulic fluid into a suitable container. 1. Turn the lock nut (2) 1 or 2 turns counter clock- wise.

  • Page 125: Chapter 15. 4 000 Hours Service

    CHAPTER 15. 4 000 HOURS SERVICE Introduction Change the Crankcase Breather (Oil Separator) The 4 000 hours service must be performed when the machine has operated for 4 000 hours and the service must be repeated every 4 000 hours thereaf- ter.
  • Page 126 870984-01 June 1, 1999...

  • Page 127: Chapter 16. As Required Service

    CHAPTER 16. AS REQUIRED SERVICE Introduction 3. Loosen the banjo union on the injection pump three or four turns. This chapter details services which are described in 4. Operate the hand priming pump until an air free the maintenance schedule as tasks which are per- flow of fuel flows from the banjo union.
  • Page 128 Note: When the main filter element is changed for the third time, the safety filter element must also be changed. Change the Safety Filter Element 1. Remove the main filter element. f000596 2. Remove the lid (1) and bowl (2) from the pre- cleaner body (3).

  • Page 129: Transmission

    ‹ Caution Check and Clean the Crankcase Breather (Oil Separator) Do not allow the fuel tank to run completely empty before re-filling If the fuel tank is ever The amount of dust and dirt encountered will deter- empty, the engine must not be started and the mine the frequency of breather cleaning.
  • Page 130 6. With the transmission in neutral, run the engine perature data for troubleshooting. at 1 200 to 1 500 rev/min for two minutes to allow BELL EQUIPMENT Product support should be noti- the transmission fluid to cool down. fied when the operator feels that the following tests 7.

  • Page 131: Hydraulics

    Neutral Cool-down Check Hydraulics The neutral cool-down check determines if the trans- Check the Steering Cylinder Pins for mission fluid cools following an engine load Free Play condition. 1. When the machine has cooled down, manually Perform the check immediately after the maximum check for any free play at the steering cylinders.

  • Page 132: Brake System

    F000775 f002037 1. Observe all the above safety precautions and 1. Unscrew and remove the bolts (1) securing the loosen all the wheel nuts (1) one full turn. wheel guards 2. Using a suitable jack under the relevant axle, 2. Remove the guards. raise the machine until the tyre is clear of the 3.
  • Page 133 Change the Service Brake Pads Adjusting the Park Brake Caliper The service brake pads should be changed if there is The park brake calipers are self adjusting and do not 2 mm of pad left. require any special adjustment procedures. 1.
  • Page 134 6. Install the new park brake disc and secure into Changing the Park Brake Disc position. The park brake disc must be changed when the disk 7. Refit and secure the prop shaft into position. reaches a minimum wear limit of 22 mm (0.8"). 8.

  • Page 135: Electrical

    5. Tighten the lock nut fully using a chain wrench. 6. Loosen the lock nut until the first set of eight ver- nier holes in the lock washer are aligned. 7. Install the four lock bolts and tighten to a torque of 150 Nm (110 ft lb).

  • Page 136: Front Park Light

    Note: The batteries are connected in series, the con- nections are as follows: • Cable (4) is positive on battery A to negative on battery B. • Cable (5) is negative on battery A to the battery disconnect switch. • Cable (6) is positive on battery B to the circuit breaker.
  • Page 137 f000639 5. Unclip the spring (1) retaining the headlight bulb. f000642 8. Replace the bulb (1). 9. Ensure that the rubber boot is fitted securely, the electrical connections are secure and re-fit the headlight assembly. 10. Functionally test the headlight. Front indicator f000640 6.

  • Page 138: Number Plate Light

    Rear Lights Note: The procedure for replacing the sealed beam unit is the same for the following rear lights: • Stop/tail lights. • indicators. • Reverse lights. f000643 2. Remove the lens cover and replace the bulb (1) in the holder (2). 3.

  • Page 139: Interior Light

    Interior Light 1. Unscrew and remove the three screws (1) se- curing the interior light lens cover. 2 m (6'6 ") S000872 4. Drive the machine towards the wall until the headlights are 2 m (6’6") from the wall. 5. Measure the height of the centre of the headlight f000648 from the ground and draw line (a) on the wall at that height.

  • Page 140: Frame And Body

    19. Select dipped beam and check that the horizon- tal cut-off line is not above line (b) and that the diagonal cut-off line tapers off to the 10 o’clock position. 20. If necessary, adjust the headlight using the ad- justment screws. 21.
  • Page 141 F000670 2. Remove the wiper blade assembly (1) from the wiper arm (2) and replace with a new assembly. 870984-01 June 1, 1999...
  • Page 142 870984-01 June 1, 1999...

  • Page 143: Chapter 17. Trouble Shooting

    CHAPTER 17. TROUBLE SHOOTING Introduction The following chapter lists the possible problems that could occur with the machine, engine, transmission and components. Note: These lists are not exhaustive. If in doubt contact your BELL Product Support Representative. Engine Difficult to Start Remedy Symptom...
  • Page 144 Locate and repair the restriction Blocked radiator Clean radiator Engine running too cold Temperature gauge faulty Check temperature gauge. Contact your BELL Product Support Repre- sentative. Incorrect fan fitted Check the manufacturer’s specifica- tion. Contact your BELL Product Support Representative Incorrect radiator fitted Check the manufacturer’s specifica-...
  • Page 145 Low Engine Oil Pressure Symptom Possible Cause Remedy Low Engine Oil Pressure Faulty pressure gauge Check gauge. Contact your BELL Product Support Representative. Incorrect grade of oil used Refer to Recommended Fuel, Lu- bricants and Coolant Chart Abnormal Oil Consumption...
  • Page 146 Change the tyre Tyre under inflated Change the tyre Uneven tyre wear Incorrect alignment Check and adjust the alignment. Contact your BELL Product Support Representative Deterioration of the tyre material Fuel or oil contamination Locate the source of contamination. Change the tyre...
  • Page 147 Oil or grease on the brake pads Check and repair the cause of the oil or grease leak. Change the brake pads Hydraulic brake components leaking Contact your BELL Product Support Representative Squealing noise from the brakes Brake pads glazed...
  • Page 148 Suspension Trouble Shooting Symptom Possible Cause Remedy Excessive movement of the walking Sandwich block split and material Contact your BELL Product Support beam sandwich blocks failure Representative Knocking from the front suspension Suspension strut nitrogen pressure Release the nitrogen pressure to get...
  • Page 149 Defective actuator Replace actuator. Contact your BELL Product Support Representa- tive Defective pressure protection valve Replace protection valve. Contact your BELL Product Support Repre- sentative Defective unloader valve Reset or replace the unloader valve. Contact your BELL Product Support Representative Defective compressor Repair or replace compressor.
  • Page 150 Brake System Troubleshooting Symptom Possible Cause Remedy System does not reach operating Leaks in the hoses/fittings Repair leak. Contact your BELL pressure Product Support Representative Manual drain valve is open Install new drain valve. Contact your BELL Product Support Representa-...
  • Page 151 Alternator drive belt is loose or bro- Adjust drive belt tension or fit new illuminated when engine is on drive belt. Contact your BELL Prod- uct Support Representative Regulator or alternator is defective Change the regulator or alternator. Contact your BELL Product Support...
  • Page 152 Investigate and rectify the cause Headlight bulb defective Change the headlight bulb Light switch defective Change the light switch. Contact your BELL Product Support Repre- sentative Loose or broken connections Tighten or repair the connections Only high beam or low beam comes...
  • Page 153 Windscreen wiper does not work Circuit breaker tripped Investigate and rectify the cause Wiper switch defective Change the wiper switch. Contact your BELL Product Support Repre- sentative Wiper motor defective Change the wiper motor. Contact your BELL Product Support Repre-...
  • Page 154 Incorrect lubrication or wear Change the bearings and pins in the pivot points articulation pivot points. Contact your BELL Product Support Repre- sentative Excessive play in the front axle Incorrect lubrication or wear Change the bushes and pins in the mounting pivot points pivot points for the front axle.
  • Page 155 Remedy Excessive noise while the fan ro- Obstruction near the fan blades Remove the obstruction tates Fan blades are bent Repair the fan blades or replace the blower vent fan. Contact your BELL Product Support Representative 870984-01 June 1, 1999...

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