ADT Service Manual

TO THE OPERATOR
WARNING
Do not operate the machine unless you have read this manual and fully understood how to operate the
machine properly.
The safe operation of your BELL 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
machine.
SAFETY SYMBOL
The following symbol is used for all safety messages. When you see the safety symbol, follow the safety message
to avoid personal injury or death.
All WARNINGS and CAUTIONS must be read, fully understood, and followed before carrying out the action or
maintenance procedure concerned.
WARNINGS and CAUTIONS are always placed before any action or maintenance procedure where personal
injury and/or damage to the machine could occur if that action or maintenance procedure is not carried out correctly.
WARNING AND CAUTION

Throughout this manual the word WARNING is used to alert the operator and others of the risk of personal injury
during the operation of the equipment. CAUTION indicates the possible damage to the machine. NOTE highlights
information of special interest.
CALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the State of California to cause Cancer,
Birth Defects and other Reproductive Harm.
.
B20B 6X4
ARTICULATED DUMP TRUCK
OPERATORS MANUAL
BELL B20B 6X4 PROMOTIONAL VIDEO
Document Part Number 870966
Issue : OCTOBER 1997
Technical Documentation
BELL EQUIPMENT COMPANY
Richards Bay
IMPORTANT
Due to BELL’s policy of continuous product improvement, the information contained in this manual was correct
upto the time of printing (Issue date of manual). Any changes after this date will only be included in the next update
of this manual.
The illustrations in this manual are pictorial and not necessarily true representations of components.
This manual conforms in-full or in-part to the following specifications:-

ISO 3600, SAE J920, SAE J284, SAE J153, SAE J208, SAE J841, SAE J115 and SAE J1362
INTRODUCTION
This manual has been produced to assist you in the correct operation, maintenance and care of your BELL
machine.
The manual is divided into chapters. The information contained in the manual is in a logical sequence, with the
instructions written in step by step format.
Effective maintenance on your BELL machine is achieved when personnel fully understand the information
contained in this manual.
Every effort has been made to ensure that the information contained in this manual was correct at the time of
publication. 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.
Whilst every endeavor has been made to provide accurate and reliable information, BELL EQUIPMENT Co.
specifically disclaims any actual or implied warranty and under no circumstances shall be liable for any loss,
damage or injury to person or property suffered, whether direct, indirect or consequential, arising from the use of
this manual. In particular and without detracting from the above, the disclaimer also applies in the event of any
specification, warning, or representation contained in this manual being inadequate, inaccurate, or unintentionally
misleading.
The user is urged to strictly comply with the instructions and warnings that are given in the interests of general
safety. Please do not hesitate to contact your BELL Product Support Representative whenever you have a query
on your BELL product or this manual. The address of your nearest BELL branch or dealer is as follows:
The following address list was correct as at 31 July 1996.
R.S.A.
Richards Bay (Head Office):

Carbonode Cell % (0351)9079111 P.O. Box 198
Alton Fax : (0351) 974336 RICHARDS BAY
RICHARDS BAY Telex: 661011 3900
3900
Richards Bay (Training):

Carbonode Cell % (0351)974302/3 P.O. Box 198
Alton Fax : (0351) 973699 RICHARDS BAY
RICHARDS BAY 3900
3900
Bloemfontein:
23 George Lubbe Street % (051) 353900/1 P.O. Box 1878
Hamilton A/H : (051) 478888 BLOEMFONTEIN
BLOEMFONTEIN Radio Page 7255 (Parts) 9300
9300 Fax : (051) 4353899
Cape Town:
Milan St. % (021) 3862252 P.O. Box 162
Airport Industria A/H : (021) 9811425 EPPINGDUST
CAPE TOWN Fax : (021) 3862260 7475
7525
Empangeni:
15 Brons Street % (0351) 26106 P.O. Box 7332
EMPANGENI RAIL A/H : (0351) 923391 EMPANGENI RAIL
3910 Fax : (0351) 924342 3910
George:
Pioneer Road % (0441) 8780930/1 P.O. Box 1697
Pacaltsdorp A/H : (0441) 741996 GEORGE
GEORGE Fax : (0441) 8780932 6530
6534
Johannesburg (Jet Park):

Griffith Road % (011) 928 9700 to 22 P.O. Box 25391
Jet Park Fax : (011) 928 9730 EAST RAND MALL
KEMPTON PARK BOKSBURG
1619 1462
Johannesburg (Sales):
1619 1462
Johannesburg (Used/Rebuild Division):

1619 1462
Johannesburg (National Distribution):

1619 1462
Kuruman:
8 Acacia Street % (05373) 30698 P.O. Box 1396
KURUMAN Fax : (05373) 30697 KURUMAN
1619 8460
Middleburg:
9 Celcius Street % (0132) 461169 P.O. Box 2821
Building B A/H : (0132) 29877 MIDDLEBURG
Industrial Area Fax : (0132)461229 1050
MIDDLEBURG
1050
Nelspruit:
3 Christie Crescent % (01311) 552110 to 6 P.O. Box 1672
Vintonia 2 A/H : (01311) 551560 NELSPRUIT
NELSPRUIT Fax : (01311) 552117 1200
1200 Radio Page 8036 (Store)
Radio Page 8037 (W/Shop)
Piet Retief:
6A Retief Street % (01343) 4110 P.O. Box 1221
PIET RETIEF % (01343) 50916 VRYHEID
2380 % (01343) 3467 3100
A/H : (01343) 807029
A/H : (01343) 3550
Fax : (01343) 4110
Pietermaritzburg:
7 Van Eck Place % (0331) 69319 P.O. Box 100436
MKONDENI A/H : (0331) 964601 SCOTSVILLE
3201 Fax : (0331) 61837 3209
Pongola:
Akasia Street % (03841) 31720 P.O. Box 681
Pongola A/H : (03841) 31162 PONGOLA
3170 Fax : (03841) 31735 3170
Port Elizabeth:
134 Patterson Road % (041) 541721/2 P.O. Box 3443
NORTH END % (041) 541794/5 NORTH END
6056 % (041) 541732/9 6056
A/H : (041) 514526
Fax : (041) 542060
Port Shepstone:
Shop 5 Industrial Park % (0391) 4124/5 P.O. Box 560
Cnr. Main Harding and A/H : (0391) 77821 PORT SHEPSTONE
Isotsha Road Fax : (0391) 815155 4240
PORT SHEPSTONE
4240
Rustenburg:
No. 16 Vanadium Street % (0142) 961003/4/5 P.O. Box 3701
Border Industry A/H : (0142) 28364 RUSTENBURG
RUSTENBURG Fax : (0142) 961005 0300
0300 Radio Page 610 (Parts)
Radio Page 600 (W/Shop)
Springbok:
Drive Inn Road % (0251) 23710 P.O. Box 618
Industrial Park % (0251) 21124 SPRINGBOK
SPRINGBOK % (0251) 21130 8240
8240 A/H : (0251) 23344
A/H : (0251) 22556
Fax : (0251) 81314
Tzaneen:
8 Impala Street % (0152) 3071129 P.O. Box 2102
Industrial Sites % (0152) 3071180 TZANEEN
TZANEEN % (0152) 3074812 0850
0850 A/H : (0152) 3074503
Fax : (0152) 3073095
Umhlali:
Old Main Road % (0322) 71637 P.O. Box 39
UMHLALI Fax : (0322) 71367 UMHLALI
4390 4390
Vryheid:
Bloekom Street % (0381) 5541/2 P.O. Box 1221
VRYHEID % (0381) 5555 VRYHEID
3100 A/H : (0381) 808112 3100
Fax : (0381) 809752
U.S.A.
Garden City (Head Office):

2843 Hwy 80 % (912) 966-2615
Garden City Fax : (912) 964-1594
GEORGIA
GA 31408
NEW ZEALAND
New Zealand (Bell Equipment (NZ) Ltd):

19 Nikau Road % (09) 276-2424 P.O. Box 22585
Otahuhu Fax : (09) 276-6379 Otahuhu
AUCKLAND AUCKLAND
AUSTRALIA
Australia (Bell Equipment):

12 Granite Place % (0961) 3561033 P.O. Box 34 SPC
Welshpool Fax : (0961) 3565229 Welshpool
WESTERN AUSTRALIA WESTERN AUSTRALIA
6106 6986
Pacific Rim Region (Western Australia):

12 Granite Place % (0961) 3505346 P.O. Box 34 SPC
Welshpool Fax : (0961) 3505437 Welshpool
WESTERN AUSTRALIA WESTERN AUSTRALIA
6106 6986
SOUTH AMERICA
Argentina:
Avda Santa Fe 1838, 9 Piso % 54 1 811-9630
C.P. 1123 Fax : 54 1 811-9630
Capital Federal
Buenos Aires
ARGENTINA
South America (Bell Equipment Chile SA):

Collao 1944 % (041) 312100 Cassilla 22-C
Concepcion Fax : (041) 313020 Concepcion
CHILE CHILE
SOUTH EAST ASIA
South East Asia (Bell Equipment (SEA) Ltd):

Lam Soon Industrial Building % (09) 65 7698394 Lam Soon Industrial Building
Unite # 03-05 Fax : (09) 65 7698029 Unite # 03-05
63 Hillview Avenue 63 Hillview Avenue
SINGAPORE SINGAPORE
2366 2366
EUROPE
Bell France SARL:

Z.A. Rte d’ Argenton sur Creuse % (09) 33 55 89 23 56
23800 Fax : (09) 33 55 89 23 24
Dun-Le-Palestel
FRANCE
DEALER
Please supply your dealer details here:

.
USER’S COMMENT FORM
Should you, as user of this manual, have any suggestion for improving the manual, or you find any errors or
omissions, then we would like to know.
Please complete a facsimile of this form and hand it in to your nearest BELL Product Support Representive or
post it directly to your nearest BELL Branch. Addresses are given at the beginning of this manual.
YOUR COMMENTS, SUGGESTIONS, OR QUERIES:
MACHINE MODEL:
SERIAL NUMBER:
VIN:
DOCUMENT PART NUMBER AND ISSUE:
PAGE NUMBER:
DOES THE MANUAL MEET YOUR NEEDS ? YES NO

DID YOU FIND THE INFORMATION ACCURATE ? YES NO
DID YOU FIND THE INFORMATION EASY TO READ AND UNDERSTAND ? YES NO
DID YOU FIND THE INFORMATION EASY TO RETRIEVE ? YES NO
DID YOU FIND THE INFORMATION WELL ILLUSTRATED ? YES NO
NAME:
COMPANY:
TITLE:
ADDRESS:
TELEPHONE NUMBER:
Thank you for your co-operation.

.
TABLE OF CONTENTS
ABBREVIATION LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Warning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Important Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
Information Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
CHAPTER 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Middle Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Park/Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Flow Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tip Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Frame and Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Recommended Fuel, Lubricants and Coolant Additives . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gradeability / Speed / Tractive Effort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Serial Number Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Machine Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Machine Tie Down Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHAPTER 2. OPERATOR CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . 15
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Transmission Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Warning Indicators (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Overspeed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Transmission Oil Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Alternator Charge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Low Coolant Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Park Brake Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inter-axle Differential Lock Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cold Start Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Confirmation Indicators (Blue or Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Left Turn Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lock-up Engaged Indicator (up to 15-11-96) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Beam Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Right Turn Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Exhaust Brake Indicator (from 16-11-96) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Digital Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Manual/Automatic Change Over Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fan Switch (if fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Interior Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Windscreen Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hazard Indicator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Master Switch and Start Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Air Conditioner (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Kick Down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Battery Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electrical Distribution Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Indicators, Lights and Horn Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Engine Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Accelerator and Brake Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Gear Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Tip Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Inter-axle Differential Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Back Rest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Squab Height and Slope Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Weight Adjustment Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Soften . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Harden . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Weight Adjustment Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Backwards and Forwards Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Arm Rests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Releasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Seat Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Shorten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lengthen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Miscellaneous Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Bonnet Catch Release Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Document Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Windscreen Washer Water Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wheel Spanner and Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Interior Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Passenger Seat (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CHAPTER 3. OPERATING TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Running-in Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Procedures Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Walk Round Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Axles and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Frame and Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Starting the Engine in Warm Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Starting the Engine in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Shutting Down the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Gear Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Gear Shifting Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CODE 10 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Gear Changing in Manual Powershift Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Forward Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Reverse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Gear Changing in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Forward Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Reverse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Service Brakes and Park Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Operating with Inter-axle Differential Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Inter-axle Differential Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Loading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Raising the Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Lowering the Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Normal Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Emergency Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Towing a Machine with Inoperable Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Towing a Machine with Operable Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Towing a Machine with Inoperable Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Operating Indoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Floor Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Travelling Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Transport Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Uphill Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Downhill Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Off-road Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Public Road Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Stuck Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Overnight Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Transporting the Machine on other Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Driving the Machine onto a Transporting Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
CHAPTER 4. BASIC PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Service Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Rules when Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Measures to Prevent Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Working on Painted Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Working with Polymer Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Maintenance Schedule in Running Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Engine (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Axles, Chassis and Drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Maintenance Schedule in Running Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Axles, Chassis and Drive Shafts (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Raise and Lower the Belly Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Install the Bin Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Without Rubber Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
With Rubber Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Install the Articulation Safety Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Check the Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Change the Oil and Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Drain the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Change the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fill the Engine with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check the Oil Filler Cap and Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Change the Crankcase Oil Separator (Breather) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Bleed the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Clean the Fuel Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Drain the Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Change the Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Change the Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Change the Secondary Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Service the Injectors and Injector Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check the Air Cleaner Assembly and Service Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 67
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Air Cleaner Service Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Change the Air Cleaner Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Change the Primary Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Change the Safety Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Check and Clean the Air Cleaner Pre-cleaner Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Check the Air Cleaner Pre-cleaner Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Clean the Air Cleaner Pre-cleaner Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Check the Induction Manifold, Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Check the Exhaust Manifold, Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Check the Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Check the Anti-freeze/Corrosion Inhibitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Renew the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Check the Radiator and Clean the Radiator Fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Check the Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Clean the Radiator Fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Check the Cowling Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Check for Oil and Fuel Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Check all Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Check the Engine Rubber Mounting and Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . 71
Adjust the Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Check the Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Check the Alternator Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Check the Air Conditioner Compressor Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . 72
Check the Drive Belt Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Adjust the Alternator Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Adjust the Air Conditioner Compressor Drive Belts. . . . . . . . . . . . . . . . . . . . . . . . . 73
Change the Alternator Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Change the Air Conditioner Compressor Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Check the Transmission Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Change the Transmission Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Check and Clean the Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Check and Clean the Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Check the Transmission Rubber Mounting and Mounting Bolts . . . . . . . . . . . . . . . . . . . . 77
Check for Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Check the Neutral Start Safety Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Check for Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Check the Hydraulic Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Change the Hydraulic Fluid and Suction Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Check the Filler Cap and Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Change the Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Check for Hydraulic Component Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Check the Suction Pump, Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Change the Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Check all Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Perform Pressure and Flow Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Axles, Chassis and Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Remove and Install the Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Check the Differential Oil Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Change the Oil in the Differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Check the Final Drive Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Change the Oil in the Final Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Check and Clean the Axle Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Check the Brake Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Change the Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Check and Change the Service Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Check the Service Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Without Mud Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
With Mud Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Change the Service Brake Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Perform the Park Brake Holding Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Park Brake Holding Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Adjust Park Brake Caliper (With Brake Relay Valve) . . . . . . . . . . . . . . . . . . . . . . . . 84
Park Brake Holding Test (Without Brake Relay Valve) . . . . . . . . . . . . . . . . . . . . . . . 84
Change the Park Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Change the Park Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Check the Axles and Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check the Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check all Exterior Lights, Reverse Buzzer and Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check the Interior Light and Vent Fan/Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check the Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Adjust the Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check the Headlight Bulb Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Check the Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Service the Air Conditioner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
External Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Internal Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Check the Pneumatic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Check and Drain the Air Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Check the Seat and Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Lubricate and Check the Door and Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Check the Fuel Tank, Fuel Filler Cap and Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Check the Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Check and Adjust the Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Check the Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Adjusting the Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Grease Points for Machines Built Before October 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Prop shaft Grease Points for Machines Built Before October 1996 . . . . . . . . . . . . . . . . . . . . 93
Drive Knuckle Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Grease Points for Machines Built After October 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Earthing points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
CHAPTER 5. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Engine Difficult to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Engine Lacks Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Engine Difficult to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Low Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Abnormal Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Internal Engine Oil Sludge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Abnormal Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Engine Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Exhaust Smoke Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Transmission Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Axle Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Wheel Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Tire Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Brakes Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Hydraulic System Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Pneumatic System Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Instruments and Controls Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Electrical Supply Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Electrical Equipment Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Starting System Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
EST 25 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Articulation and Oscillation Assembly Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . 115
Rear Frame and Walking Beam Assembly Trouble Shooting . . . . . . . . . . . . . . . . . . . . . 115
Bin Assembly Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cab and Bonnet Assembly Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
ABBREVIATION LIST
ADE Atlantic Diesel Engines JIC Joint Industry Conference Standards

o
C Degree Celsius kg Kilogram
Ω Ohm km/h Kilometre Per Hour
A Ampere kPa Kilopascal
A/R As Required kW Kilowatt
AC Alternating Current l/min Litre Per Minute
Ah Ampere Hours lb Pound
API American Petroleum Institute LED Light Emitting Diode
approx Approximately LH Left Hand
assy Assembly lube Lubrication
ATDC After Top Dead Centre m Metre
BHP Brake Horse Power m3 Cubic Metre
BSP British Standard Pipe mA Miliampere
BTDC Before Top Dead Centre max Maximum
CGA Compressed Gas Association Inc min Minimum
CO2 Carbon Dioxide mm Millimetre
CTD Control Traction Differential mm3 Cubic Milimetre
db Decibels MPa Megapascal
DC Direct Current N Newton
o
deg or Degree N/C Normally Closed
dia Diameter Nm Newton Metre
diff Differential No. Number
E.G.S. Electronic Gear Shifting N/O Normally Open
ext Extension NPT National Pipe Thread
FMC Front Mount Cab NSI Non Stock Item
ft lb Foot Pound OD Outside Diameter
FWD Forward P/N Part Number
g Gram press Pressure
GAL/min Gallon Per Minute psi Pound per Square Inch
Gr Grade PTO Power Take Off
hex Hexagonal Qty Quantity
HT High Tensile REV Reverse
hz Hertz rev/min Revolutions Per Minute
ID Internal Diameter RH Right Hand
in3 Cubic Inch RSG Recommended Service Guide
incl Including SABS South African Bureau of Standards
October 17, 1997 i

SMC Side Mounted cab thru Through to and Including
SMR Service Meter Reading UNC Unified National Coarse
std Standard USGAL United States Gallon (3.7854 litre)
strt Straight V Volt
TBN Total Base Number W Watt
TDC Top Dead Centre W/O With out
temp Temperature ZF Zahnradfabrik Passau Gmbh
ii October 17, 1997

SAFETY
Material Safety Data Sheets (MSDS)
The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 CFR 1910.1200 and in some
cases, State and Local Right-to-Know laws, may require that specific MSDS be available to the employees prior
to operating this equipment. This may include information on substances contained in this equipment such as
antifreeze, engine oil, battery acid, hydraulic fluid and freon (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.
To ensure a prompt response, please be sure to include your return address and ZIP (postal) code, along with
the model, serial number and/or VIN number of your machine.
Unauthorised Modifications of the Roll Over Protective Structure (ROPS) and the
Falling Objects Protective Structure (FOPS)
Do not make unauthorised modifications or alterations to the ROPS and FOPS such as: welding on extinguisher
brackets, CB aerial brackets, fire suppression systems etc. Unauthorised modifications will affect the structural
limits of the ROPS and FOPS and will void the certification.
The Roll Over Protective Structure has been certified to meet specified test requirements according to SAE J1040
and ISO 3471. The Falling Objects Protective Structure has been certified to meet specified test requirements
according to SAE J231 and ISO 3449.
Any planned modification or change must be reviewed in advance by the Engineering Department to determine
if the modification or change can be made within the limits of the certifying tests. It is important that each person
in your organisation, including management, be made fully aware of these rules involving ROPS and FOPS.
Whenever anyone sees unauthorised modifications or changes to a machine’s ROPS or FOPS both the customer
and manufacturer must be notified in writing.
Make sure that all parts are installed correctly if the ROPS or FOPS is loosened or removed for any reason.
Tighten mounting bolts to the correct torque. The protection offered by ROPS or FOPS will be impaired if they are
subjected to structural damage, is involved in an overturn incident, or is altered in any way. A damaged ROPS or
FOPS must be replaced, not reused.
Unauthorised Modifications of the Operator Protective Structure (OPS)
Do not make unauthorised modifications or alterations to the OPS such as: welding, drilling, cutting, bending,
removal etc. The above restrictions pertain to all OPS components which include: guards, lexan windows, doors,
fasteners and retaining plates. Unauthorised modifications will affect the structural limits of the OPS and will void
the certification.
The Operator Protective Structure has been certified to meet specified test requirements according to SAE J1084.
Any planned modification or change must be reviewed in advance by the Engineering Department to determine
if the modification or change can be made within the limits of the certifying tests. It is important that each person
in your organisation, including management, be made fully aware of these rules involving OPS. Whenever anyone
sees unauthorised modifications or changes to a machine’s ROPS or FOPS both the customer and manufacturer
must be notified in writing.
Make sure that all parts are installed correctly if the OPS is loosened or removed for any reason. Tighten mounting
bolts to the correct torque. The protection offered by OPS will be impaired if it is subjected to structural damage,
is involved in an accident, or is altered in any way. A damaged OPS must be replaced, not reused.
Noise Emission Levels

The sound pressure was tested according to ISO 6394 (SAE J 2103) and the sound power was tested according
to ISO 6393 (SAE J 2102).
October 17, 1997 iii

GENERAL SAFETY
Safety Regulations
Every country (State) has its own safety regulations. It is the obligation of the operator to know and follow these.
This also applies to local regulations covering different types of work. Should the recommendations in this manual
deviate from those of your country, your local safety regulations should be followed.
Mounting and Dismounting the Machine

Always use the handrails and steps provided to get on and off the machine. Use both hands and face the machine.
Never get on or off a moving machine. Never jump off the machine. Use a hand line to pull equipment up onto the
platform, do not climb on or off the machine carrying tools or supplies.
Avoid Power Lines

Never move any part of the machine within 3 m (10 ft) plus twice the line insulator length, as serious injury or
death may result.
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.
Handle Flammable Fluids Safely

Handle fuel with care, as it is highly flammable. Do not smoke or go near an open flame or sparks while refueling.
Always stop the engine before refueling the machine and fill the fuel tank outdoors.
Keep all fuels and lubricants in properly marked containers and away from all unauthorised persons. Do not smoke
in the storage areas. Store all oily rags and other flammable material in a protective container, in a safe place.
Do not weld or flame cut on pipes or tubes that have contained flammable fluids. Clean them thoroughly with
nonflammable solvent before welding or flame cutting on them.
Starting fluid is highly flammable. Keep all sparks and flames away when using it. To prevent accidental discharge
when storing the pressurised can, keep the cap on the can and store it in a cool protected place. Do not burn or
puncture a starting fluid container.
Clean the Machine Regularly

Wait until the engine has cooled before removing trash from areas such as the engine, radiator, batteries, hydraulic
lines, fuel tank and operators cab. Remove any grease, oil or debris build-up. Keep the machine, especially the
walkways and steps, free of foreign material, such as debris, oil, tools and other items which are not part of the
machine.
iv October 17, 1997

Prevent Battery Explosions and Acid Burns
The standard battery supplied with the machine is a sealed type that does not need maintenance. keep sparks
and flames away from the batteries.
Where a non-sealed battery is subsequently fitted, keep sparks and flames away from the batteries. Use a
flashlight to check the battery electrolyte level. Use a voltmeter or hydrometer to check battery charge, never
place a metal object across the posts. Always remove the grounded (Negative -) battery clamp first and replace
it last.
Do not smoke in areas where batteries are being charged.
Sulphuric acid in battery electrolyte is poisonous and is strong enough to burn skin, eat holes in clothing and cause
blindness if splashed into the eyes.
Avoid the hazard by:
• Filling the batteries in a well ventilated area.
• Wearing eye protection and rubber gloves.
• Avoid breathing fumes when electrolyte is added.
• Avoid spilling or dripping electrolyte.

If you spill acid on yourself:
• Flush your skin with water.
• Apply baking soda or lime to help neutralise the acid.
• Flush your eyes with water for 10 - 15 minutes and get medical attention immediately.
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.
When you drive connecting pins in or out, guard against injury from flying pieces of debris by wearing goggles or
protective glasses. Prolonged exposure to loud noise can cause impairment or loss of hearing. So wear a suitable
hearing protective device such as earmuffs or earplugs. Wear gloves when handling wire rope cable.
Use the Seat Belt

Use a seat belt at all times to minimise the chance of injury from an accident such as an overturn.
Inspect the condition of the seat belt and mounting hardware. Replace any damaged or worn parts. Replace the
seat belt regardless of appearance, after three years.
Avoid High Pressure Fluids

Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve the pressure before
disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body
October 17, 1997 v

away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to
search for leaks.
If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor who is familiar with
this type of injury or gangrene may result.
Tire Information
Welding or heating of the rim components, external fire or excessive use of brakes can cause overheating of the
tires, which could cause a tire explosion.
This explosion can propel the tire, rim and final drive components approximately 500 metres from the machine,
which may cause personal injury or death and/or property damage.
If the tire is overheating and could explode, do not approach it within the area represented by the shaded area
in the drawing, until it has cooled.
Stand behind the tread and use a self attaching chuck with extension hose to inflate the tires. Use a safety cage
if available. Do not stand over the tire.
Note: It is recommended that trained personnel service and change tires and rims.
15 m
(49'3")
Use a safety cage if available
500 m Do not stand over the tire, use a clip-on chuck and extension hose
(1 640'5")
S002056
vi October 17, 1997

SAFETY DECALS
There are several safety decals on your BELL 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. If a decal is on a part that is replaced, ensure a new decal is
installed on the replacement part. Contact your BELL Representative for new decals.
Warning Decals
WARNING WARNING
SPRING UNDER PRESSURE
CHECK ALL WHEEL NUTS AFTER DO NOT CARRY OUT DISASSEMBLY
THE FIRST 5 SMR AND THEN AFTER OF THIS PART WITHOUT THE
EVERY 50 SMR OF OPERATION REQUIRED APPARATUS
P/N 202856
202858
Located inside the cab and next to each wheel Located on the park brake actuator
WARNING WARNING
NO CLEARANCE FOR MAN IN THIS AREA WHEN MACHINE
INSTALL BIN PROP BEFORE TURNS; SEVERE INJURY OR DEATH MAY OCCUR.
WORKING UNDER RAISED BIN TO CONNECT ARTICULATION LOCK BEFORE LIFTING,

TRANSPORTING THE MACHINE OR PERFORMING ANY
PREVENT IT FROM FALLING WHICH MAINTENANCE IN THIS AREA.
MAY RESULT IN PERSONAL INJURY THE MACHINE WILL NOT STEER WHEN THE
ARTICULATION LOCK IS INSTALLED.
OR DEATH.
202859
202852
Located in the articulation area
Located on the front and both sides of the bin
WARNING WARNING
STRUCTURAL DAMAGE, AN OVERTURN,
MODIFICATION, IMPROPER REPAIR OR
INSTALL ARTICULATION SAFETY ALTERATION, CAN IMPAIR THIS MACHINES
CERTIFICATION. CONSULT A BELL
BAR BEFORE ENTERING THIS AREA
REPRESENTATIVE TO DETERMINE THIS
P/N 201571 MACHINES CERTIFICATION LIMITATIONS.
Located on both sides of the articulation area 202851
Located on the front of the cab
WARNING WARNING
BATTERY DISCONNECT
SWITCH LOCATED IN CASE OF BONNET
CABLE FAILURE:
ALONGSIDE BATTERY P/N 202844 DIRECT ACCESS TO CATCH VIA AIR
CLEANER INSPECTION COVER
Located alongside battery
WARNING 202861
Located on the bonnet.

IN CASE OF EMERGENCY PUSH OUT
THIS WINDOW
202857
Located inside the cab on the operator’s side win-
dow
October 17, 1997 vii

WARNING
THIS HYDRAULIC SYSTEM IS FILLED
WITH AUTOMATIC TRANSMISSION
FLUID DO NOT TOP UP WITH
HYDRAULIC OIL
203238
Located on the hydraulic tank
WARNING
MACHINE OPERATOR HAS LIMITED
VISIBILTY. DO NOT REMAIN IN THIS
AREA WHEN ENGINE IS RUNNING.
PERSONAL INJURY OR DEATH MAY
RESULT
202855
Located on the both sides, front and rear of the

bin and the front of the machine
Located inside the PM Pack Wallet
viii October 17, 1997

WARNING
STRUCTURAL DAMAGE, AN OVERTURN, MODIFICATION,
IMPROPER REPAIR OR ALTERATION, CAN IMPAIR THIS
MACHINES CERTIFICATION. CONSULT A BELL
REPRESENTATIVE TO DETERMINE THIS MACHINES
CERTIFICATION LIMITATIONS.
SUSPENSION SYSTEM MAY DROP MACHINE SUDDENLY IF

THE LEVELLING VALVE IS TAMPERED WITH. THIS LEAVES
NO CLEARANCE BETWEEN THE AXLE HOUSING,
MAINFRAME, TYRES, AND MUD GUARDS.
WORKING IN THESE AREAS CAN RESULT IN PERSONAL

INJURY OR DEATH.
KEEP AREA AROUND EXHAUST SYSTEM AND MANIFOLDS

CLEAR OF COMBUSTIBLE MATERIAL. SHUT DOWN ENGINE
BEFORE CLEANING.
MACHINE OPERATOR HAS LIMITED VISIBILITY. DO NOT

REMAIN IN THIS AREA WHEN ENGINE IS RUNNING.
PERSONAL INJURY OR DEATH MAY RESULT.
NO CLEARANCE FOR MAN IN THE ARTICULATION AREA.

CHECK ALL WHEEL NUTS AFTER THE FIRST 5 SMR AND

THEN AFTER EVERY 50 SMR OF OPERATION.
INSTALL ARTICULATION LOCK BEFORE LIFTING,

MAINTENANCE IN THIS AREA.
203152
Located on both sides of the articulation joint
October 17, 1997 ix

Located on the dashboard.
x October 17, 1997

WARNING
STRUCTURAL DAMAGE, AN OVERTURN, MODIFICATION,
IMPROPER REPAIR OR ALTERATION, CAN IMPAIR THIS
MACHINES CERTIFICATION. CONSULT A BELL
REPRESENTATIVE TO DETERMINE THIS MACHINES
CERTIFICATION LIMITATIONS.
KEEP AREA AROUND EXHAUST SYSTEM AND MANIFOLDS

CLEAR OF COMBUSTIBLE MATERIAL. SHUT DOWN ENGINE
BEFORE CLEANING.
MACHINE OPERATOR HAS LIMITED VISIBILITY. DO NOT

REMAIN IN THIS AREA WHEN ENGINE IS RUNNING.
NO CLEARANCE FOR MAN IN THE ARTICULATION AREA.

CHECK ALL WHEEL NUTS AFTER THE FIRST 5 SMR AND

THEN AFTER EVERY 50 SMR OF OPERATION.
INSTALL ARTICULATION LOCK BEFORE LIFTING,

MAINTENANCE IN THIS AREA.
BEFORE WELDING, DISCONNECT ALL ELECTRONICS ON

ENGINE AND TRANSMISSION.
THIS IS A COMPRESSED AIR SYSTEM, SHUT DOWN ENGINE

AND BLEED PRESSURE FROM SYSTEM BEFORE CARRYING
OUT MAINTENANCE.
CHECK COOLANT, ENGINE AND TRANSMISSION OIL LEVELS

DAILY.
203843
Located on both sides of the machine
October 17, 1997 xi

Important Decals Information Decals
IMPORTANT
THE OVERSPEEDING OR
FREEWHEELING OF THIS MACHINE
WILL RESULT IN SERIOUS DAMAGE
TO ENGINE, TRANSMISSION
AND DRIVELINE
202846
Located inside the cab
IMPORTANT 202721
BEFORE WELDING
DISCONNECT ALL ELECTRONICS
Located on the front and rear of the machine
ON ENGINE AND TRANSMISSION
202848
Located on the right side of the cab
ENGINE
Located on both sides of the articulation joint
STOP
202828
Located on the dash board
Located on the left side of the articulation joint (Up 204262

To October 1996)
xii October 17, 1997

TYRE PRESSURE B20B 6x4
FRONT MIDDLE REAR
MAKE MODEL SIZE kPa PSI kPa PSI kPa PSI
BRIDGESTONE VKT 20.5R25HHE2 375 54 425 62 425 62
GOODYEAR RL-2+ 20.5R25HH177B 375 54 425 62 425 62
X X X X X X X X X
X X X X X X X X X
X X X X X X X X X
204836 PAYLOAD: 18 000 kg (39 600 lbs)
Located inside the cab
POWER POINT
24V USE ONLY
204907
October 17, 1997 xiii

xiv October 17, 1997
BULLETINS
Record the relevant information from the Technical Documentation Bulletins, Service Bulletins and Parts Bulletins
into this manual as follows:
i. Ensure the manual number (87——) reflected in the bulletin is the same as the 87—— number at the bottom
of the main content pages.
ii. Carry out the instructions as detailed in the bulletin.
iii. Record the required information below.
File the bulletins in numerical order in a suitable 3 or 4 ring binder.
TECHNICAL DOCUMENTATION BULLETIN RECORD
INSERTED BY
BULLETIN NO. SUBJECT
NAME SIGNATURE DATE
October 17, 1997 xv

TECHNICAL DOCUMENTATION BULLETIN RECORD
INSERTED BY
BULLETIN NO. SUBJECT
NAME SIGNATURE DATE
xvi October 17, 1997

CHAPTER 1. SPECIFICATIONS
Machine Specifications
The specifications for the B20B 6X4 Articulated Dump Truck s are as follows:-
Engine
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADE 366TI
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Six-cylinder, in-line
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged and intercooled
Injection type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct
Opening pressure (used). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 000 kPa (2 610 psi)
Opening pressure (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 800 kPa (3 017 psi)
Nett power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 kW @ 2 300 rev/min
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 rev/min
Governed over-run rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 530 rev/min
Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 kW @ 2 300 rev/min
Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 Nm @ 1 600 rev/min
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 958 cm3 (363.5 in3)
Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.5 mm (3.83")
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 mm (5.24")
Inlet valve clearance (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm
Exhaust valve clearance (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 mm
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Working cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 stroke
Direction of rotation (facing flywheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counter-clockwise
Start of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15o
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5:1
Compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 000 kPa (290 psi) @180 to 200 rev/min
Transmission
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF 6 WG 200
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Countershaft design with integral drop box
Gear layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Constant mesh
Input power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up to 190 kW
Input speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 300 rev/min
Maximum turbine torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 450 Nm
Output differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard planetary type, lockable
Output differential torque split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33% front/67% rear
Number of forward gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Six
Number of reverse gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three
Clutch type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically operated, multiple disc
Control type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift modulated, electronic over hydraulic
Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrodynamic, trilock system with lock-up clutch
870966 1
October 17, 1997
Axles
Front Axle
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELL 14T
Differential type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spiral Bevel Gear
Differential ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36:1
Final ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.125:1
Final drive type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outboard heavy duty planetary reduction hubs
Housing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel fabricated
Middle Axle
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELL 14T
Differential type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spiral Bevel Gear
Differential ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36:1
Final ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.125:1
Final drive type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outboard heavy duty planetary reduction hubs
Rear Axle
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELL
Brakes
Service
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual circuit, air over hydraulic, dry disc brakes on all six wheels
Maximum brake force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 kN (36 117 ft lb)
Brake caliper type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self adjusting
Piston quantity per caliper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake pad material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-asbestos
Park/Emergency
Park brake type (Up to July 1997). . . Spring applied, air released mechanical caliper on drive-line mounted disc
Emergency retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot operated engine exhaust brake
Maximum brake force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 kN (11 465 ft lb)
Park brake type (From July 1997). . . Spring applied, air released mechanical caliper on drive-line mounted disc
Wheels
tyre size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5R25
Service code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2
Static loaded radius. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660 mm (2’1")
Rolling radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692 mm (2’3")
Free radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735 mm (2’5")
Sectional width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525 mm (1’9")
Maximum load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 300 kg @ 525 kPa
Rim size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 00x25x2.5
Wheel nut torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Nm (369 ft lb)
2 870966
October 17, 1997
Suspension
Front Suspension
Air bag nominal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368 mm (14.5")
Air bag maximum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 mm (11")
Air bag minimum height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 mm (2.75")
Air bag load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 320 kg (9 504 lb) @ 560 kPa (81 psi)
Shock absorbers (extended length) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804 mm (32")
Shock absorbers (closed length). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474 mm (19")
Shock absorbers (nominal stroke). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375 mm (15")
Shock absorbers (bore size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 mm (1.6")
Bump stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber to steel backing plate
Rear Suspension
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Walking beam with heavy duty rubber mountings
Sandwich blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel and rubber compound
Bump stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber to steel backing plate
Hydraulic System
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic, load sensing with flow amplifier for steering
Pressure rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 000 kPa (3 625 psi)
Flow rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 litre/min (38.7 USGAL/min) @ 2 300 rev/min
Hydraulic Pump
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AA10 VO 71
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axial piston variable displacement load sensing
Pump displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 litre/min (40.7 USGAL/min) @ 2 300 rev/min
Pump pressure rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 000 kPa (3 771 psi)
Flow Amplifier
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic with load sensing
Application factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rated hydraulic flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 litre/min (43.32 USGAL/min)
Maximum pressure (steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 500 kPa (2 538 psi)
Maximum pressure (working hydraulics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 500 kPa (3 408 psi)
Control spring pressure (in valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 kPa (101 psi)
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 500 kPa (2 538 psi)
Shock valve spring setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 000 kPa (3 480 psi)
Back pressure valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 kPa (72.5 psi)
Control Valve
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sp18 1 bank
Maximum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 litre/min
Maximum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 000 kPa (3 046psi)
Minimum filtration required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 microns
Pressure setting (bin up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 000 kPa (2 611 psi)
Steering Valve
Rated hydraulic flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 litre/min
Maximum pressure on pump (P) ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 500 kPa (2 538 psi)
Maximum pressure on tank (T) ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 500 kPa (218 psi)
Pressure setting (steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 500 kPa (2 538 psi)
870966 3
October 17, 1997
Cylinders
Tip Cylinder
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single stage, double acting
Tipping angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70o
Steering Cylinder
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single stage, double acting
Steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40o
Pneumatic System
Type . . . . Four-way pressure protected, dual brake circuit incorporating an air drier with integral unloader valve
System pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810 kPa (117 psi)
Compressor rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 kPa (46 psi) at governed rev/min
Total reservoir capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 litre (16 USGAL)
Electrical System
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance free
Number of batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ah
Starter motor capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 kW
Alternator voltage rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Alternator amperage rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A
Headlight type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealed beam
Headlight power rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70/75 W
Tail light rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 W
Stop light rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 W
Turn indicator light rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 W
Reverse light rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 W
Steering System
Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hydromechanically articulated with two double acting hydraulic cylinders
Number of turns to lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Six
Frame and Body
Cab
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOPS (SAE J231/ISO 3449)/ROPS (SAE J1040/ISO 3471/1)
Bin
Type . . . . . . . . . . . . . . General purpose. Manufactured from high tensile wear and impact resistant alloy steels
Capacity (struck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 m3 (11.1 yd3)
Capacity (SAE 2:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.0 m3 (14.3 yd3)
Rated payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 000 kg (39 600 lb)
Tipping system . . . . . . . . . . . . . . . . . . . . . . . . . . Two long life, flex free, single stage double-acting lift cylinders
Bin power down time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 seconds
Bin raise time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 seconds
Tipping angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70o
4 870966
October 17, 1997
Mass
Engine mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495 kg (1 089 lb)
Transmission mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480 kg (1 056 lb)
Total mass, empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 350 kg (31 570 lb)
Total mass, loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 350kg (71 170 lb)
Front axle, operating mass empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 120 kg (15 664 lb)
Front axle, operating mass loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 434 kg (20 754 lb)
Middle axle, operating mass empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 795 kg (8 349 lb)
Middle axle, operating mass loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 638 kg (25 604 lb)
Rear axle, operating mass empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 435 kg (7 557 lb)
Rear axle, operating mass loaded. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 278 kg (24 812 lb)
Road legal payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 750 kg (19 290 lb)
Service Capacities
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 litre (53.9 USGAL)
Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 litre (3.7 USGAL)
Engine coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 litre (10 USGAL)
Transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 litre (7.4 USGAL)
Hydraulic oil (Reservoir) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 litre (21.1 USGAL)
Axle oil (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 litre (11.9 USGAL)
Axle oil (middle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 litre (11.9 USGAL)
870966 5
October 17, 1997
Recommended Fuel, Lubricants and Coolant Additives
The following chart details the recommended fuel, lubricants and coolant additives.
BELL RECOMMENDED LUBRICANT CHART

B16B, B17B, B25B, B30B, T17B, T25B ARTICULATED TRUCKS
Recommended Lubricant Viscosities for use at Ambient Temperatures from

O O O O
-40 C (-40 F) to 50 C (122 F)
O
F -40 -22 -4 14 32 50 68 86 104 122
O
Ambient C -40 -30 -20 -10 0 10 20 30 40 50
Temperature
SAE 5W/20
ENGINE - ADE 366T/TI
OILS TO MEET SAE 10W
API GRADE CC/SE
OR CCMC GRADE D4 SAE 10W/30
SPECIFICATIONS
SAE 15W/40
SAE 20W/40
SAE 30
TRANSMISSION - ZF6WG ATF
OILS TO MEET
API CE, CF, SF, SG SAE 10W
SPECIFICATIONS
SAE 10W/30
SAE 15W/40
SAE 20W/20
DRIVE AXLES - BELL SAE 85W/140

OILS TO MEET
API GL5
SPECIFICATION
HYDRAULIC SYSTEM ISO 10

OILS TO MEET
VICKERS M-2952-S
OR A SUFFIX A (ATF)
ATF
SPECIFICATION
ISO 32
ISO 46
ISO 68
BRAKES SAE DOT 4

TO CONFORM TO
SAE J1703
ANTIFREEZE COOLANT: BELL PART NUMBER 910121

DIESEL: CETANE 48, SULPHUR 0.52% W/W
GREASE: EP2 LITHIUM BASED
204544
S000442
6 870966
October 17, 1997
Recommended Torque Settings
The following tables detail the recommended torque settings
The torques recommended below are for HAND TIGHTENING unplated fasteners with no
lubrication.
When using a bolt or screw in a tapped hole it is assumed that there is sufficient thread
engagement to accept the applied torque. Discretion must be used when torqueing into a shallow
hole or into soft or brittle materials.
Always adhere to engine/gearbox etc. manufacturer's specified torques.

Nuts should be of the same grade as the corresponding bolt or screw.
The torques recommended impose a loading in the bolt equivalent to 75% of the proof load, where
the proof loading it 90% of the yeild load.
1 lb ft = 1.35582 Nm 1 Nm = 0.737561lb ft
1 lb ft = 0.112985 Nm 1 Nm = 8.85073 lb in
METRIC SIZES
METRIC BOLT GRADE INTERPRETATION
8x100=800 Mpa 10x100=1000 Mpa 12x100=1200 Mpa
(Ultimate Tensile Stress) (Ultimate Tensile Stress) (Ultimate Tensile Stress)
8.8 10.9 12.9
8x8x10=640 Mpa 10x9x10=900 Mpa 12x9x10=1080 Mpa
(Yield Stress or Stress (Yield Stress or Stress (Yield Stress or Stress
at 0.2% premanent set) at 0.2% premanent set) at 0.2% premanent set)
METRIC NUT GRADE INTERPRETATION
CURRENT STANDARD :
Nuts which are 0.8xD high.
|8| 8x100=800 Mpa Proof Stress
FUTURE STANDARD :
(Subject to international agreement) ISO Grade 8.8 Manufacturer's
Mark
8 8x100=800 Mpa Proof Stress 800 MPa (51.80 tsi)
Nuts which are 1.0xD high. 8.8 Grade
ISO Grade 4.6 Manufacturer's

Mark
Mark
400 MPa (25.90 tsi) 4.6 Grade (Optional)
1000MPa (64.75 tsi) 10.9 Grade

Mark
Mark
600 MPa (38.85 tsi) 6.9
Grade (Optional)
1200MPa (77.70 tsi) 12.9 Grade
ISO Metric Coarse -Torques [Nm]

Size M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M36
Pitch (mm) 0.8 1 1.25 1.5 1.75 2 2 2.5 2.5 2.5 3 3 3.5 4
T/Stress area (mm2) 14.2 20.1 36.6 58 84.3 115 157 193 245 303 353 459 561 817
ISO Gr. 4.6 2 4 10 19 34 58 85 115 165 220 285 420 560 980
ISO Gr. 6.9 5 8.5 21 41 72 115 180 245 345 465 600 890 1200 2118
ISO Gr. 8.8 6 10 25 49 86 135 210 290 410 550 710 1050 1450 2520
ISO Gr. 10.9 8 14 35 69 120 190 295 400 580 780 1000 1500 2000 3430
ISO Gr. 12.9 10 17 41 83 145 230 355 485 690 930 1200 1800 2400 4100
ISO Metric Fine -Torques [Nm]
Size M8 M10 M12 M12 M14 M16 M18 M20 M22 M24 M27 M30
Pitch (mm) 1 1.25 1.25 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2
T/Stress area (mm2) 39.2 61.2 92.1 88.1 125 167 216 272 333 384 496 621
ISO Gr. 6.9 23 44 80 76 125 190 275 385 520 650 970 1350
ISO Gr. 8.8 27 52 95 90 150 225 325 460 610 780 1150 1600
ISO Gr. 10.9 38 73 135 125 210 315 460 640 860 1100 1600 2250
ISO Gr. 12.9 45 88 160 150 250 380 550 770 1050 1300 1950 2700
RESEARCH AND DEVELOPMENT
Drawing Number 700999/1 rev A 24/6/96 X000386
870966 7
October 17, 1997
IMPERIAL SIZES - BS GRADES
BS Grade A Manufacturer's
Mark
BS Grade T Manufacturer's
Mark
Coarse Coarse
28 tsi (432 Mpa) or Fine CA Grade 55 tsi (849 Mpa) or Fine CT Grade
BS Grade S Manufacturer's
Mark
BS Grade V Manufacturer's
Mark
Coarse Coarse
50 tsi (772 Mpa) or Fine FA Grade 65 tsi (1004 Mpa) or Fine FV Grade
Unified Coarse (UNC) - Torques in Nm.
Size 1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1" 1 1/8" 1 1/4" 1 3/8" 1 1/2"
Threads/inch 20 18 16 14 13 12 11 10 9 8 7 7 6 6
2
T/Stress area (mm ) 20.5 33.8 50 68.6 91.5 117.4 146 215 298 391 492 625 745 906
BS Grade A 4 9 16 25 38 56 78 138 221 335 467 670 861 1148
BS Grade S 12 24 43 66 108 150 209 371 586 885 1256 1735 2333 3051
BS Grade T 12 26 45 72 114 162 221 383 646 957 1376 1914 2512 3290
BS Grade V 16 31 55 90 138 191 263 479 766 1148 1615 2273 2991 4008
Unified Fine (UNF) up to 1", and UN-8 TPI for dia 1 1/8" and above. Torques in Nm.
Size 1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1" 1 1/8" 1 1/4" 1 3/8" 1 1/2"
Threads/inch 28 24 24 20 20 18 18 16 14 12 8 8 8 8
2
T/Stress area (mm ) 23.5 37.4 56.6 76.6 103 131 165 241 328 428 510 645 795 963
BS Grade A 5 10 18 29 43 60 90 150 239 359 490 670 933 1196
BS Grade S 13 26 48 78 114 167 233 407 646 957 1316 1794 2452 3230
BS Grade T 14 29 51 84 126 179 239 431 694 1029 1376 1974 2632 3529
BS Grade V 17 35 60 96 150 215 299 526 837 1256 1675 2393 3230 4247
IMPERIAL SIZES - SAE GRADES

Manufacturer's Manufacturer's
SAE Grade 1 Mark SAE Grade 5 (1/4" - 1") Mark
26.8 tsi (414 Mpa) 53.6 tsi (828 Mpa)
Manufacturer's
SAE Grade 5 (1 1/8" - 1 1/2") SAE Grade 8 Mark
46.9 tsi (724 Mpa) Manufacturer's
Mark
67 tsi (1035 Mpa)
Unified Coarse (UNC) - Torques in Nm.

Size 1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1" 1 1/8" 1 1/4" 1 3/8" 1 1/2"
Threads/inch 20 18 16 14 13 12 11 10 9 8 7 7 6 6
2
T/Stress area (mm ) 20.5 33.8 50 68.6 91.5 117.4 146 215 298 391 492 625 745 906
SAE Grade 1 4 9 16 25 38 56 78 138 221 335 467 670 861 1148
SAE Grade 5 11 22 40 62 101 140 196 348 550 830 1347 1860 2501 3270
SAE Grade 8 16 32 57 92 142 197 271 493 789 1184 1665 2343 3083 4131
Unified Fine (UNF) up to 1", and UN-8 TPI for dia 1 1/8" and above. Torques in Nm.
Size 1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1" 1 1/8" 1 1/4" 1 3/8" 1 1/2"
Threads/inch 28 24 24 20 20 18 18 16 14 12 8 8 8 8
2
T/Stress area (mm ) 23.5 37.4 56.6 76.6 103 131 165 241 328 428 510 645 795 963
SAE Grade 1 5 10 18 29 43 60 90 150 239 359 490 670 933 1196
SAE Grade 5 12 25 45 73 107 157 219 382 606 898 1411 1924 2629 3463
SAE Grade 8 17 36 62 99 154 222 308 543 863 1295 1726 2466 3329 4378
RESEARCH AND DEVELOPMENT X000385
Drawing Number 700999/2 rev A 24/6/96
8 870966
October 17, 1997
Machine Dimensions
The following figure details the dimensions of the B20B 6X4.
70°
5 982 (19' 7")
4 648 (15' 3")
B20B supertruck
3 126 (10' 3")
2 423 (7' 11")
B20B supertruck
1 898 (6' 3")
975 (3' 2")
25°
430 (1' 5")
1 342 800 800

(4' 5") (2' 7") (2' 7") 4 157 (13' 8") 1 960 (6' 5")
9 059 (29' 9")
3 140 (10' 4")

3 260 (10' 8")
374 (1' 3")
2 580 (8' 6")
Inside Turning Radius

4 919 mm (16' 1")
Outside Turning Radius
9 093 mm (29' 9")
X000175
870966 9
October 17, 1997
14350 kg
10
32350 kg
(31636 lbs) (71320 lbs)
lbft kN NVM GVM
x 1000 x 1000
45 200
%
180
60
40
160
%
35
50
140
%
30
40
120
%
25 30
100
Gradeability / Speed / Tractive Effort
20 %
25
80
%
20
1st Gear
15
%
60 15
2nd Gear 10%

10
40
Total Resistance = % Rolling Resistance + % Grade
3rd Gear 8%
6%
The following figure details the gradeability, speed and tractive force for the B20B 6X4.
5 4th Gear 4%
20 5th Gear 2%
6th Gear 0%
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 kph
X000419
5 10 15 20 25 30 35 40 mph
Speed
870966
October 17, 1997
Serial Number Plates
The following figure details the serial number plates for the machine, engine and transmission and where they
are located on the B20B 6X4.
Note: The standard B20B will not be fitted with the CE plate.
ATLANTIS DIESEL ENGINES (PTY) LTD

LICENCE DAIMLER-BENZ AG
ENGINE No. DB
ADE
MADE IN RSA
B25B
AEB XXXXXX TRA XXXXX
X000221
870966 11
October 17, 1997
Component Terminology
The following figure details the component terminology throughout the manual.
1 2 3 4
18
17
16
5
15 B20B
6
14
8 7
9
10
13 11
12 S002206
1. Cab 10. Front wheel

2. Bin 11. Battery box
3. Exhaust stack 12. Hand rail
4. Bin tip cylinder 13. Headlights
5. Rear wheel 14. Front grille
6. Middle wheel 15. Bonnet
7. Middle axle 16. Pre-cleaner
8. Vent filter 17. Mirror
9. Cab access door 18. Windshield wiper
12 870966
October 17, 1997
Machine Lifting Points
The following figure details the machine lifting points.
Note: Ensure that the articulation safety bar is installed.
CRANE
B20B
CRANE
X000416
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October 17, 1997
Machine Tie Down Points
The following figure indicates the machine tie down points.
Note: Ensure that the articulation safety bar is installed.
B20B
X000417
14 870966
October 17, 1997
CHAPTER 2. OPERATOR CONTROLS AND INSTRUMENTS
Introduction
This chapter details the layout and operation of the controls and instruments in the B20B Articulated Dump Truck.
The main operator controls and instruments for the B20B are located in the cab.
The following figure details the layout of the controls and instruments in the cab for the B20B.
21 22 1 2 3
20
6
7
8
19
9
10
18
17
16
11
S002185
15 14 13 12
1. Steering wheel 12. Tip control lever

2. Main instrument panel 13. Operator’s seat
3. Steering wheel tilt adjustment lever 14. Document pocket
4. Engine stop control 15. Passenger seat (optional)
5. Digital display unit 16. Brake pedal
6. Gear shift lever 17. Electrical distribution box
7. Accelerator pedal 18. Indicator, lights and horn control
8. Inter-axle differential lock control 19. Bonnet catch release lever
9. Park brake lever 20. Cigarette lighter
10. Windscreen washer water bottle 21. Speedometer
11. Air conditioner (optional) 22. Main warning light/cold start panel
870966 15
October 17, 1997
The following figure details the controls and instruments on the main instrument panel (up to 15-11-96).
19 20 21 22 23 24 1 2 3 4 5 6 7
X P
LOCK-UP INTER-AXLE BEAM TRANSMISSION LOW COOLANT BRAKE ALT
ENGAGED DIFF LOCK OIL PRESSURE LEVEL CHARGE
8
18 Cels.
60
4 5 6 Cels.
50 10 3 7 80 100
2 3 4 40 120
80 100 120 2 8 1
5
50 150 0
QUARTZ 1 9 X100 kPa
40 20 0
0000 02 10
X100 kPa
30
TRANSMISSION OIL TEMP AIR PRESSURE ENGINE OIL PRESS ENGINE TEMP
HOUR METER
15 9
20
10
25
5 START
A 30
2 x100
REV/MIN
MAN/AUTO FAN INTERIOR LIGHTS WIPER HAZARD P/N 202154

LIGHT
17 16 15 14 13 12 11 10 S002089
1. Air pressure gauge 13. Headlight switch

2. Blank indicator insert 14. Tachometer
3. Low engine coolant level indicator 15. Interior light switch
4. Engine oil pressure gauge 16. Fan switch
5. Park brake indicator 17. Manual/automatic change over switch
6. Alternator charge indicator 18. Transmission oil temperature gauge
7. Right turn indicator 19. Left turn indicator
8. Engine temperature gauge 20. Lock-up engaged indicator
9. Master switch 21. Hour meter
10. Start button 22. Inter-axle differential lock indicator
11. Hazard indicator switch 23. Beam indicator
12. Windscreen wiper/washer switch 24. Transmission oil pressure indicator
16 870966
October 17, 1997
The following figure details the controls and instruments on the main instrument panel (from 16-11-96).
19 20 21 22 23 24 1 2 3 4 5 6 7
X P
EXHAUST INTER-AXLE BEAM TRANSMISSION LOW COOLANT BRAKE ALT
BRAKE DIFF LOCK OIL PRESSURE LEVEL CHARGE
8
60
Cels. 5 Cels.
18 50 10 3
4 6
7 80 100
2 3 4 40 120
80 100 120 2 8 1
5
50 150 0
QUARTZ 1 9 X100 kPa
40 20 0
0000 02 10
X100 kPa
30
TRANSMISSION OIL TEMP AIR PRESSURE ENGINE OIL PRESS ENGINE TEMP
HOUR METER
15
20
10
25
9
5
START
A 30
2 x100
REV/MIN
MAN/AUTO FAN INTERIOR LIGHTS WIPER HAZARD P/N 202154

LIGHT
17 16 15 14 13 12 11 10 S002099
1. Air pressure gauge 13. Headlight switch

2. Blank indicator insert 14. Tachometer
3. Low engine coolant level indicator 15. Interior light switch
4. Engine oil pressure gauge 16. Fan switch (optional)
5. Park brake indicator 17. Manual/automatic change over switch
6. Alternator charge indicator 18. Transmission oil temperature gauge
7. Right turn indicator 19. Left turn indicator
8. Engine temperature gauge 20. Exhaust brake indicator
9. Master switch 21. Hour meter
10. Start button 22. Inter-axle differential lock indicator
11. Hazard indicator switch 23. High beam indicator
12. Windscreen wiper/washer switch 24. Transmission oil pressure indicator
Note: The configuration of the face plates and symbols on the controls and instruments may vary slightly.
870966 17
October 17, 1997
The following figure details the main warning light/cold start panel.
! WARNING ! WARNING
ENGINE COOLANT ENGINE OIL
TEMPERATURE PRESSURE
2
ENGINE OVERSPEED
Reduce speed immediately!
TRANSMISSION BIN RAISED
OIL
TEMPERATURE
COLD START
EMERGENCY
STEERING
4
COLD START
203250
8
7
6 5 S002091
1. Main warning light 6. Blank switch insert

2. Cold start indicator (or insert) 7. Blank switch insert
3. Blank indicator insert 8. Cold start switch insert
4. Blank indicator insert 9. Engine overspeed indicator
5. Emergency steering indicator
18 870966
October 17, 1997
The following figure details the main warning light panel.
1 2
WARNING WARNING
HIGH ENGINE TEMPERATURE
LOW OIL PRESSURE
HIGH TRANSMISSION
TEMPERATURE
ENGINE OVERSPEED;
BIN UP
REDUCE SPEED IMMEDIATELY
203377
3 S002202
1. Engine overspeed warning light 3. Warning decal

2. Main warning light
870966 19
October 17, 1997
The following figure details the electrical distribution box front panel.
ELECTRICAL DISTRIBUTION
BOX B-SERIES ADT
CB7
20
IGNITION
INDEPENDENT SPARE
(BATT. DIRECT)
CB2 CB3 CB4 CB5 CB6
2
15 15 15 5 15
PARK LIGHTS HEADLIGHTS HOOTER TRANSMISSION TURN INDICATORS
HAZARDS DIP/BRIGHTS STOPLIGHTS AIR CONDITIONER
REVERSE LIGHTS BLOWER FAN
GAUGES WINDSCREEN WIPER
WIRING LIGHTS INTERIOR LIGHT
RETARDER
EXHAUST BRAKE
6 5 4 3 S002204
1. 20 amp circuit breaker (CB7) 4. 15 amp circuit breaker (CB4)

20 870966
October 17, 1997
Introduction Engine Oil Pressure Gauge
All the gauges, indicators, switches and controls
fitted to the B20B are described in this chapter.
Note: The configuration of the face plates on the

gauges may vary slightly.
Gauges 1 2 3 4
0 5
Air Pressure Gauge
X100 kPa
4 5 6
3 7
2 8 ENGINE OIL PRESS S002086
The engine oil pressure gauge is located on the main

1 9 instrument panel.
0 10
X100 kPa The gauge measures the engine oil pressure.
The table below details the relative engine pressures:
Minimum operating pre- 50 kPa (7 psi) @ 500

AIR PRESSURE sure rev/min
S002085
M a x i m u m o p e r a t i ng 250 to 600 kPa (36 to 87
The air pressure gauge is located on the main instru- pressure psi) @ 2 300 rev/min
ment panel.
Relief valve setting 250 kPa (36 psi)
The gauge measures the brake system air pressure.
The normal operation pressure is 810 kPa ± 20 kPa Engine Temperature Gauge
( 117 psi ± 3 psi ).
WARNING
Never operate the machine with low air pressure. Cels.
This may result in personal injury and/or death
and machine damage. 80 100
40 120
ENGINE TEMP S002087
The engine oil temperature gauge is located on the

main instrument panel.
870966 21
October 17, 1997
The gauge measures the engine oil temperature. Transmission Oil Temperature
The normal operating temperature is 95oC (203oF). Gauge
The maximum engine oil temperature must not ex-
ceed 120oC (248oF).
CAUTION Cels.
The maximum engine oil temperature must not
exceed 120oC (248oF) for longer than 3 minutes.
Operating the engine for longer periods will 80 100 120
cause serious engine damage. 50 150
Tachometer
15 TRANSMISSION OIL TEMP

20 S002082
10 The transmission oil temperature gauge is located
on the main instrument panel.
25
The transmission oil temperature gauge measures
5 the transmission oil temperature in degrees Celsius
(oC).
2 x100 30
REV/MIN The normal operating temperature is 80oC to 110oC
(176oF to 230oF).
The maximum temperature is 120oC (248oF).

S002084
The tachometer is located on the main instrument CAUTION

panel.
The machine must not be operated at maximum
temperature for more than 3 minutes. This will
The tachometer monitors the engine speed in revo-
cause serious damage to the transmission.
lutions per minute (rev/min).
A maximum engine speed of 2 300 rev/min must not

be exceeded.
CAUTION
A maximum engine speed of 2 300 rev/min must
not be exceeded or serious damage will be
caused to the engine.
22 870966
October 17, 1997
Hour Meter Warning Indicators (Red)
When the master switch is turned to the ON position
the following indicators illuminate:
60 • Main warning light.
• Transmission oil pressure indicator.

50 10
• Alternator charge indicator.
• Low coolant level indicator (illuminated for a

QUARTZ few seconds).
40 20
0000 02
• Park brake indicator.
30
• Inter-axle differential lock indicator.
Note: The symbols on the warning indicators may
HOUR METER vary slightly.
S002083
Main Warning Light
The hour meter is located on the main instrument
panel.
The gauge displays the service meter readings for

the machines operational life.
The gauge is used to determine the service intervals

for the machine.
Speedometer
40
km/h
20 60
0 80 F000352
The main warning light is located on the dashboard.
The main warning light illuminates to warn the opera-

tor of one or more of the following problems with the
S002090 machine:
The speedometer is located on the left side of the • High engine coolant temperature.
dashboard.
• High transmission oil temperature.
The speedometer monitors the machine speed in
kilometers per hour (km/h).
• Low engine oil pressure.
• Bin raised.
870966 23
October 17, 1997
If the main warning light illuminates, stop the ma- If the indicator illuminates and a warning buzzer
chine immediately and investigate the cause. sounds the machine engine speed must be reduced
immediately (below 2 300 rev/min) using the service
Note: If one or more of the following faults occur, brakes.
the respective warning indicator on the main instru-
ment panel will also illuminate when the main Note: The warning system is used to protect the
warning light illuminates. engine from excessive overspeeding, giving the en-
gine a longer operational life.
• High engine coolant temperature.
Transmission Oil Pressure Indicator
• High transmission oil temperature.
• Low engine oil pressure. 1

Note: If the main warning light illuminates to indicate
that the bin is raised, stop the machine immediately
and wait until the bin is fully lowered.
CAUTION
TRANSMISSION
Continued operation of the machine with the
main warning light illuminated will cause seri-
OIL PRESSURE
S002077
ous damage to the engine, transmission or the
bin. The transmission oil pressure indicator (1) is located
Engine Overspeed Indicator
The indicator illuminates to indicate low transmis-
sion oil pressure.
Note: The indicator illuminates briefly when a new

gear is selected (during normal operation).
If the indicator remains illuminated for more than a

few seconds the machine must be stopped and shut
down immediately and the cause investigated and
rectified.
CAUTION
Failure to check and rectify the cause of low
transmission oil pressure will cause serious
damage to the transmission.
Alternator Charge Indicator
1
F000354
The engine overspeed indicator is located on the

dashboard.
The indicator illuminates and a warning buzzer ALT

sounds when the engine speed exceeds 2 800
rev/min. CHARGE
S002080
Note: The engine rev limiter automatically activate The alternator charge indicator (1) is located on the
when the engine speed exceeds 2 800 rev/min. main instrument panel.
24 870966
October 17, 1997
The indicator illuminates when the alternator is not The indicator illuminates when:
charging the battery.
• The park brake is applied.
When the indicator illuminates the cause must be
investigated and rectified immediately. • The hold-off pressure in the park brake
actuators drops below 450 kPa (65 psi),
allowing the park brakes to drag.
CAUTION
Failure to check and rectify the cause of the Inter-axle Differential Lock Indicator
alternator charge indicator illuminating will result
in battery failure.
1
Low Coolant Level Indicator
1 X
P INTER-AXLE
DIFF LOCK
BEAM
S002075
LOW COOLANT BRAKE The inter-axle differential lock indicator (1) is located
LEVEL S002078
The low coolant level indicator (1) is located on the The indicator illuminates when the inter-axle differen-
main instrument panel. tial lock is engaged.
The low coolant level indicator illuminates when the Cold Start Indicator
engine coolant is low.
Note: The low coolant level indicator will illuminate

for a few seconds when the master switch is turned 1
to the ON position.
CAUTION
When the indicator illuminates the machine must
be stopped and shut down immediately and the COLD START
cause investigated and rectified, or serious dam-
age to the engine will result. S002093
Park Brake Indicator The cold start indicator (1) is located on the main
warning light/cold start panel.
Note: The cold start function on the machine is

1 automatic when the outside temperature is below
15oC (59oF).
When the outside temperature is below 15oC (59oF)

P and the master switch is moved to the ON position
the cold start indicator illuminates.
LOW COOLANT BRAKE

CAUTION
LEVEL S002079
Do not start the engine until the cold start indica-
tor goes off. Starting the engine when the tem-
The park brake indicator (1) is located on the main perature is below 15oC (59oF) will cause serious
instrument panel. damage to the engine.
870966 25
October 17, 1997
When the cold start indicator goes off the machine Beam Indicator
can be started.
Confirmation Indicators (Blue or 1

Green)
Note: The symbols on the confirmation indicators
may vary slightly. X
Left Turn Indicator
INTER-AXLE BEAM
DIFF LOCK
S002076
1
The beam indicator (1) is located on the main instru-
ment panel.
The indicator illuminates when the main beam is

selected when the the indicators, lights and horn
switch is moved downwards.
LOCK-UP
ENGAGED Right Turn Indicator
S002073
The left turn indicator (1) is located on the main

instrument panel. 1
The indicator flashes when the indicator, lights and
horn switch is moved towards the operator for a left
turn.
Lock-up Engaged Indicator (up to

15-11-96) ALT
CHARGE
S002081
1 The right turn indicator (1) is located on the main

instrument panel.
The indicator flashes when the indicator, lights and

horn switch is moved away from the operator for a
right turn.
LOCK-UP Exhaust Brake Indicator (from

ENGAGED 16-11-96)
S002074
The lock-up engaged indicator (1) is located on the 1

The indicator illuminates when the transmission

lock-up is engaged.
EXHAUST
BRAKE
The exhaust brake indicator (1) is located on the

26 870966
October 17, 1997
The indicator illuminates when the exhaust brake is The purpose of the manual/automatic change over
activated. switch is to change the transmission operation from
manual powershift mode to full automatic mode.
To operate the exhaust brake the accelerator pedal
must be released Note: The switch has two positions:
Note: The exhaust brake is automatically activated Manual powershift mode. Switch in the normal
when the accelerator pedal is released. (up) position.
Digital Display Unit Fully automatic mode. Switch in the down posi-
tion
Refer to Gear Changing in the Operating Tech-

niques for the operating procedures.
Fan Switch (if fitted)
F000353
A
The digital display unit is located on the right side of

the dashboard.
MAN/AUTO FAN INTERIOR
LIGHT
The purpose of the digital display unit is to display the
transmission current operation mode and the current S002068
gear selected. Refer to Gear Shifting in the Operat-
ing Techniques, for the digital display unit operation. The fan switch (1) is located on the main instrument
panel.
Switches
Note: The switch has two positions:
Manual/Automatic Change Over
OFF. Switch in the normal (up) position.
Switch
ON. Switch in the down position.
1

LIGHT
S002067
The manual/automatic change over switch (1) is

located on the main instrument panel.
870966 27
October 17, 1997
Interior Light Switch Windscreen Wiper/Washer Switch
1 1
MAN/AUTO FAN INTERIOR LIGHTS WIPER HAZARD

S002071
LIGHT
S002069
The windscreen wiper/washer switch (1) is located
The interior light switch (1) is located on the main
instrument panel. Note: The switch has three positions:
Note: The switch has two positions: OFF. Switch in the normal (up) position.
OFF. Switch in the normal (up) position. ON. Switch in the central position.
ON. Switch in the down position. Windscreen washer water pump. Switch in the
down position is to activate the pump.
Headlight Switch Note: The switch is spring-loaded to the central
position from the washer position.
1 Hazard Indicator Switch
LIGHTS WIPER HAZARD

S002070
The headlight switch (1) is located on the main

instrument panel. LIGHTS WIPER HAZARD
S002072
Note: The switch has three positions.

The hazard indicator switch (1) is located on the
OFF. Switch in the normal (up) position. main instrument panel.
Side lights ON. Switch in the central position. Note: The switch has two positions.
All lights ON. Switch in the down position. OFF. Switch in the normal (up) position.
ON. Switch in the down position.
28 870966
October 17, 1997
Master Switch and Start Button CAUTION
OFF Do not hold the start button down and operate the
starter motor for more than seventeen seconds.
ON If the engine does not start, wait for one minute
1 before attempting to restart the engine. If the
engine does not start after two attempts, investi-
gate and rectify the cause.
CAUTION
Do not continually operate the start button when
START the battery is flat. This causes damage to the
starter motor.
2
Air Conditioner (Optional)
P/N 202154
4 1
S002088
The start button (1) and master switch (2) are located
Note: The master switch is key operated and is a two

position switch.
OFF. 2
3
ON. F000166
The key is inserted and turned clockwise to the ON The air conditioner switch panel is located on the air
position. conditioner on the right side of the cab.
When the master switch (2) is in the ON position the The air conditioners switches and levers control the
following indicators illuminate: following functions:
• Main warning light. Switch (1) controls the air conditioner unit func-
tions. The lever has 2 positions:
• HEAT (heater).
• Alternator charge indicator.
• AC (air conditioner).
• Low coolant level indicator (illuminated for a Lever (2) controls the air flow in the cab. The
few seconds).
lever has two positions:
• Park brake indicator. • FRESH. This allows fresh air (from outside the
cab) to be circulated into the cab.
• Digital display.
The start button (1) is a push button switch located
• RECRC (re-circulate). This re-circulates the air
inside the cab.
to the left of the master switch.
Lever (3) controls the temperature in the cab.
The start button is operated by pushing down to start
the engine, when the master switch is in the ON
position. • The temperature is decreased when the lever
is moved towards the COOL position.
Note: The start button is spring-loaded to the up
position. • The temperature is increased when the lever
is moved to the HOT position.
870966 29
October 17, 1997
Lever (4) controls the air conditioner fan speed. Battery Disconnect Switch
The lever has four positions:
Note: Machines are fitted with a battery disconnect
• OFF switch and a 60 amp battery circuit breaker in the
battery box or only a 60 amp battery circuit breaker,
• LOW depending upon specific requirements.
• MED
• HIGH
Kick Down Switch
F000356
The battery disconnect switch is located inside the

battery box.
Note: Move the battery disconnect switch to the

OFF position when the machine is shut down or
when the batteries are to be removed from the
machine.
F000355 The battery disconnect switch is a two position rotary

type switch. The switch is operated as follows:
The kick down switch is located under the accelera-
tor pedal.
Turn the switch counter-clockwise to the OFF
position to disconnect the battery.
To activate the kick down switch the accelerator
pedal must be pressed down firmly.
Turn the switch clockwise to the ON position to
connect the battery.
The switch is used when a lower gear is required
while using the automatic transmission operation
mode.
CAUTION
Do not leave the battery disconnect switch in the
ON position when the machine is shutdown.
This will cause the battery to discharge and may
cause damage to the battery.
30 870966
October 17, 1997
Battery Circuit Breaker • CB7 (20 amp): Spare S(this circuit breaker
should be used when installing accessories,
such as a radio. Remember that the machines
electrical system is 24 V.
2
1 Indicators, Lights and Horn Control
2 4
F000492
A 60 amp circuit breaker (1) is located inside the 1

3
battery box.
The purpose of the circuit breaker is to protect the

F000357
machines electrical installation from a possible fault
and/or overload condition. The indicators, lights and horn control is a stalk switch
located on the steering column.
Located above the circuit breaker, on the same
mounting bracket, is the ignition solenoid (2). The operation of the switch is as follows:
Electrical Distribution Box • To indicate a left turn move the switch towards
(1) the operator.
• To indicate a right turn move the switch away

(2) from the operator.
• For high beam head lights move the switch

downwards (3).
• To dip the head lights move the switch upwards

(4).
• To operate the horn push the end (5) of the

F000493
switch.
The electrical distribution box is located below the

dashboard on the left side of the cab.
The electrical distribution box comprises six circuit

breakers which provide electrical overload protection
for the following:
• CB2 (15 amp): Ignition, park lights and hazard

warning lights.
• CB3 (15 amp): Headlight, including high beam.
• CB4 (15 amp): Horn, stop lights, reverse lights,

gauges, wiring lights and exhaust brake.
• CB5 (5 amp): Transmission.
• CB6 (15 amp): Turn indicators, air conditioner,

blower fan, windscreen wiper and interior light.
870966 31
October 17, 1997
Controls Engine Stop Control
Steering Wheel
F000358
The steering wheel is turned clockwise or counter-

clockwise to make the machine articulate to the left
or to the right. F000360
When the steering wheel is turned, hydraulic fluid is The engine stop control is located on the right side
passed to the two hydraulic steering cylinders at- of the dashboard.
tached across the articulation assembly.
The control is pulled to shut down the engine.
Note: There is no self-centring action on the steer-
ing. The machine must be returned to the straight Note: Ensure the control is pushed in fully once the
ahead position by turning the steering wheel. engine is shut down completely.
Accelerator and Brake Pedals

CAUTION
If there is an engine failure, the steering requires
numerous turns of the steering wheel to turn
from lock to lock. If the engine fails the machine 2
must be stopped immediately.
F000361
The accelerator pedal (1) and brake pedal (2) are

located on the cab floor.
Both pedals are treadle type and are spring-loaded

to the up position.
32 870966
October 17, 1997
Gear Shift To operate the park brake, proceed as follows:
To release the park brake pull the lever up and

move it forward to the RELEASE position.
To apply the park brake move the lever back-

wards to the APPLY position.
Note: When the park brake lever is in the APPLY

position the park brake indicator on the instrument
panel illuminates.
WARNING
After releasing the park brake the operator must
wait until the air pressure has returned to normal
operating pressure (810 kPa {117 psi}) before
driving off. This prevents the machine from being
driven with the park brake applied because of low
air pressure.
Note: The TEST position is functional depending on

the brake system installed in the machine. Refer to
F000362 Park Brake Holding Test in Basic Preventive
Maintenance for the test procedure.
The gear shift is located on the right side of the cab.
To select any of the gears the gear shift lever must Tip Control Lever
be moved forward and then to the right or to the left.
Refer to Gear Shifting in the Operating Techniques
for the correct gear shifting procedures.
All selected gears will be indicated on the digital

display unit.
When reverse gear is selected, the reverse light/s

illuminate/s and a warning buzzer sounds at the rear
of the machine.
Park Brake
F000364
The tip control lever (1) is located on the cab floor to

the right of the operator’s seat.
F000363 To operate the tip control, proceed as follows:
The park brake lever is located on the right side of To tip the bin the tip control lever must be moved
the cab. backwards.
To lower the bin the tip control lever must be

moved forwards.
870966 33
October 17, 1997
Note: The tip control lever is spring-loaded to the Operator’s Seat
central (holding) position.
The operator’s seat is fully adjustable to suit an
Inter-axle Differential Lock Control operator’s individual height, weight and reach.
The seat is adjusted as follows:
Back Rest Adjustment
F000365
The inter-axle differential lock control is located on

the right side of the cab.
F000175
CAUTION The back rest adjuster alters the angle of the seat
The inter-axle differential lock control must not back rest.
be engaged when the machine is moving.
The back rest adjustment levers (1) are located on
the left and right side of the back rest.
CAUTION
The back rest adjustment levers are spring-loaded
The inter-axle differential lock control must only to the lock position.
be used when the ground conditions are very
poor and must not be used on graded or tar To adjust the back rest, proceed as the follows:
surfaces.
Press and hold the adjustment lever (1) to
To operate the control, proceed as follows: release the lock.
To engage the inter-axle differential lock the Push or pull the top of the back rest to the
control must be turned counter-clockwise to required angle and then release the lever to
the IN position. enable the lock to engage into the selected
notch.
To disengage the inter-axle differential lock the
control must be turned clockwise to the OUT
position.
Note: When the inter-axle differential lock is en-

gaged the inter-axle differential lock indicator on the
main instrument panel illuminates.
Refer to Operating with Inter-axle Differential

Locks in Operating Techniques for the correct
operating procedures.
34 870966
October 17, 1997
Squab Height and Slope Adjustment The weight adjustment lever allows the seat suspen-
sion to be adjusted.
To adjust the seat suspension, proceed as follows:
Soften
Pull and then turn the lever until the minus

symbol (-) is facing up.
Move the lever up and down until the required

1 adjustment is obtained.
Harden
F000082
Pull and then turn the lever until the plus symbol
The seat squab height and slope adjustment lever is (+) is facing up.
located at front below the seat.
Move the lever up and down until the required
The seat squab height and slope adjustment lever (1) adjustment is obtained.
allows the seat squab tilt to be adjusted.
Weight Adjustment Indicator
To adjust the seat squab tilt, proceed as follows:
Pull and hold the adjustment lever (1) up to release

the squab lock.
Lift or lower the squab tilt until the required

height is reached and then release the lever to
enable the lock to engage into the selected A B
notch. C
To adjust the rear slope of the squab, proceed as 1

follows:
Firmly grip the rear of the squab.
Raise or lower the rear of the squab until the

required height is reached, allowing the lock to F000174
engage into the selected notch.

The weight adjustment indicator (1) is located on the
left side of the seat below the back rest adjustment
Weight Adjustment Lever lever.
The weight adjustment indicator (1), indicates the

seat suspension adjustment to the operator’s weight.
• When the seat suspension is hard the indicator

will move forward (A).
• When the seat suspension is soft the indicator

will move backwards (B).
• When the correct suspension is reached the

indicator will be level with the plate (C).
The weight adjustment lever is located on the right

side of the seat.
870966 35
October 17, 1997
Backwards and Forwards Adjustment Seat Belt
1 3
F000083
The backwards and forwards adjustment lever is

located at front below the seat.
The slide adjuster (1) allows the seat to be moved

closer to or further away from the steering wheel.
To move the seat, proceed as follows:

2
Pull and hold the lever up.
Move the seat towards or away from the steer- A fully adjustable, lap strap seat belt is an integral
ing wheel until the required position is reached. part of the seat.
Release the lever. The seat belt is designed to fit firmly across the front
of the pelvis.
Arm Rests
Fastening
Firmly push the buckle (1) into the fixed clasp (2)
until it clicks into position and ensure that the con-
nection is secure.
Releasing
Press the red push button (3) down on the fixed
clasp and remove the buckle.
WARNING
f000209
Always wear a seat belt when operating the
The arm rests may be lifted to allow easier access machine. In an accident it may save your life.
to the seat and then lowered for driver comfort.
WARNING
Check the condition of the seat belt and mount-
ing hardware before operating the machine. Re-
place the seat belt at least every three years,
regardless of the condition.
36 870966
October 17, 1997
Seat Belt Adjustment Wait until a “click” is heard.
When fastened, the seat belt may be adjusted as Remove the lighter from the housing.
follows:
Shorten WARNING
Do not touch the front of the lighter when remov-
Hold the buckle in your right hand in front of you and ing if from the housing. This will cause a serious
pull the free end of the belt across to the left. burn.
Lengthen The lighter housing can be used as a 24 V power

supply point.
Hold the buckle in your right hand, tilt to be at right
angles to the belt and pull across to the right.
To use the housing as a power point, proceed as
follows:
Miscellaneous Equipment
Remove the lighter from the housing and store
Bonnet Catch Release Lever in a safe place.
Place the 24 V accessory plug into the housing

and use.
When the accessory is no longer required re-

place the lighter into the housing.
Ashtray
F000366
The bonnet catch release lever is located on the left

side of the dashboard.
When the lever is pulled the bonnet catch is released.
Note: When the bonnet catch is released the lever

F000368
must be pushed in fully.
The ashtray is located on the left side of the dash-
Cigarette Lighter board.
To open or close the ashtray, proceed as follows:
To open the ashtray pull the top.
To close the ashtray push the top.
To empty the ashtray, proceed as follows:
Open the ashtray.
Push down on the lid and pull the ashtray out.
F000367 Note: If the ashtray is permanently fitted to the hous-

ing it must be emptied into another container.
The cigarette lighter is located on the left side of the
dashboard. To replace the ashtray, proceed as follows:
To operate the cigarette lighter, proceed as follows: Place the bottom of the ashtray against the
housing.
Press the lighter push button in and release.
870966 37
October 17, 1997
Firmly push the ashtray down and in until it is Wheel Spanner and Brace
closed.
A wheel spanner and brace are located in the cab,
Document Pocket below the operators seat and are secured in position
by two plates.
Interior Light
F000369
f000504
The document pocket is located behind the opera-
tor’s seat on the left side of the cab. The interior light is located in the top right corner of
the cab.
The document pocket is used as a storage compart-
ment for the machine PM Pack, which comprises an Passenger Seat (Optional)
Operator Manual and Parts Manual.
Windscreen Washer Water Bottle
F000370
The windscreen washer water bottle is located un-

der the dashboard on the left side of the cab or on
the right side of the cab below the park brake
mounting plate.
To refill the windscreen washer water bottle, pro-

ceed as follows:
Remove the bottle filler cap.
Refill the bottle with clean water and window

cleaning agent. Re-fit the bottle filler cap. The passenger seat is located on the left side of the
operator’s seat.
The seat is not adjustable and is equipped with a

seat belt.
38 870966
October 17, 1997
The seat belt for the passenger is fastened, released
and adjusted in the same way as the operator’s seat WARNING
belt. Check the condition of the seat belt and mounting
hardware before traveling in the passenger seat.
Replace the seat belt at least every three years,
WARNING regardless of the condition.
Always wear a seat belt when traveling as a
passenger in the machine. In an accident it may
save your life.
870966 39
October 17, 1997
40 870966
October 17, 1997
CHAPTER 3. OPERATING TECHNIQUES
Safety Instructions Walk Round Check
Before Operating the machine the following safety The Walk Round Check must always be carried out
instructions must be observed. before operating the machine. The check is started
on the right side of the machine and is continued in
Read and fully understand this manual, before you a clockwise direction around the machine.
start operating the machine.
It is recommended that the machine is thoroughly
Never operate the machine while under the influence washed before starting the Walk Round Check.
of alcohol, medication or any other drugs.
Engine
Wear the required protective clothing for safe ma-
chine operation. Check the engine, hoses, sump and injectors for
damage, leaks and security.
When mounting or dismounting the machine always
face the machine and use the hand rails and steps Check the engine oil level.
provided. Always use both hands and one foot or one
hand and both feet. Never jump off the machine. Drain the water from the primary fuel filter/water trap.
The cab has 2 exit points, which are as follows:- Check the air cleaner indicator. If the indicator indi-
cates red the filter must be cleaned.
• The cab access door (for normal access and
exiting of the cab). Check the pre-cleaner bowl dirt level. If the dirt has
reached the full mark the bowl must be cleaned.
Running-in Instructions
Check engine mountings for damage and security.
The machine’s run-in period is the First 100 SMR of
operation. The machine MUST be serviced at 100 Transmission
SMR to ensure maximum machine service life.
Check the transmission sump for damage, leaks and
The 100 SMR service MUST ONLY be done by BELL security.
Service Personnel.
Check the transmission oil level.
Procedures Before Starting
Check the transmission mountings for damage and
security.
Safety Rules
Operator Duties Axles and Wheels

Check all the axles for damage, leaks and security.
The operator must know the rules and safety aspects
of the site. The operator must study the following
Check all the final drives for damage, leaks and
rules and become aware of how to avoid serious
security.
injury and/or machine damage.
Check the brake fluid level in the reservoirs.
It is the operator’s duty to report all damage and wear
which may endanger the operator or cause damage
Check all brake calipers for wear and security.
to the machine.
Check the tyres for damage and pressure.
Only trained personnel may operate the machine.
Check that a “DO NOT OPERATE” tag is not at- Hydraulics

tached to the steering wheel. If the tag is attached,
do not operate the machine. Check the hydraulic fluid level.
Complete the Walk Round Check. If any defects are Check all hoses, cylinders and components for dam-
found, do not operate the machine. Attach the “DO age, leaks and security.
NOT OPERATE” tag to the steering wheel and re-
move the machine key.
870966 41
October 17, 1997
Pneumatic Ensure the battery disconnect switch is turned
ON (if fitted).
Drain any water from the pneumatic reservoirs.
Ensure the park brake is applied.
Check all hoses, reservoirs and components for
damage, leaks and security. Ensure the gear shift is in the neutral position.
Note: The engine cannot be started when any gear

Electrical is selected.
Check all electrical wires for cuts and security. Push the engine stop control in fully.
Check all electrical components for operation and
security. OFF
ON
Check the batteries for damage and leaks.
2
Frame and Body
Check all the frame and body components for dam-
age and security.
Starting START
Safety Rules 1
Passengers are only allowed on machines provided
with a passenger seat and with approval by site
P/N 202154
management.
S002088
Always wear the seat belt when operating the ma-
chine. Insert the machine key into the master switch
(1).
Check that the mirrors are correctly positioned for
the best visibility. Turn the master switch clockwise to the ON
position and check that the following indicators
Check that no personnel are near the machine. illuminate:-
Starting the Engine • Main warning light.
Before Starting the Engine • Transmission oil pressure indicator.
Adjust the operator’s seat for the best operator • Alternator charge indicator.
comfort and easy access to the machine controls.
Refer to Operator’s Seat in Operator Comfort. • Park brake indicator.
Fasten the seat belt and adjust the seat belt to fit • Inter-axle differential lock indicator.
firmly across the front of the pelvis. Refer to Opera-
tor’s Seat in Operator Comfort.
CAUTION
When starting in cold weather (below 15oC {59oF})
If any of the indicators do not illuminate then
ensure the coolant freezing point corresponds to the
either the bulb is blown or there is an electrical
weather conditions. Refer to the Recommended
fault. The fault must be rectified immediately.
Lubricants Chart.
Press the accelerator pedal approx. 1 quarter
Starting the Engine in Warm Weather of its travel.
Starting the engine in warm weather does not re-

quire any special procedures. To start the engine
the following must be done:-
42 870966
October 17, 1997
Insert the machine key into the master switch
CAUTION (1).
Do not run the engine at high speed (rev/min) or
heavy loading until the engine oil, transmission Turn the master switch clockwise to the ON
oil and hydraulic oil have warmed up to normal position and check that the following indicators
operating temperatures. illuminate:-
Press the start button (2) until the engine starts. • Main warning light.

CAUTION
Do not hold the start button in the start position • Alternator charge indicator.
for more than seventeen seconds. If the engine
does not start, wait one minute before attempting • Park brake indicator.
to restart the engine to allow the battery to stabi-
lise. If the engine does not start after two at- • Inter-axle differential lock indicator.
tempts investigate the cause.
• Cold start indicator will also illuminate.
Starting the Engine in Cold Weather
Note: The cold start function of the machine is auto-
matic. The cold start function will only operate when
CAUTION the outside temperature drops below 15oC (59oF).
In extremely cold weather the transmission must Wait until the cold start indicator goes off (ap-
be allowed to warm up before operation. Allow prox. 20 seconds).
the engine to idle idle for fifteen to twenty minutes
before the machine is operated. Press the accelerator pedal approx. 1 quarter of
its travel.
To start the engine in cold weather the following must
be done:-
CAUTION
Ensure the battery disconnect switch is turned
ON (if fitted). Do not run the engine at high speed (rev/min) or
heavy loading until the engine oil, transmission
Ensure the park brake is applied. oil and hydraulic oil has warmed up to the normal
operating temperature.
Ensure the gear shift is in the neutral position.
Press the start button (2) until the engine starts.
Note: The engine can only be started with the gear
shift in the neutral position.
CAUTION
Push the engine stop control in fully. Do not hold the start button in the start position
for more than 17 seconds. If the engine does not
OFF start, wait 1 minute before attempting to restart
the engine to allow the battery to stabilise. If the
ON engine does not start after 2 attempts investigate
2 the cause.
Shutting Down the Engine

To shut down the engine the following must be done:-
Stop the machine in the straight ahead position.

START Refer to Braking for the correct procedure for
stopping the machine.
1
Apply the park brake.
Move the gear shift to the neutral position.

P/N 202154
S002088
870966 43
October 17, 1997
Note: It is recommended that after changing gears
CAUTION the gear shift is released.
Never stop the engine from high idle. This will
cause damage to the turbochargers and the en- Gear Shifting Safety Functions
gine.
The inhibitor will not allow a lower gear to be se-
Allow the engine to run for 2 minutes to allow lected until the engine speed has been reduced
the turbochargers to slow down and the engine sufficiently to prevent overspeeding of the transmis-
temperature to stabilise. sion.
Turn the master switch counter-clockwise to CODE 10 Warning

the OFF position.
Pull the engine stop control up and hold it in

this position until the engine has stopped.
Push the engine stop control in fully
Remove the machine key.
If the machine is stopped overnight ensure the

battery disconnect switch is turned to the OFF
position.
Moving
f000542
Safety Rules
Check that all the gauges and indicators are opera-
tional. Ensure the readings are correct. Refer to
WARNING
Operator, Controls and Instruments for the cor- If the digital display unit shows a CODE 10, the
rect readings. machine must be stopped immediately, as seri-
ous damage and/or injury may result.
Wait until there is sufficient air pressure (810 kPa
{117 psi}) before driving the machine. Note: When the master switch is turned to the ON
position before operating the machine, the transmis-
Check that there are no personnel on or around the sion will do a self diagnosis.
machine before driving the machine.
If the digital display unit shows a flashing spanner
Gear Changing the following must be done:-
Note: Do not move the shift lever to the neutral

CAUTION position while the machine is still moving.
Do not allow the machine to free wheel as this
Stop the machine immediately.
will cause damage to the transmission from lack
of lubrication.
Shutdown the engine.
The machine transmission has 6 forward gears and
If the digital display unit shows a CODE 10 and
3 reverse gears with automatic lock-up for all gears.
a flashing spanner, consult your BELL Product
The transmission can be operated as a fully auto-
Support Representative for further advice.
matic transmission or a manual powershift
transmission.
Gear Changing in Manual
The automatic or manual powershift selection is Powershift Mode
done via the automatic/manual change over switch.
Gear changing is dependent on engine speed
Note: Transmission function (manual powershift or (rev/min) and operating (site) conditions.
automatic) is dependent on operator choice.
For manual powershift operation the the following
When changing gears it is recommended that the must be done:-
accelerator is eased slightly to minimise shock load-
ing to the transmission. Start the machine.
44 870966
October 17, 1997
Ensure that park brake is applied. As the machine speed increases, decrease the
engine speed slightly and move the gear shift
(sequentially) to the next gear.
1
Increase engine speed until the next gear is
required.
All selected forward gears will be indicated on the

digital display. The selected gears will be indicated
as follows:-

LIGHT
S002067
Neutral
Move the automatic/manual change over switch
to the manual operation position.
Apply the service brake.
Forward Selection
1st Gear 4th Gear
6th 5th
4th
3rd
2nd
1st
6th 2nd Gear 5th Gear

5th
4th
3rd
3rd
2nd
2nd
N1
1st 1st
NN S002059 3rd Gear 6th Gear S002094
Move the gear shift from the neutral position to To change to a lower gear, decrease the engine
1st forward position. speed and move the gear shift to the next lower
gear (e.g. from 5th gear to 4th gear).
Release the park brake.
Release the service brake and increase the

engine speed (rev/min).
870966 45
October 17, 1997
Reverse Selection To change to a lower reverse gear, decrease
the engine speed and move the gear shift to
the next lower position.
3rd
2nd
1st
CAUTION
Do not continually move the gear lever from 1st
forward to 1st reverse as this will cause damage
to the transmission.
6th
5th Gear Changing in Automatic Mode

4th
3rd Gear changing is dependent on engine speed
3rd
(rev/min) and operation (site) conditions. All normal
2nd
2nd gear shifting will be controlled by the machine’s
N1
1st 1st electronic control unit.
NN S002059
For automatic operation the the following must be
done:-
Move the gear shift from the neutral position to
1st reverse position. Start the machine.
Release the park brake. Ensure that park brake is applied.
Release the service brake and increase the Move the automatic/manual change over
engine speed (rev/min). switch to the automatic operation position.
As the machine speed increases, decrease the Apply the service brake.
engine speed slightly and move the gear shift
(sequentially) to the next gear. Forward Selection
Increase engine speed until the next gear is Move the gear shift from the neutral position to
required. the 4th gear position.
All selected reverse gears will be indicated on the Release the park brake.
digital display. The selected gears will be indicated
as follows:- Release the service brake and increase the
engine speed (rev/min).
Note: Gear changing will start from 1st gear.
As the engine speed increases the transmis-

sion will select the next gear up (sequentially).
When the gear shift is moved to the forward posi-

tions the transmission will select the following
Neutral gears:-
• 1st gear is first gear only.
• 2nd gear is second gear only.
• 3rd gear is third gear only.

1st Gear 2nd Gear • 4th gear is the normal driving gear and the
transmission will start selecting from 1st gear
and sequentially change gear to a maximum
of 4th gear.
3rd Gear S002096
46 870966
October 17, 1997
• 5th gear is the driving gear for medium traveling Braking
distances. The transmission will start selecting
from 2nd gear and sequentially change gear to
a maximum of 5th gear.
Retarder
Note: The retarder system is fully automatic and will
• 6th gear is the driving gear for long traveling be activated when the accelerator pedal is released
distances. The transmission will start selecting and the transmission is in lock-up.
from 2nd gear and sequentially change gear to
a maximum of 6th gear.
Service Brakes and Park Brakes
All selected forward gears will be indicated on the During normal operation the machine must be
digital display. The selected gears will be indicated stopped using the service brakes. When the machine
as follows:- is stopped for more than a few seconds the park
brake must be applied.
Service Brakes
WARNING
Excessive use of the service brakes will result in
the brake assembly overheating which may
Neutral cause a brake assembly fire.
CAUTION
Avoid using the service brake for long periods as
this causes unnecessary wear of the brake pads.
1st Gear 1st to 4th Gear (Auto)
Stopping the machine with the service brakes is done
as follows:-
Release the accelerator.
Note: When the accelerator is released the retarder

will be activated, while the transmission is in lock-up.
2nd Gear 2nd to 5th Gear (Auto)
While driving the machine normally the brake
pedal must be pressed.
When the machine has come to a full stop, the

gear shift must be moved to the 1st position.
3rd Gear 2nd to 6th Gear (Auto) Release the brake pedal and drive off.
Note: If a lower gear is required the transmission Note: It the transmission is in automatic mode the
control unit will select the lower gear. No downshifting lowest pull off gear will automatically be selected by
of the gear shift is required. the transmission.
The inhibitor will not allow a lower gear to be selected Park Brake
until the engine speed has been reduced sufficiently
to prevent overspeeding of the transmission. Note: The park brake must only be applied when the
machine is completely stationary.
Reverse Selection
When the machine is to be stopped for more than a
Note: Reverse selection is not automatic, the reverse few seconds the following must be done:-
gears must be selected manually. Refer to Gear
changing in Manual Powershift mode. Stop the machine using the service brake.
870966 47
October 17, 1997
Inter-axle Differential Lock Control
The machine operation with the inter-axle differen-
tial lock is as follows:-
Stop the machine before entering poor ground

conditions.
Turn the differential lock control counter-clock-

wise to the IN position.
F000363
• The inter-axle differential lock indicator will

Apply the park brake by moving the park brake illuminate.
control towards the operator.
Move the gear shift to the 1st position.
Release the service brake.
Drive off slowly changing gears when required.
Operating with Inter-axle
When the ground conditions improve the inter-axle
Differential Locks differential lock must be disengaged. To disengage
the inter-axle differential lock the following must be
Note: It is recommended that the inter-axle differen-
done:-
tial locks are only engaged when the machine is
operating on very poor ground conditions. The dif-
Stop the machine when on the improved
ferential locks must not be engaged when the
ground surface.
machine is operating on tar or graded surfaces.
Turn the differential lock clockwise to the OUT

position.
• The inter-axle differential lock indicator will go

off.
Drive off slowly changing gears when required.
F000365
Loading
The inter-axle differential lock control operates the Safety Rules
differential lock in the transmission.
Ensure there is sufficient space for the machine
When ground conditions are poor the inter-axle before entering confined areas.
differential lock must be used.
Ensure that no personnel are near the machine or
loading area.
CAUTION
The differential locks must not be engaged when Do not operate too close to quarry edges, ramp
the machine is moving. This will cause damage edges, quay edges and soft edges that may col-
to the differentials. lapse under the machine’s weight.
48 870966
October 17, 1997
Be aware of other machines and personnel when Raising the Bin
entering or leaving the loading area.
To raising the bin the following must be done:-
If a spotter is present follow only his instructions.
Position the machine straight for dumping.
Stop the machine on a firm level surface.
Do not exceed the rated capacity of the machine.
Ensure the machine is loaded evenly. An uneven
load will cause tyre and axle damage. To raise the bin increase the engine speed to
approx. 1 500 rev/min, move the tip control lever
Loading the Machine towards the rear of the cab and hold in position
until the bin is almost to maximum travel.
When loading the machine the following must be
done:- Reduce engine speed as the bin reaches maxi-
mum travel.
Position the machine straight for loading.
Release the tip control lever.
Note: The tip control lever is spring-loaded to the
Move the gear shift to the neutral position. central position (holding position).
When the loading operator signals that the bin is fully Lowering the Bin
loaded the following must be done:-
To lower the bin the following must be done:-
Move the tip control lever towards the front of
Release the park brake and drive off slowly. the cab and hold in position until the bin is fully
lowered
Dumping
Release the tip control lever.
Safety Rules Move the gear shift to the 1st position.
Ensure there is sufficient space for the machine
before entering confined areas. Release the park brake and drive off slowly.
Do not operate too close to quarry edges, ramp Note: The tip control lever is spring-loaded to the
edges, quay edges and soft edges that may collapse central position (holding position).
under the machine weight.
Steering
Never drive the machine while the bin is raised.
Normal Steering
When raising the bin ensure that when the bin is fully
raised it is no less than 4 metres away from any power The machine’s normal steering system is operational
lines. when the engine is operating. To steer the machine
the following must be done:-
Ensure that no personnel are near the machine or
dumping area.
Be aware of other machines and personnel when

entering or leaving the dumping area.
If a spotter is present follow only his instructions.
Do not stop too close to soft edges that may collapse

under the machine’s weight when dumping into an
excavation site. The use of stopping chocks or other
safety devices is recommended.
Do not drive off until the bin is fully lowered.

F000358
870966 49
October 17, 1997
Turn the steering wheel counter-clockwise to Always chock the machine before releasing the
turn the machine left. brakes and/or disconnecting the propshafts.
Turn the steering wheel clockwise to the turn Only use a rigid tow bar preferably an A-frame.
the machine right.
Ensure the tow bar is strong enough to tow a ma-
chine at least 1.5 times the gross weight of the
WARNING towing machine when towing from mud or on a
There is no self-centering function on the ma- grade.
chine steering. The machine must be straight-
ened by turning the steering wheel to the Never exceed 2 km/h (1 to 2 mph) when towing a
straight ahead position. disabled machine for short distances.
Load a disabled machine onto a suitable breakdown

WARNING vehicle or remove the propshafts between the trans-
mission and drop box when moving it long distances.
If there is an engine failure the steering requires
numerous turns of the steering wheel from lock Shielding must be provided on the towing machine
to lock. If the machine is not fitted with an emer- and the disabled machine if the operator can be
gency steering system, the machine must be injured due to the tow bar breaking.
stopped immediately.
Do not allow any unauthorised personnel on the
Emergency Steering disabled machine.
Note: The emergency steering system is an optional Gradual smooth movement is necessary for safe
fitting. towing. Quick movements will overload the tow bar
and cause it to break.
Note: The emergency steering is only operational
when the engine fails. The towing machine must be the same size or larger
than the disabled machine. Ensure the towing ma-
When the engine fails the emergency steering indi- chine has sufficient brake capacity, weight and
cator will illuminate. power to control both machines. Take account of the
ground conditions and gradient when towing a dis-
The machine’s emergency steering system is elec- abled machine.
trically operated. To steer the machine the following
must be done:- A larger machine and a solid tow bar is required
when towing a disabled machine downhill. The ar-
Turn the steering wheel counter-clockwise to ticulation safety bar must also be installed. An
turn the machine left. additional machine connected to the rear may also
be required to prevent the disabled machine from
Turn the steering wheel clockwise to the turn rolling away.
the machine right.
If the disabled machine is to be articulated (manoeu-
vered) a towing machine with a solid tow bar must
WARNING be attached to the front of the machine for ma-
There is no self-centering function on the ma- noeuvring and a machine attached to the rear for
chine steering. The machine must be straight- controlling.
ened by turning the steering wheel to the
straight ahead position. Minimum towing capacity is required for towing on
smooth level surfaces and maximum towing capac-
ity is required for towing on gradients and poor
WARNING ground conditions.
When the engine fails the machine must be
steered to safety as soon as possible. Towing a Machine with Inoperable
Engine
Towing
WARNING
Safety Rules Always chock the wheels to prevent the machine
from rolling before releasing the brakes.
Always consult your BELL Product Support Repre-
sentative before towing a disabled machine.
50 870966
October 17, 1997
If the machine must articulate while being towed and
WARNING the steering system is inoperable disconnect as fol-
Ensure the brake system of the towing machine lows:-
is sufficient to hold the combined weight of the
towing machine and the disabled machine. Remove the supply hoses from the T pieces on
the left hand steering cylinder.
WARNING Block off the two supply hoses using suitable

plugs.
Removing the propshafts renders the park brake
inoperative.
Note: Oil loss will be unavoidable. Catch as much oil
as possible and apply a suitable absorbent material
With the engine stopped the machine hydraulic and
to any spilt oil.
pneumatic systems are not operative. This means
there is no powered steering or pneumatic braking
Loop the two steering cylinder T pieces together
system.
using a suitable hose.
Note: The park brake may be released mechanically
but the steering system will remain inoperative. Ar- Operating Tips
ticulation can only be obtained by disconnecting the
steering cylinders hydraulic supply hoses. The following information details suggested tech-
niques to obtain the safest and most efficient use of
Road speed must not exceed 2 km/h (1 to 2 mph). your machine.
Before towing disconnect the propshaft between the Safety Rules

transmission and the drop box.
Operating Indoors
With the brakes released and the propshafts discon-
nected, the towing machine must be capable of When operating the machine indoors ensure that
steering and stopping the complete mass of the there is sufficient ventilation for the exhaust fumes to
disabled machine. escape. Machines may only be operated in buildings
approved by site management.
Note: Given the danger in towing a vehicle without
an effective braking system it is recommended that,
if the engine is not operable, the machine is trans- Floor Load
ported on a suitable breakdown vehicle.
Do not exceed the maximum floor load when operat-
ing indoors.
Towing a Machine with Operable
Engine
Travelling Speed
If the steering system has no fault and the engine can
be run, an operator must steer the machine. Adapt the machine speed to road conditions, load
and visibility.
If the failure is in the transmission do not run the
engine, as the engine is directly coupled to the trans- Ensure there is sufficient space for the machine
mission. Refer to Towing A Machine With before entering confined areas.
Inoperable Engine.
Accidents and injuries must be reported immediately.
If the failure is in the drop box, engage neutral and
disconnect the propshaft connecting the drop box to If possible, after an accident, the machine must be
the front differential and the propshaft connecting the left in its position.
drop box to the through drive.
Do not do anything to the machine that may hamper
If the fault does not affect the braking system the an investigation into the accident.
brakes can be released using the park brake hand
control AFTER the wheels have been chocked. Follow the instructions given by the site manage-
ment.
Towing a Machine with Inoperable
Steering System Transport Operation
Use these procedure in conjunction with relevant When operating the machine in ideal conditions (e.g.
Engine Operative or Engine Inoperative Towing Pro- level graded surfaces) normal driving and gear selec-
cedures detailed previously. tion must be used.
870966 51
October 17, 1997
The machine may be operated at maximum speed When driving downhill the following must be done:-
in accordance with the site and road regulations.
Slow the machine using the service brakes.
Always adapt the machine speed to the road and
traffic conditions. Select the lower gears.
Do not drive too fast when fully loaded as this may Drive the machine downhill.
cause the rear chassis to tip or roll over.
If the machine must be slowed down release
When driving through a bend do not drive too fast. the accelerator and use the retarder.
The machine’s center of gravity is changed which
may cause the machine to tip or roll if the road is When level ground is reached the machine
slippery or cambered the wrong way. must be operated normally.
The machine load must not be allowed to fall off the Off-road Operation
machine at any time.
Do not operate too close to quarry edges, ramp
Do not use the inter-axle differential locks when edges, quay edges and soft edges that may collapse
operating on smooth graded surfaces. under the machine weight.
Due to the extreme weight of the machine allow for Note: Avoid operation on steep hills or over sharp
long braking distances, especially on slippery roads. stones and tree stumps.
Uphill Operation Always use the inter-axle differential lock when there
is a risk of wheel slip. Wheel slip must be avoided
Note: If the machine is operated with the full auto- to prevent driveline damage.
matic mode, the transmission will select the correct
gear for traveling uphill. When operating with the To cover difficult areas (e.g. soft mud) use the
powershift mode the best gear for driving uphill must articulation steering combined with the inter-axle
be selected manually. differential lock to move through the area.
Note: When operating on slippery roads the inter- When the ground is very soft choose a new track for
axle differential lock must be applied to allow for the machine to drive on.
even traction on all the driving wheels.
Public Road Operation
When approaching an uphill the following must be
done:- The operator must abide with all traffic regulations.
Slow down the machine. The operator must understand that the machine is
wider, slower and heavier than other vehicles and
Select the correct gear for driving uphill. 2nd may be an obstruction to other traffic.
gear is recommended.
Always have the headlights and roof warning bea-
Maintain a constant engine speed (rev/min) con on when operating on public road.
when climbing the hill.
Ensure the machine is evenly loaded and that none
Note: The engine speed must be kept constant at of the load can fall off the machine.
all times when driving uphill.
It is recommended that the load is covered when
When level ground is reached the machine operating on public roads.
must be operated normally.
Do not exceed the legal limit of the pay load on the
Downhill Operation road (8 750 Kg {19 250 lb}).
When driving downhill the retarder must be used Stuck Machine

instead of the service brakes.
Note: If the ground is soft with deep wheel tracks
When operating on slippery roads the inter-axle constant attention must be given to the rear chassis
differential lock must be applied to allow for even angle.
braking on all the driving wheels.
If the rear chassis starts to lean sideways exces-
Select the correct gear for driving downhill. 2nd gear sively, stop the machine immediately and dump the
is recommended.
52 870966
October 17, 1997
load. If the rear chassis leans over more lower the bin Transporting the Machine on
immediately.
other Vehicles
If the machine gets stuck the following must be done:-
The Machine can be loaded onto the transporting
Engage the inter-axle differential locks. vehicle by 2 methods:-
Move the gear shift to 1st gear. • Lifting the machine.
Drive off slowly keeping the engine speed • Driving the machine.
(rev/min) constant and not too high.
Safety Rules
Turn the steering wheel to full lock in either
direction. Always use the aid of spotters when loading the
machine onto the transporting vehicle.
Ensure the transporting vehicle is capable of safely

carrying the machine.
When driving the machine onto other transportation

vehicles do not install the articulation safety bars until
S002060
the machine is secured.
When the machine is lifted onto the transportation

When the machine is about to stop turn the
vehicle the articulation safety bar must be installed.
steering wheel to full lock in the opposite direc-
tion (duck waddle).
Always chock the machine when securing it to the
transportation vehicle.
Continue with this movement until the machine
is free and can be operated normally.
Ensure the lifting equipment is suitable for lifting the
machine safely.
Note: If the machine does not move get a towing
vehicle to move the machine from the soft soil.
Ensure the securing equipment is sufficient to hold
the machine in position.
Note: If the machine is not bogged down it can be
pushed out with an excavator or pulled out with a
Always install the articulation lock bar.
towing vehicle. If the machine is bogged down, the
ground may have to be dug out from under the
Ensure there are no personnel near or under the
chassis before it can be towed.
machine when it is lifted.
Overnight Parking Lifting the Machine

When the machine is to be parked overnight the
Note: The machine lifting points are indicated in red
following must be done:-
on the machine. Refer to Specifications for the lifting
points.
Ensure the machine is unloaded.
When lifting the machine the following must be done:-
Park the machine is on firm level ground.
Park the transporting vehicle next to the ma-
Move all the switches to the OFF position.
chine being lifted.
Ensure the gear shift is in the neutral position.
Install the articulation safety bar.
Ensure the park brake is applied.
Attach the chains to the machine lifting points
and the lifting beam.
Lock the cab door.
Note: The lifting beam must be longer than the
Open the battery box lid and move the battery
machine length to avoid damaging the machine and
disconnect switch to the OFF position (if fitted).
must be able to carry the total machine weight.
Ensure the battery box lid is closed properly.
Attach the lifting beam to the crane.
870966 53
October 17, 1997
Note: The crane must be able to carry total machine Driving the Machine onto a
weight. Transporting Vehicle
Lift the lifting beam until all the play in the chain To drive the machine onto the transporting vehicle
is removed. the following must be done:-
Lift the machine until it is clear of the transport- Position the transporting vehicle’s trailer
ing vehicles trailer. against the loading ramp.
Note: The crane must be moved slowly to prevent Drive the machine onto the trailer very slowly
excessive swinging of the lifted machine. following the instruction of the spotter.
Move the machine over the transporting vehi- Install the articulation safety bar.
cles trailer slowly.
Chock all the machine wheels.
When the machine is directly over the trans-
porting vehicle’s trailer lower the machine onto Secure the machine to the transporting vehi-
the trailer slowly, following the instructions of cle’s trailer with chains. Refer to Specifica-
the spotters. tions for the correct securing points for the
machine.
Lower the lifting beam until the chain can be
removed from the machine. Drive the transporting machine away slowly.
Lift the lifting beam and move it away from the

machine.
Install the articulation safety bar.
Chock all the machine’s wheels.
Secure the machine to the transporting vehi-

cles trailer with chains. Refer to Specifica-
tions for the correct securing points for the
machine.
Drive transporting machine away slowly.
54 870966
October 17, 1997
CHAPTER 4. BASIC PREVENTIVE MAINTENANCE
Service Position
Before starting to work on the machine, unload it, wash it thoroughly and park it on firm level ground with the bin
lowered.
1 2 3
WARNING
DO NOT
OPERATE
7
THIS TAG MUST ONLY BE
REMOVED BY THE PERSON
SERVICING THE MACHINE
BELL
B20B
HOT
COLD
BELL MACHINES ARE FITTED WITH ONE

5 4 OR TWO ARTICULATION SAFETY BARS
S002207
Park the machine in the straight ahead position and

prepare for servicing as detailed below: WARNING
When servicing the machine and one of the axles
of the machine is raised off the ground using
WARNING jacks, the wheels on at least one of the other axles
If the following steps are not observed it could must be chocked. This is because there is a risk
result in injury or death. that the machine may roll off the jacks, even if the
park brake is applied.
1. Stop the engine and remove the keys from the
ignition switch.
WARNING
2. Apply the park brake. If work must be done on a warm machine, beware
of hot fluids and components.
3. Attach the “DO NOT OPERATE” warning sign
to the steering wheel.
Rules when Servicing
4. Install the articulation safety bar. General
5. Install the wheel chocks. Do not carry out any work on the machine unless you
are trained and have the knowledge to carry out the
6. Allow the machine to cool down. work.
7. Relieve all pressure in the relevant air, oil, fuel, Service which is not carried out in the correct way
or cooling systems gradually, before any lines, may be dangerous. Make sure that you have suffi-
fittings or related items are disconnected or cient knowledge, the correct information, the correct
removed. tools and the right equipment in order to carry out the
service in the correct way. Repair or change broken
tools and faulty equipment.
870966 55
October 17, 1997
Read all plates and decals on the machine and in Measures to Prevent Fires
the manual before you start servicing the machine.
Each of the instructions contains important informa- There is always a risk of fire. Find out which type of
tion about handling and servicing. fire extinguisher to use, where it is kept and how to
use it.
Do not wear loose fitting clothing or jewellery when
working on the machine. Any fire fighting equipment stored on the machine
must be maintained in working order.
Always wear a hard hat, safety glasses, gloves,
shoes and other protective articles as the job re- At the slightest sign of fire, and if the situation allows,
quires. take the following steps:
When carrying out service work in the articulation • Move the machine away from the danger
area, ensure that the articulation safety bar has been area.
installed.
• Stop the engine and turn the ignition to the
Always stop the engine to service the machine, OFF position.
unless otherwise instructed in this manual.
• Leave the cab.
When changing oil in the engine, fluid in the hydrau-
lic system or transmission, remember that the oil
and fluid may be hot and can cause burns.
• Start putting out the fire and notify the fire
brigade if required.
When lifting or supporting components, use equip-
Do not smoke or have a naked flame near a machine
ment with a lifting capacity which is at least as great
when filling with fuel or when the fuel system has
as the components.
been opened.
All lifting devices, for example slings and ratchet
Diesel fuel oil is flammable and should not be used
blocks, must comply with national regulations for
for cleaning, instead use an approved solvent.
lifting devices. BELL EQUIPMENT COMPANY will
not accept any responsibility if any lifting devices,
Remember that certain solvents can cause skin
tools or working methods are used other than those
rashes and are usually flammable. Do not inhale
described in this manual.
solvent vapour.
Stop the engine before removing engine covers or
Store flammable starting aids in a cool, well venti-
similar.
lated location. Remember that such aids (starting
gas) must not be used in connection with preheating
Make sure that no tools or other objects which can
of the induction manifold.
cause damage are left in or on the machine.
Keep the work place clean. Oil or water on the floor
Release the pressure in the hydraulic and brake
makes it slippery and also dangerous in connection
system gradually before starting work.
with electrical equipment or electrically powered
tools. Oily clothes are a serious fire hazard.
All pressurized vessels must be opened very care-
fully.
Check daily that the machine and equipment are
free from dirt and oil. In this way the risk of fire is
When checking for leaks, use a piece of paper or
reduced and it is easier to detect faulty or loose
wood, not your hand.
components.
Never set a pressure limiting valve to a higher
pressure than that recommended by the manufac-
turer.
CAUTION
If a high pressure jet is used for cleaning, take
Before starting the engine indoors, make sure that great care as the insulation of electrical leads
the ventilation is sufficient to cope with the exhaust can become damaged even at a moderately high
gases. pressure and temperature.
Do not stand behind the machine while the engine

is running. WARNING
Do not point the high pressure jet at personnel.
Check if the electric leads have been damaged by

chafing which could lead to a short circuit and fire.
56 870966
October 17, 1997
Check that there is no damage to hydraulic and brake Working on Painted Surfaces
hoses caused by chafing.
When welding and cutting, the paint must first be
removed up to a distance of 10 cm (4") from the
CAUTION welding or cutting point. Paint which is heated gives
Disconnect the battery when welding on the ma- off unhealthy gases.
chine.
Ideally paint should be removed using sand blasting.
Welding and grinding may only be done on the ma- If the paint cannot be removed using sand blasting,
chine when it is placed in a clean area where there it must be removed in some other way for example
are no fuel tanks, hydraulic pipes or similar lying using paint stripper or a high speed grinder.
around. Take extra care when welding and grinding
near flammable objects. A fire extinguisher should be Note: When using paint stripper or a high speed
kept handy. grinder, you must use a portable air extractor, safety
glasses and protective gloves.
Refrigerant R134a
Working with Polymer Material
The air conditioning system contains refrigerant
R134a. Servicing, refilling or emptying of the refrig- Polymer materials, such as rubber and certain kinds
erant R134a must only be done by trained and of plastics, can, when heated, give off gases which
qualified service personnel. are dangerous to health and environment.
The following protective measures should be taken:

WARNING
Refrigerant R134a can cause frostbite, if it comes
• Protect the polymer material from heat before
welding or cutting near the material.
into contact with bare skin.
• Do not burn polymer materials when disposing
WARNING of them.
The air conditioning system is pressurized.
Never loosen the filling plug on the compressor
or any hose and pipe unions, as an unintentional
leak could result. If a leak is suspected, do not try
to refill the system. Contact your BELL Repre-
sentative.
Avoid breathing in the air conditioner refrigerant and

lubricant vapour or mist. Exposure may irritate the
eyes, nose and throat.
The refrigerant is under high pressure and the system

must be serviced by qualified personnel only. Im-
proper service methods may cause injury.
If accidental system discharge occurs, ventilate the

work area before resuming work.
Additional health and safety information may be

obtained from your refrigerant and lubricant manu-
facturers.
870966 57
October 17, 1997
Service Guide
The preventive maintenance is most important. It includes lubrication and various checks and adjustments which
you can carry out yourself.
Most of these service measures are simple to carry out and do not need any further explanation. But, in some
cases more detailed instructions are needed and these are given on the following pages.
Note: The 100 hour service is done by BELL Product Support.
Maintenance Schedule in Running Hours
Every Every Every Every As

Daily
250 500 1 000 2 000 Req.
Engine
Note: For further maintenance and service procedures, refer to the ADE Engine Repair Manual 360 Series
Check the oil level X
Change the oil and oil filters X
Change the crankcase oil separator 3 000
Clean the fuel screen X
Drain the primary fuel filter X
Change the primary fuel filter X
Change the secondary fuel filters X
Service the injectors 1 200
Change the injectors 2 400
Service and calibrate the injector pump 3 600
Check the air cleaner assembly and the service
X
indicator
Change the air cleaner primary filter element X
Note: Change the air cleaner safety filter element when the primary filter element is changed for the third time.
Check and clean the air cleaner pre-cleaner bowl X
Check the induction manifold, hoses and clamps X
Check the exhaust manifold, hoses and clamps X
Service the turbocharger 3 000
Check the coolant level in the radiator header tank X
Check the anti-freeze/corrosion inhibitors X
Renew the coolant 3 000
Clean the radiator fins X
Clean the intercooler X
Check the cowling covers X
Check for oil and fuel leaks X
Check all hoses and clamps X
58 870966
October 17, 1997

Daily
250 500 1 000 2 000 Req.
Engine (continued)
Check the rubber mountings and mounting bolts X
Adjust the engine valve clearance X
Check the alternator drive belts X
Check the air conditioner compressor drive belts X
Check and adjust the drive belts tensioning X
Change the alternator drive belts X
Change the air conditioner compressor drive belts X
Transmission
Note: For further maintenance and service procedures refer to the ZF Transmission manual
Check the oil level X
Change the oil and oil filter X
Check and clean the breather X
Check and clean the oil cooler X
Check for oil leaks X
Check the neutral start safety function X
Check for error codes X
Hydraulics
Check the fluid level X
Change the hydraulic fluid and the suction filter X
Change the return filters X
Check for component leaks X
Change the breather filter X
Check all hoses and clamps X
Perform pressure and flow tests X
Axles, Chassis and Drive shafts

Check the differential oil levels X
Change the oil in the differentials X
Check the final drive oil levels X
Change the oil in the final drives X
Check and clean the axle breathers X
Check the brake fluid level X
Change the brake fluid 4 000
Check the service brake pads and change if re-
X
quired
870966 59
October 17, 1997

Daily
250 500 1 000 2 000 Req.
Axles, Chassis and Drive Shafts (continued)

Perform a park brake holding test and adjust cali-
X
pers or change park brake disc/pads as required
Electrical
Check the controls and instruments X
Check the batteries X
Check all the lights, the reverse buzzer and the horn X
Check the wiring X
Adjust the headlights X
Check the headlight bulb position X
Other
Check the tires X
Service the air conditioner filters X
Check pneumatic components, pipes, fittings and
X
hoses
Check and drain the air reservoirs X
Check the steering cylinder pins and adjust if re-
X
quired (from July 1997)
Lubricate at grease points X
Lubricate prop shafts (machines built before Octo-
X
ber 1996)
Lubricate drive knuckle (machines built before Oc-
X
tober 1996)
60 870966
October 17, 1997
Raise and Lower the Belly Plate 1. The operator, in the cab, must control the bin
operation, refer to Raising and Lowering the
To perform some maintenance tasks it is necessary Bin in Operating Techniques.
to lower the belly plate to provide access.
The following procedures must be used to raise and

lower the belly plate:
1
2
f000496
WARNING
Be careful when working with the belly plate as it
can cause injury or even death. f000420
1. Position a trolley jack under the belly plate (1). 2. A second person must raise the bin prop (1),
locate it in the holder (2) and inform the operator
2. Raise the trolley jack until it touches against the when it is safely installed.
underside of the belly plate.
3. Release the clips (2) on both sides of the belly

With Rubber Stop
plate. The bin prop can be installed by one person if the
machine is fitted with a rubber stop.
4. Slowly lower the trolley jack.
5. Remove the trolley jack and allow the belly plate

to rest on the ground.
6. Replace the belly plate by using the trolley jack

to support the weight until the securing clips are
fastened safely.
1
Install the Bin Prop
2
WARNING 3
f000474
When the bin is raised in order to perform main-
tenance tasks, ensure that the bin prop is in-
stalled 1. Raise the bin to full height, making sure the tip
cylinders (1) are fully extended.
Without Rubber Stop 2. Switch the engine off.
The following procedures must be used to install the
3. Raise the bin prop (2) against the rubber stop
bin prop on machines not fitted with a rubber stop:
(3).
WARNING 4. Start the engine, and lower the bin until it rests
on the bin prop.
Two people are needed to install the bin prop
safely.
870966 61
October 17, 1997
The following procedure must be used to check the
WARNING oil level:
Check to ensure that the bin prop is located
safely inside the holder . Note: The following procedures are to be followed
before starting the engine.
Install the Articulation Safety Bar
The following procedures must be used to install the
articulation safety bar:
1
The machine must be in the service position. Refer
to Service Position.
f000422
1. Release the dipstick clip.
2. Remove the dipstick.
3. Wipe the dipstick clean with a lint free cloth.

f000421
4. Re-insert the dipstick, ensuring that it is prop-
1. Remove the pin (1) from the articulation safety erly seated.
bar mounting.
5. Remove the dipstick.
6. Check that the oil level reaches the upper mark

on the dipstick.
1 7. Re-insert the dipstick, ensuring that it is prop-

erly seated.
8. Fasten the dipstick clip.
9. If necessary remove the engine oil filler cap (1)

and top up with engine oil until the level
reaches the upper mark on the dipstick.
f000421a 10. Refer to Specifications for Recommended

Fuels, Lubricants and Coolant.
2. Swing the articulation safety bar out and locate
on lug (1). Change the Oil and Oil Filters
3. Fit the pin through the holes to secure in posi- The oil must be changed every 250 hours.
tion.
4. Secure the articulation safety bar back in the WARNING

traveling position after the service.
Be careful when changing oil, hot oil can cause
burns to unprotected skin.
Engine
Note: For further information or details not shown in Drain the Oil
this manual, refer to the ADE Engine Repair Manual
440 Series. Note: The engine oil will drain easier when the
engine is hot.
Check the Oil Level
The following procedure must be used to drain the
The oil level must be checked daily or every 10 oil:
hours.
62 870966
October 17, 1997
1. Lower the belly plate, refer to Raise and Lower 1. Place a 4 litre (1 USGAL) container under the
the Belly Plate. oil filter.
2. Remove the oil filter drain plug and sealing

washer (1).
3. Allow the oil to drain into the container.

1
4. Unscrew the oil filter retaining bolt, sealing
washer and gasket (2).
5. Remove the oil filter bowl and the filter element.
f000423
2. Place a 16 litre (4.2 USGAL) container under

5
the sump drain plug (1).
3. Remove the drain plug and the sealing washer

2
from the sump.
4
Note: The sealing washer may stick to the sump, 8
ensure that it is removed. 3 7
4. Allow the oil to drain into the container.
5. Clean the drain plug and check the thread. 6
6. Re-install the drain plug with a new sealing

washer into the sump and tighten to 80 Nm (59 S002188
ft lb)
6. Discard the filter element (1).
Change the Oil Filter
7. Clean the filter bowl (2) with diesel fuel and dry
The oil filter must be changed at every oil change with compressed air.
(every 250 hours).
8. Fit the drain plug (3) with a new seal (4) and
tighten to 20 Nm (15 ft lb).
CAUTION
The oil filters must be changed and cannot be 9. Smear a film of oil onto a new sealing ring (5)
cleaned. and fit to the filter bowl.
The following procedure must be used to change the 10. Insert a new filter element into the filter bowl.
oil filter:
11. Fill the oil filter bowl with oil. Refer to Specifica-
tions for Recommended Fuels, Lubricants
and Coolant.
1
CAUTION
It is important to fill the filter bowl with oil before
2
fitting. This ensures lubrication directly after
starting the engine.
12. Position the filter bowl to the center of the filter

head, insert the retaining bolt (6) with new seal-
ing washer (7) and gasket (8).
f000424
13. Tighten the retaining bolt to 45 Nm (33 ft lb).
870966 63
October 17, 1997
Note: After replacing the oil filter, replenish the
engine oil. Refer to Fill the Engine with Oil (the 1
following procedure), allow the machine to run at low
2
idle for at least one minute.
3
Fill the Engine with Oil
The following procedure must be used to fill the
engine with oil:
f000480
1 The following procedures must be used to change

the crankcase oil separator (breather).
Loosen the clamp (1) and pull the rubber pipe (2)
from the outlet port.
Unscrew nut (3), remove the crankcase oil separa-

tor (breather) and discard it.
f000422
Fit a new crankcase oil separator (breather) and
secure the rubber pipe with the jubilee clip.
1. Clean the oil filler cap (1) and the area around
it.
Bleed the Fuel System
2. Remove the oil filler cap.
The fuel system must be bled after performing cer-
tain services. This ensures that any air that may
3. Fill with oil until the oil level is on the upper mark
on the dipstick. Refer to Specifications for have entered the fuel system has been expelled.
Recommended Fuels, Lubricants and Cool-
ant. The following procedures must be used to bleed the
fuel system:
CAUTION 1. Ensure that there is at least a quarter tank of

fuel in the tank.
Re-fit the filler cap securely.
Check the Oil Filler Cap and Seal

The oil filler cap and seal must be checked daily and
whenever the cap is removed.
The following procedures must be used to check the

filler cap and seal.
1
Change the Crankcase Oil
Separator (Breather)
The crankcase oil separator (breather) must be
changed every 3 000 hours. f000426
2. Loosen the bleed screws (1) on the filter by

screwing them out one or two turns.
64 870966
October 17, 1997
1
1
f000450
3. Operate the hand priming pump (1) until an air

free flow of fuel flows from the bleed points. 4
4. Tighten the bleed screws.

S002171
Clean the Fuel Screen
The fuel screen must be cleaned every 250 hours. 2. Carefully remove the spring (1), fuel screen (2)
and sealing ring (3) from the fuel screen housing
The following procedures must be used to clean the (4).
fuel screen:
3. Place the components in a container with clean
fuel.
4. Gently rinse the fuel screen housing and all the

components.
1 5. Assemble the components in the fuel screen

housing.
6. Install the fuel screen assembly securely.
Drain the Primary Fuel Filter

f000451 Draining of the primary fuel filter must be done daily
1. Unscrew and remove the fuel screen housing or every 10 hours.
(1).
870966 65
October 17, 1997
The following procedures must be used to drain the 3. Discard the fuel filter, do not re-use.
primary fuel filter:
4. Fill a new primary fuel filter with fuel and secure
in place.
5. Remove the hose clamp from the fuel hose.
6. Bleed the fuel system.
7. Start the engine and check for leaks at the

primary fuel filter head.
Change the Secondary Fuel Filters
1 The secondary fuel filters must be changed every

250 hours.
f000425 The following procedures must be used to change

the secondary fuel filters:
1. Loosen the wing nut (1) on the primary fuel
filter.
2. Drain the accumulated water into a container.
3. Tighten the wing nut when fuel flows out water 2

free.
Change the Fuel Filters 1
Change the Primary Fuel Filter

The primary fuel filter must be changed every 500 f000426
hours.
1. Unscrew and remove both secondary fuel fil-
The following procedures must be used to change ters (1) from the filter head (2).
the primary fuel filter:
2. Discard the secondary fuel filters, do not re-
use.
1
3. Smear a little fuel on the sealing ring of the new
secondary fuel filters.
2 4. Re-fit new secondary fuel filters.
5. Tighten the secondary fuel filters by hand and

then one half turn further.
6. Bleed the fuel system.
7. Start the engine and check for leaks at the

secondary fuel filter head.
Service the Injectors and Injector

Pump.
f000427
The injectors must be serviced every 1 200 hours.
1. Fit a hose clamp on the fuel hose (1) between The injectors must be changed every 2 400 hours.
the fuel tank and the primary fuel filter (2), to
stop fuel flow. The injector pump must be serviced and calibrated
every 3 600 hours.
2. Unscrew and remove the primary fuel filter.
66 870966
October 17, 1997
Contact Bosch personnel to perform any services on The following procedures must be used to check the
the injectors and injector pump. air cleaner service indicator:
Check the Air Cleaner Assembly

and Service Indicator 1
Air Cleaner Assembly

The air cleaner hoses and clamps must be checked
daily or every 10 hours.
The following procedures must be used to check the

air cleaner hoses and clamps:
2
1
6 1. Check the indication window (1). If the window

shows a red flag, the air cleaner filter element
5 must be changed.
4 Change the Air Cleaner Filter

3 Elements
f000436
Change the Primary Filter Element

1. Check the air cleaner assembly for damage to
the air cleaner (1) and pre-cleaner (2). The air cleaner primary filter element must be
changed every 2 000 hours or if the service indicator
2. Check the rubber elbow (3) and connecting shows red.
hoses, T-bolt clamps (4), mounting bolts (5)
and service indicator (6) for security and dam- The following procedures must be used to change the
age. air cleaner primary filter element:
1
5
4 6
2 2 7
1
3
s002189
f000452
1. Open the clips (1) and remove the end cover (2)
3. Check the U-bolt mounting (1) and mounting from the air cleaner housing (3).
band (2) for security and damage.
2. Unscrew and remove the wing nut (4) and seal
4. Check that the vacuator valve (3) is undamaged (6) from the primary filter element (5).
and free from obstruction.
3. Discard the seal (6).
Air Cleaner Service Indicator
4. Remove the primary filter element from the air
The air cleaner service indicator must be checked cleaner housing.
5. Discard the primary filter element, do not re-use.
870966 67
October 17, 1997
6. Clean the end cover and air cleaner housing 9. Install the primary filter element and the end
and inspect for damage. cover with the O-ring onto the air cleaner hous-
ing, securing it with the clips.
7. Install the new primary filter element into the
air cleaner housing and secure with the wing 10. Press the top of the air cleaner service indica-
nut and a new seal. Do not over-tighten the tor, to reset it, after installation is complete.
wing nut.
Check and Clean the Air Cleaner
8. Inspect the O-ring (7) for damage, replace if Pre-cleaner Bowl
necessary.
9. Install the end cover with the O-ring onto the

Check the Air Cleaner Pre-cleaner
air cleaner housing, securing it with the clips. Bowl
The air cleaner pre-cleaner bowl must be checked
Change the Safety Filter Element daily or every 10 hours.
When the primary filter element is changed for the The following procedure must be used to check the
third time, the safety filter element must also be air cleaner pre-cleaner bowl:
changed.
The following procedures must be used to change

the safety filter element: 1
1 2
f000481
Check the level of the dirt in the bowl, if it reaches

3 4 the level (1) marked on the bowl, the bowl must be
s002190 cleaned.
1. Remove the primary filter element from the air

cleaner housing. Clean the Air Cleaner Pre-cleaner
Bowl
2. Remove the wing nut (1) and seal (3) from the
safety filter element (2). The following procedure must be used to clean the
air cleaner pre-cleaner bowl:
3. Discard the seal (3)
4. Remove the safety filter element from the air 1

cleaner housing and discard.
2
5. Cut the tie strap and remove the vacuator valve
(4) from the air cleaner housing.
3
6. Clean and inspect the vacuator valve for dam-
age.
7. Re-fit the vacuator valve and secure with a tie

strap.
f000435
8. Install the new safety filter element into the air

cleaner housing and secure with the wing nut 1. Remove the wing nut (1) securing the lid (2) to
and a new seal. Do not over-tighten the wing the bowl (3).
nut.
68 870966
October 17, 1997
1 exhaust manifold hoses and clamps:
2 1
2
s002191
2. Remove the lid (1) and bowl (2) from the pre-
cleaner body (3).
3
f000454
3. Remove the dirt from the bowl and clean the
bowl with a lint-free cloth.
1. Visually inspect the hoses (1) and clamps (2) for
4. Install first the bowl then the lid onto the pre- damage and security.
cleaner body and secure them with the wing nut.
2. Check the exhaust brake valve (3) for damage
Check the Induction Manifold, and security.
Hoses and Clamps 3. Check the manifold for cracks and security.
The induction manifold, hoses and clamps must be
checked every 250 hours. 4. Check the exhaust pipes (1) and mounting bolts
and clamps (2) for security and damage.
induction manifold, hoses and clamps: 5. Check the exhaust stack (1) and mounting bolts
and clamps (2) for security and damage.
2 Check the Coolant Level

1
The coolant level must be checked daily or every 10
hours.

coolant level:
WARNING
The system may be under pressure.
f000453
1. Visually inspect the hoses (1) and clamps (2) for

damage and security.
2. Check the manifold for cracks and security.
Check the Exhaust Manifold, Hoses

and Clamps
The exhaust manifold, hoses and clamps must be 1
checked every 250 hours.
f000447
1. Remove the filler cap (1) on the radiator header

tank.
2. The coolant should be level with the inlet hole.

If not, top up with coolant. Refer to Specifica-
tions for Recommended Fuels, Lubricants
and Coolant.
870966 69
October 17, 1997
Check the Anti-freeze/Corrosion Check the Radiator and Clean the
Inhibitors Radiator Fins
The anti-freeze/corrosion inhibitors solution must be Check the Radiator
The radiator must be checked daily and the radiator
Contact BELL Product Support when the check is fins cleaned every 250 hours or as required.
required.
Renew the Coolant radiator and clean the radiator fins:
The coolant must be renewed every 3 000 hours.
The following procedure must be used to renew the

coolant:
1. Lower the belly plate. Refer to Raise and

Lower the Belly Plate.
1
the drain plug (1) at the left, bottom corner of
the radiator.
f000456
1 1. Check the radiator (1), mounting bolts , mount-

ings, hoses and clamps for damage and secu-
rity.
2. Check the radiator fins for damage and clean-

liness. Clean if required and ensure that there
is no restriction to the air flow.
Clean the Radiator Fins

f000429
3. Wash the radiator from the rear using a pres-

3. Unscrew and remove the drain plug (1). sure washer and a mild detergent that is not
caustic to aluminum.
4. Allow the coolant to drain into the container.
4. Keep the radiator free from obstructions which
5. Replace the drain plug. may restrict the air flow.
6. Fill the radiator header tank until the water runs Check the Cowling Covers
from the fill port.
The cowling covers must be checked every 250
7. Unscrew and remove the drain plug and allow hours.
the water to drain.
8. Flush the cooling system by repeating the pro-

cedure until clean water runs from the radiator.
Note: To ease drainage loosen the header tank filler

cap.
9. Secure the drain plug and add the correct ratio

of water to coolant into the radiator. Refer to
Specifications for the correct ratios.
70 870966
October 17, 1997
The following procedure must be used to check the The following procedure must be used to check the
cowling covers: engine rubber mounting and mounting bolts:
2
f000457
f000458
1. Check the cowling covers (1) for damage and
cracks.
1. Inspect all four of the engine mounting bolts (1)
2. Ensure that the mounting bolts (2) are secure. for security.
2. Check that the rubber mountings (2) are secure

Check for Oil and Fuel Leaks and not damaged.
The engine must be checked for oil and fuel leaks
every 250 hours. Adjust the Engine Valve Clearance
Perform a visual inspection for oil and fuel leaks on The engine valve clearance must be adjusted every
and around the engine and components inside the 1 000 hours.
engine compartment.
Refer to the ADE Engine Repair Manual 360 Series
for the procedures.
Check all Hoses and Clamps
The hoses and clamps in the engine compartment Check the Drive Belts
must be checked every 250 hours.
Check the Alternator Drive Belts
The following procedure must be used check the
hoses and clamps: The alternator drive belts must be checked every 250
hours.
1. Visually inspect all the hoses in the engine
compartment for wear and leaks. The following procedure must be used to check the
alternator drive belts:
2. Check all the clamps in the engine compartment
to ensure that they are secure.
Check the Engine Rubber Mounting

and Mounting Bolts
The engine rubber mounting and mounting bolts 1
must be checked every 250 hours.
f000459
1. Inspect the alternator drive belts (1) for cracks,

fraying, wear and tensioning.
2. If necessary change damaged drive belts or

adjust the tensioning as required.
870966 71
October 17, 1997
CAUTION
Do not replace drive belts individually. Replace
both if one is faulty.
Check the Air Conditioner

Compressor Drive Belts
1
The air conditioner compressor drive belts must be

air conditioner compressor drive belts:
f000483
2. Inspect the air conditioner compressor drive

belts (1) for cracks, fraying, wear and tension-
1. Unscrew and remove six bolts (1) and remove ing.
the cab floor plate for access to the air condi-
tioner compressor. 3. If necessary change damaged drive belts or
adjust the tensioning as required.
CAUTION
Do not replace drive belts individually. Replace
both if one is faulty.
72 870966
October 17, 1997
Check the Drive Belt Tensioning Adjust the Alternator Drive Belts
The following procedure is applicable to the alternator Adjust the alternator drive belts if the tensioning is
drive belts and the air conditioner compressor drive wrong.
belts.
The following procedure must be used to adjust the
Use a tension gauge to measure the drive belts alternator drive belts:
tension, contact BELL Product Support for further
information.
4. Position the tension gauge (1) on the drive belt,

with the flange parallel against the belt edge.
5. Apply pressure to the pressure pad. When a

CLICK is heard or felt, stop immediately and
remove the gauge.
1
6. Turn the gauge sideways and take a kg reading
in the exact spot where the indicator arm inter-
sects the scale.
f000484
7. The tension should be: new belts 40 to 45 kg

(88 to 99 lb); old belts 30 to 40 kg (66 to 88 lb). 1. Tighten the adjusting nut (1) on the alternator to
increase the tension of the drive belts.
8. If the correct readings are not obtained, adjust
the drive belts. 2. Use the tension gauge to measure the tension.
Refer to Check the Drive Belt Tensioning.
If no tension gauge is available check the tension
using the following method: 3. Repeat the procedure until the correct tension
is achieved.
1. Press the belt using a fairly hard thumb pressure
midway between the pulleys. 4. The tension should be: new belts 40 to 45 kg
(88 to 99 lb); old belts 30 to 40 kg (66 to 88 lb).
2. The belt should move about 15 mm (0.6 in).
Adjust the Air Conditioner Compressor
Note: Always change both alternator belts at the
Drive Belts.
same time.
Adjust the air conditioner compressor drive belts if the
tensioning is incorrect.
1. Slacken the nuts.
2. Move the compressor outwards until the correct

belt tension has been obtained.
3. Tighten the nuts.
870966 73
October 17, 1997
The following procedure must be used to adjust the Change the Air Conditioner
air conditioner compressor drive belts: Compressor Drive Belts
The air conditioner compressor drive belts must be
changed every 1 000 hours or if required.
The following procedure must be used to change the

air conditioner compressor drive belts.
1. Release the tension on the alternator drive

belts, refer Adjust the Air Compressor Drive
Belts.
2. Replace both of the old drive belts with new

2
ones.
3. Re-check the tension of the drive belts after a

10 hour running-in period. Refer Check the
Drive Belt Tensioning.
1
Transmission
The exterior of the transmission should be kept
clean and inspected at regular intervals. Check for
f000485
loose bolts and leaking fluid lines.
1. Loosen the adjusting bolts (1) and manually Investigate immediately any problems encountered
move the air conditioner compressor down on in the gear selection function.
the bracket (2) to apply tension to the drive
belts. Check the Transmission Oil Level
2. Secure the adjusting bolts and measure the The transmission oil level must be checked daily or
tension. every 10 hours.
3. Use the tension gauge to measure the tension. The following procedure must be used to check the
Refer to Check the Drive Belt Tensioning. transmission oil level.
On obtaining the correct tension (new belts 40 to 45 1. Apply the park brake
kg {88 to 99 lb}; old belts 30 to 40 kg {66 to 88 lb}),
ensure that the adjusting bolts are secure. 2. Start the engine and run it at high idle for
approximately two minutes to expel all air from
Change the Alternator Drive Belts the transmission oil cooler.
The drive belts must be changed every 1 000 hours 3. Slow engine speed to idle.
or if required.
The following procedure must be used to change the CAUTION

alternator drive belts.
The engine must be running at low idle to obtain
a correct oil level reading in the transmission.
1. Release the tension on the alternator drive
belts, refer Adjust the Alternator Drive Belts.
4. Apply the service brake and keep the brake
pedal depressed.
2. Replace both of the old drive belts with new
ones.
5. Select all gears in turn.
3. Re-check the tension of the drive belts after a
6. Select neutral and apply the park brake.
10 hour running-in period. Refer Check the
Drive Belt Tensioning.
7. Note the transmission oil temperature, on the
transmission oil temperature gauge, to identify
which notch on the dipstick is applicable.
74 870966
October 17, 1997
Change the Transmission Oil and
Oil Filter
1
The transmission oil and oil filter must be changed at
every 1 000 hour service or once a year.

oil and oil filter:
CAUTION
Do not use the following warm-up procedure over
f000431
a period longer than 30 seconds when warming
up the transmission oil.
8. Remove the dipstick (1) from the transmission.
1. Start the engine and apply the park brake and
9. Clean the dipstick with a lint-free cloth.
service brake.
10. Insert the dipstick.
2. Select second forward gear and press the ac-
celerator pedal down fully for 5 seconds.
Note: The dipstick must be inserted until it is against
its seat.
3. Repeat the above procedure until the transmis-
sion oil has reached operating temperature,
11. Remove the dipstick and check the oil level.
(80oC {176oF}) as indicated on the transmission
oil temperature gauge.
12. When the oil is cold (40oC {104oF}) the level
must be on the lower notch marked COLD.
4. Stop the engine.
o o
13. When the oil is hot (80 C {176 F}) the level must
be on the top notch marked HOT.
the transmission drain plug (1).
CAUTION
Always use the correct grade of oil.
CAUTION 1
Too much or too little oil in the transmission will
cause damage.
14. If necessary top up the transmission oil. Refer

to Specifications for Recommended Fuels,
Lubricants and Coolant.
Note: Top up the transmission with small volumes of

f000461
oil and check the oil level regularly during the top up
procedure.
15. Insert the oil dipstick again and tighten it by 6. Remove the drain plug (1) with its O-ring and
turning the dipstick in a clockwise direction. allow the oil to drain into the container.
16. If the transmission is overfilled by accident,

drain the oil to the correct level, checking the oil
level as detailed above.
870966 75
October 17, 1997
17. Check for oil leaks at the filter and re-tighten if
necessary
Check and Clean the Breather

The breather must be checked and cleaned every
1 250 hours.
The following procedure must be used to clean the

breather:
f000486
1
7. Disconnect the pipes (1) from the transmission
oil cooler, allowing the oil drain into the con-
tainer.
8. Reconnect the pipes to the transmission oil

cooler.
Note: Only the oil in the transmission and the upper

part of the torque converter can be drained. f000433
9. Clean the drain plug and the sealing surface 1. Clean the breather (1) and the area around it.
on the housing.
2. Unscrew the breather and rinse in paraffin.
10. Install the drain plug with a new O-ring.
Check and Clean the Oil Cooler
The oil cooler must be checked and cleaned every
250 hours.
The following procedure must be used to check and

1
clean the oil cooler:
1. Check the outside of the oil cooler, if it is dusty

and mud-packed, clean the outside with a soap
and water solution.
f000432
11. Unscrew and remove the filter (1) and discard

it.
12. Smear a small amount of oil on the O-ring of 1

the new filter. 3
13. Screw the filter in until it has made contact with 2
the surface.
14. Then turn it a further 1/3 to 1/2 turn.

f000462
15. Fill the transmission with the correct grade of
oil. Refer to Specifications f o r Recom-
mended Fuels, Lubricants and Coolant. 2. Check hoses (1) and fasteners (2) for security
and leaks, and ensure that the four mounting
16. Check the transmission oil level. Refer to bolts (3) are secure to prevent vibration.
Check the Transmission Oil Level.
76 870966
October 17, 1997
Note: If there has been transmission failure the oil 7. If the engine starts, the neutral start function is
cooler must be sent in for ultra-sonic cleaning. Con- unserviceable. The engine MUST be stopped
tact BELL Product Support. immediately and the fault reported to BELL
Product Support.
Check the Transmission Rubber
Mounting and Mounting Bolts Repeat the above procedure for each gear lever
position.
The transmission rubber mountings and mounting
bolts must be checked every 250 hours. Check for Error Codes
The following procedure must be used to check the Check for error codes daily and during operation.
transmission rubber mounting and mounting bolts:
The error codes will be displayed on the digital display
unit in the cab. Refer to Operator Controls, Instru-
ments and Instructions.
If during operation the transmission shows any error

codes, stop the machine immediately and contact
BELL Product Support.
1 Hydraulics
2
Check the Hydraulic Fluid Level
The hydraulic fluid level must be checked daily or
every 10 hours.
F000495

1. Inspect the transmission mounting bolts (1) for
hydraulic fluid level:
security.
1. Ensure the bin is in the lowered position.
2. Check that the rubber mountings (2) are secure
and not damaged.
Check for Oil Leaks

Visually inspect for oil leaks on and around the trans-
mission, daily or every 10 hours.
Check the Neutral Start Safety

Function 1
The neutral start safety function must be checked


neutral start safety function:
1. Place the gear lever in the neutral position. f000463
2. Turn the ignition master switch to the ON posi- 2. The fluid level must just show in the upper sight
tion and press the starter button. glass (1) when the fluid is cold.
3. If the engine starts, the neutral start function is 3. If necessary replenish the fluid in the hydraulic
serviceable. tank. Refer to Specifications for recommended
fuels, lubricants and coolants.
4. Stop the engine.
5. Move the gear lever to first forward.
6. Press the start button.
870966 77
October 17, 1997
Change the Hydraulic Fluid and 2
Suction Filter
The hydraulic fluid and suction filter must be
changed every 2 000 hours.

hydraulic fluid and suction filter:
1. Clean the top and back of the hydraulic tank. 1
s0002192
10. Unscrew and remove the suction filter (1) from

the hydraulic tank using the special spanner
2 P/N 280029.
1 11. Discard the old suction filter and fit a new one.
f000464
12. Check the suction hose and clamps in the

2. Remove the bolts (1) from the cover. hydraulic tank for damage.
3. Remove the cover from the top of the hydraulic 13. Install the cover onto the hydraulic tank with a
tank. new gasket (2).
4. Remove and discard the gasket (2) from the 14. Replenish the hydraulic tank with clean hy-
cover. draulic fluid. Refer to Specifications for Rec-
ommended Fuels, Lubricants and Coolant.
Check the Filler Cap and Seal

The filler cap and seal must be checked every time
it is removed from the hydraulic tank.

filler cap and seal.
1
Unscrew and remove the filler cap (1) and inspect
the filler cap and seal (2) for damage.
Change the Return Filters

The return filters must be changed every 1 000
f000465 hours.
5. Place a 140 litre (37 USGAL) container under The following procedure must be used to change the
the drain plug (1) on the hydraulic tank. return filters:
6. Remove the drain plug and allow the fluid to 1. Clean the area around the filters and the filter
drain into the container. housing.
7. Remove the seal from the drain plug and dis-

card.
8. Clean the drain plug and fit a new seal.
9. Install the drain plug into the hydraulic tank.
78 870966
October 17, 1997
1. Check the suction pump mounting bolts, hoses
and clamps for security.
2. Check the hoses and connections for damage

and leaks.
Change the Breather Filter

The breather filter must be changed every 500 hours.

2
breather filter:
f000455
2. Unscrew and remove the return filters (1) and

seals from the return filter housing (2).
3. Install new filters s and seals onto the return filter

housing. Lubricate the seals with a film of clean
oil before assembly
4. Hand tighten the filters and then tighten a further

90o.
CAUTION
Only BELL EQUIPMENT filters are to be used.
BELL EQUIPMENT filters have the correct mi-
cron filtration rating for the hydraulic system.
Check for Hydraulic Component

Leaks f000466
The components of the hydraulic system must be 1. Unscrew and remove the breather filter from the
inspected daily for leaks and damage. filter housing.
1. Check for signs of hydraulic fluid on or around 2. Discard the breather filter and seal.
the hydraulic components on the transmission.
3. Lubricate the seal of the new breather filter and
Check the steering cylinders and tip cylinders for install.
damage and leaks.
4. Tighten the filter hand tight, then a further 90o.
Check the Suction Pump, Hoses
and Clamps Check all Hoses and Clamps
The suction pump, hoses and clamps must be All the hoses and clamps of the hydraulic system
checked every 500 hours. must be checked every 500 hours for security and
wear.
suction pump, hoses and clamps:
870966 79
October 17, 1997
Perform Pressure and Flow Tests 10. The wheel installation is the opposite proce-
dure to that of removal and the wheel nuts are
Pressure and flow tests must be done every 1 000 torqued to 500 Nm (369 ft lb)
hours.
11. Re-check the torque after the machine has
Contact BELL Product Support. been driven for 5 hours and then after every 50
hours of operation.
Axles, Chassis and Drive Shafts
Check the Differential Oil Levels
Remove and Install the Wheels
The differential oil level must be checked every 250
The following procedure must be used to remove hours.
and install a wheel.
Note: The procedure is the same for all the wheels. differential oil level.
Note: The procedure is the same for all the differen-

CAUTION tials.
The following safety precautions must be fol-
lowed to avoid injury and damage to the ma-
chine.
1
1. The machine must be in the service position.
Refer to Operating Techniques.
2. The articulation bar must be installed. Refer to

Install the Articulation Bar.
3. All lifting and support equipment must be ca-

pable of safely accepting the mass of the ma-
chine machine and its components. f000467
4. The wheel and tire have a combined mass of 1. Clean the area around the level plug (1).
520 kg. Care must be taken when removing or
installing. 2. Remove the level plug from the axle The oil
must be level with the bottom of the level plug
hole.
3. Top up with new oil if necessary, via the level

holes. Refer to Specifications for Recom-
mended Fuels, Lubricants and Coolant.
4. Re-install the level plug.

1
Change the Oil in the Differentials
The oil in the differentials must be changed every
F000487 500 hours.
5. Observe all the above safety precautions and

loosen all the wheel nuts (1) one full turn.
6. Using a suitable jack under the relevant axle,

raise the machine until the tire is clear of the
ground.
7. Support the chassis and axles of the machine

with suitable stands.
8. Remove all the wheel nuts from the wheel.
9. Remove the wheel from the axle.
80 870966
October 17, 1997
The following procedure must be used to check the The following procedure must be used to check the
oil in the differentials. The procedure is the same for oil in the final drive.
all the differentials.
Note: The procedure is the same for all the final
drives.
f000468
1. Remove the drain plugs (1) from the differential

and allow the oil to drain into a 45 litre (11,9 f000470
USGAL) container.
1. Rotate the wheels so that the word BELL can
2. Clean the drain plugs and re-install them in the be read in the horizontal position.
differentials.
2. Remove the level plug (1) from the level/filler
hole and check the oil level in each of the final
drives.
1 3. The oil level must be at the bottom of the

level/filler hole.
4. If necessary top up the oil until the oil flows from

the level/filler hole. Refer to Specifications for
ant.
5. Re-install the level plug securely.

f000467
Change the Oil in the Final Drives

3. Remove the level plug (1) from the axles.
The final drive oil must be changed every 500 hours.
4. Refill the differentials with new oil via the axle
level holes until the oil begins to flow from the
level holes. Refer to Specifications for Recom-
mended Fuels, Lubricants and Coolant.
5. Re-install the level plugs.
Check the Final Drive Oil Level

The final drive oil level must be checked every 250
hours.
870966 81
October 17, 1997
The following procedure must be used to change the The following procedure must be used to check and
oil in the final drive. clean the axle breathers.
Note: The procedure is the same for all the final Note: The procedure is the same for all the axle
drives. breathers.
1
1
f000471
1. Clean the area around the axle breather (1).

f000488
1. Rotate each wheel so that the drain plug (1) is 2. Unscrew and remove the axle breathers.
at the lowest point.
3. Check the axle breather for damage.
2. Unscrew and remove the drain plug from the
final drive and allow the oil drain into a 20 litre 4. Clean the axle breather and install.
(5.3 USGAL) container.
Check the Brake Fluid Level
3. Rotate each of the wheels so that the word
BELL can be read in the horizontal position. The brake fluid level in the front and rear reservoirs
must be checked every 10 hours or daily.
4. Fill the final drive with clean oil through the
level/filler hole, until the oil flows from the The following procedure must be used to check the
level/filler hole. Refer to Specifications for brake fluid level.
ant. Note: The procedure is the same for all brake fluid
reservoirs.
5. Clean the drain plug and install into the final
drive.
Check and Clean the Axle Breathers

1
The axle breathers must be checked and cleaned
every 250 hours.
f000472
1. The brake fluid level must be on the upper level

mark (1).
Change the Brake Fluid

The brake fluid must be changed every 4 000 hours.
Contact your nearest BELL Product Support
82 870966
October 17, 1997
Check and Change the Service Change the Service Brake Pad
Brake Pads
The service brake pads should be changed if there is
Check the Service Brake Pads 2 mm of pad left.

Without Mud Covers
service brake pads.
The service brake pads must be checked daily or
every 10 hours on machines not fitted with mud Note: The procedure is the same for all the brake
covers. pads.
The following procedure must be used to check the 1. Remove the wheel from the axle. Refer to Re-
brake pads: move and Install the Wheel.
2
1
f000446
f000477
1. Inspect between the brake disk and the caliper

(1) , if the there is less than 2 mm between the 2. Remove the locking bolts (1) from one end of
the two, change the pads. the brake caliper and remove the retaining
bracket.
With Mud Covers
3. Remove the brake pads (2) from the brake
The service brake pads must be checked every 50 caliper.
hours on machines fitted with mud covers.
4. Install the new brake pads into the brake caliper.
brake pads: 5. Install the brake pad retaining brackets.
6. Tighten the locking bolts to 210 Nm (154 ft lb).
7. Install the wheel onto the axle and tighten the

wheel nuts to 500 Nm (369 ft lb).
Perform the Park Brake Holding Test

1
The park brake holding test must be performed every
10 hours or daily.
There are two different types of park brakes installed

in the B20B range.
f000445
Note: The park brake caliper must be adjusted if the

1. Unscrew and remove the securing bolts (1) and machine fails the park brake holding test.
remove the mud covers.
2. Inspect between the brake disk and the caliper

(1) , if the there is less than 2 mm between the
the two, change the pads.
870966 83
October 17, 1997
Park Brake Holding Test
2
S000523
3. Release the adjusting screw lock nut (1) and

tighten the adjuster screw (2) until the pads just
F000363
contact the disc.
The brake lever has two positions, APPLY and
RELEASE. The procedure to perform the park CAUTION
brake holding test is as follows:
The pads must be adjusted to have minimum
1. Start the engine. clearance from the disc.
2. Apply the park brake. 4. Turn the adjuster screw back a 1/4 turn and
tighten the adjuster screw lock nut.
3. Select third gear.
5. Remove the wheel chocks.
4. Drive forward.
6. Start the engine and repeat the park brake
5. If the machine moves, adjust the park brake holding test. Refer to Park Brake Holding
caliper and repeat the test. Test.
7. If the park brake holding test is still unsuccess-

Adjust Park Brake Caliper (With Brake ful and the machine moves forward, change
Relay Valve) the park brake pads. Refer to Change the Park
Brake Pads.
Park Brake Holding Test (Without

Brake Relay Valve)
f000490
The park brake caliper should be adjusted if the park

brake holding test is unsuccessful.
The following procedure must be used to adjust the

park brake caliper.
F000363
1. Chock the wheels and release the park brake.

The brake lever has two positions, APPLY and
2. Inspect the caliper, spring actuator, links, cle- RELEASE. The procedure to perform the park
vises and pins for damage or wear. brake holding test is as follows:
1. Start the engine.
84 870966
October 17, 1997
2. Push the brake lever in and then down into the
TEST position. Hold for five seconds until all the
air pressure is released.
3. Keep the lever in the TEST position. Select third

gear. 1
4. Drive forward.
f000476
3. Remove the securing bolts and drop the prop

shaft (1).
4. Remove the securing bolts (2) from the park

brake disc.
f000491
5. Remove the park brake disc.
Note: the park brake caliper is self-adjusting. 6. Install the new park brake disc and secure in
position. Torque the securing bolts to Nm (ft lb).
If the machine moves change the park brake caliper.
Refer to Change the Park Brake Pads. 7. Re-fit and secure the prop shaft into position.
Torque the securing bolts to 120 Nm (89 ft lb).
Change the Park Brake Disc
8. Move the lever clockwise.
The park brake disc must be changed when the disc
reaches its wear limit of 41 mm (1.6"). 9. Connect the lever to the yoke assembly and
secure in position.
park brake disc: 10. Start the machine and allow the system pres-
sure to build to operating pressure.
WARNING 11. Release the park brake.

Ensure that the wheels are firmly chocked and air
pressure has been released from the system. 12. Apply the park brake.
13. Perform the park brake holding test. Refer to

Park Brake Holding Test.
Change the Park Brake Pads
1
1
2 f000444
f000475
The park brake pads must be changed when the pads
reach their wear limit.
1. Remove the yoke assembly (1) from the lever
(2).
2. Move the lever counter-clockwise to release the

brake pads.
870966 85
October 17, 1997
The following procedure must be used to change the 4. Slide out the shims (1).
park brake pads:
Warning
Ensure that the wheels are firmly chocked.
1
1. Release the park brake.
1
f000441
5. Lift out the top plate (1).
f000439
1
2. Back-off the slack adjuster by rotating the ad-
justment screw (1) counter-clockwise until it
stops turning.
1 6. Slide out the worn brake pads (1).
7. Replace with new brake pads.
Note: Ensure that the brake pads are located on the

bottom mounting plate.
8. Re-insert the top plate.

f000438
9. Slide the shims into place.
3. Remove the four cap screws (1) from the 10. Replace the lock bolts and torque to 150 Nm
mounting plate. (110 ft lb).
Note: To ease the removal of the top mounting plate,
the bottom cap screws can be loosened to tilt the 2.5mm
brake unit towards the prop shaft.
min
Note: Ensure that there is a minimum clearance of

2.5 mm between the rear disc and the slot in the top
plate.
f000440
86 870966
October 17, 1997
Check all Exterior Lights, Reverse
Buzzer and Horn
All the lights and the reverse buzzer must be checked
1
daily.
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.
Refer to Operator Controls and Instruments if
necessary.
Check the following:
f000439 1. Switch all the lights on in turn, including head-

light (dipped and high beam), indicators, hazard
11. Readjust the pressure on the pads by using the and brake lights.
adjustment screw (1).
2. Make sure the path is clear behind the machine,
12. Start the machine and allow the system pres- and then reverse to make sure the buzzer and
sure to build to maximum operating pressure. reverse lights are working.
13. Apply the park brake. 3. Ensure that the buzzer is securely mounted.
14. Perform the relevant park brake holding test. 4. Functionally test the horn and ensure that it is
Refer to Park Brake Holding Test (Caliper securely mounted.
without/with Brake Relay Valve).
Check the Interior Light and Vent
Check the Axles and Chassis Fan/Air Conditioner
Components
Carry out a functional check on the interior light and
The axles and chassis components should be the vent fan or air conditioner daily. Refer to Operator
checked daily. Controls and Instruments.
The following procedures must be used to check the Check that the interior light and the vent fan or air
axles and chassis components: conditioner are mounted securely and are not dam-
aged.
1. Raise the bin, refer to Raising and Lowering
the Bin in Operating Techniques. Check the Wiring
2. Check for damage to the chassis, axles, differ- Check the wiring daily for security and to ensure that
entials, prop shafts, torque tube and their com- no fraying has taken place.
ponents.
Ensure that the connections are secure and that the
3. Ensure that the mountings and mounting bolts alternator, starter motor, buzzer and horn earth ca-
are secure and not damaged. bles are secure.
Electrical Adjust the Headlights

Check the Controls and Instruments The machine’s headlights must be adjusted to the
correct height so that the operator can safely operate
Carry out a functional check on all controls and the machine at night or in poor light conditions.
instruments daily. Refer to Operator Controls and
Instruments. The following procedure must be used when it be-
comes necessary to adjust the headlights:
Check the fuse box and circuit breakers for damage
and security daily. 1. Ensure the machine’s tires are at the correct
pressure.
Check the Batteries
2. Park the machine on firm level ground, facing a
Check the batteries and cables for cleanliness, dam- wall that is at a 90o vertical to the ground.
age and stability daily. Ensure that the batteries have
been properly mounted.
870966 87
October 17, 1997
Select high beam and ensure that all four of the 9. Blackout all of the headlights except the out-
headlights are working. side left headlight.
Note: All four headlights operate when high beam

is selected. But only the outside headlights operate
when the dipped beam is selected.
f d c e g
a
x b
h
S000507
10. Select dipped beam (outside headlights only)

and check that the horizontal cut-off line is not
SIDE VIEW
OFFSET NOTCH
LAMP above line (b) and that the diagonal cut-off line
tapers off to the 10 o’clock position.
REAR VIEW OF HEADLIGHT S000505
1. Ensure that the headlight bulb is located in the

correct position in the outside headlights. Refer
to Check the Headlight Bulb Position. 1
2. The headlight bulbs must be located with the
offset notch from the bottom of the headlight.
C
D
A1 2
A E
B
F000399
2 m (6'6 ")
11. If necessary, adjust the headlight using the
adjustment screws (1) and (2) to move the light
S000872
beam to the left or right, or up and down.
12. Blackout the outside left headlight and uncover

3. Drive the machine towards the wall until the
the inside left headlight.
headlights are 2 meters (6’6") from the wall.
4. Measure the height of the center of the head-

f d c e g
light from the ground and draw line (a) on the
wall at that height.
a
5. Using the formula (x)=(h)x0.0444, draw line (b) x b
distance (x) below and parallel to line (a). h
6. Draw line (c) on the wall at 90o to lines (a) and HOT SPOT
(b) at the center point between the two head- CENTRE
lights.
WALL PATTERN : HIGH BEAM
Draw lines (d), (e). (f) and (g) on the wall at 90o
S000508
7.
to lines (a) and (b) at the center point of each
headlight. 13. Select high beam and check that the headlight
hot spot center is where lines (a) and (b) inter-
8. Switch ON the headlights. sect.
88 870966
October 17, 1997
HEADLIGHT ADJUSTMENT TEMPLATE
adjustment screws.
TOP
15. Blackout the inside left headlight and uncover

the inside right headlight. LIGHT AREA
16. With the headlights still set on high beam check INCORRECT
that the headlight hot spot center is where lines HORIZONTAL CUT-OFF LINE
(a) and (e) intersect. DIA

GO
NA
LC
UT-O
FF
LIN
E
adjustment screws. BULB INCORRECTLY SHADED AREA
SET IN
HEADLIGHT
18. Blackout the inside right headlight and uncover
the outside right headlight.
19. Select dipped beam (outside headlights only) TOP
and check that the horizontal cut-off line is not

above line (b) and that the diagonal cut-off line LIGHT AREA
tapers off to the 10 o’clock position.

CORRECT
20. If necessary, adjust the headlight using the HORIZONTAL CUT-OFF LINE
adjustment screws. FL
INE
F
UT-O
LC
NA
GO
DIA
21. Uncover and switch OFF the headlights when
the adjustment is correct. BULB CORRECTLY
SHADED AREA
SET IN
HEADLIGHT
Check the Headlight Bulb Position

PART No. 870997
The headlight bulb position can be checked without

removing the bulb by using the following procedure:
2. Cover the headlight with the adjustment tem-
plate P/N 870997.
1. Select dipped beam.
3. Check that the horizontal cut-off line is in the 3
o’clock position and the diagonal cut-off line is
in the 8 o’clock position.
4. Use the following illustration to determine the

correct/incorrect bulb setting.
Other
Check the Tires
Check the tires daily for wear and large cuts, as well
as tire pressures. Refer to Specifications for general
tire pressures.
If in doubt consult your tire supplier for the correct tire

pressures for your application.
Service the Air Conditioner Filter
External Filter
The external filter on the air conditioner must be
replaced every 1 000 hours.
870966 89
October 17, 1997
The following procedure must be used to change the Note: If there is any damage,then the filter element
air conditioner external filter: must be changed.
Note: If the filter element is not damaged it must be

1 cleaned and re-fitted to the air conditioner.
4. Re-fit the internal filter onto the bottom of the

air conditioner and re-clip securely into place.
The air conditioning unit requires specialized serv-

icing annually. Contact your nearest BELL Product
Support.
Any problems with the air conditioning unit must be

reported to your BELL Product Support.
2 f000479 Check the Pneumatic Components

1. Unscrew and remove the wing nut securing the Check all pneumatic components, pipes, fittings and
cover (1) over the filter element (2) on the side hoses, for leaks and damage daily.
of the cab.
Check and Drain the Air Reservoirs
2. Remove the cover from the air conditioner
external filter element and clean with a soap The air reservoirs must be checked and drained
and water solution. daily.
3. Remove the filter element. The following procedure must be used to check and
drain the air reservoirs:
4. Install the new filter element.
5. Install the cover over the filter element. 1

2
Note: The procedure is the same to change the
external filter on machines fitted with a cab ventila-
tion fan.
Internal Filter
The internal air conditioner filter must be cleaned
every 1 000 hours. f000473
The following procedure must be used to change the 1. Drain the air reservoirs by holding open the
air conditioner internal filter: manually operated drain valve (1) until all mois-
ture has been expelled.
2. Check the air reservoir for damage and ensure

the mounting bolts (2) are and connections are
secure.
Check the Seat and Seat Belt

Check the seat and seat belt daily
F000410
1. Unclip the air conditioner internal filter and 1. Functionally test the seat and backrest adjust-
remove it from the bottom of the air conditioner. ments. Refer to Operator Controls and In-
struments.
2. Clean the filter element using compressed air
blown from the inside to the outside of the filter 2. Ensure that the seat and backrest are clean
element. and undamaged and that the seat is mounted
securely.
3. Inspect the filter element for any damage.
90 870966
October 17, 1997
3. Functionally test the seat belt adjustments. Re- Check and Adjust the Steering
fer to Operator Controls and Instruments. Cylinders
4. Ensure that the seat belt is undamaged and is Only applicable for machines built after July 1997.
mounted securely. Information to follow.
Lubricate and Check the Door and Check the Steering Cylinders
Latches
The steering cylinders must be checked daily or every
Check the operation of the door and latches daily and
10 hours for free play.
lubricate as required.
When the machine has cooled down, manually check
Check the Fuel Tank, Fuel Filler Cap for any free play. If the cylinder moves it must be
and Gasket adjusted.
Check the fuel tank, fuel filler cap and gasket daily.
Adjusting the Steering Cylinders
If the steering cylinders need to be adjusted tighten
1. Inspect the fuel tank for damage and security. the adjusting bolts until there is no longer any play.
2. Every time that the fuel cap is removed, check

it for damage and ensure that the gasket is
serviceable.
Check the Structure

Perform a visual check daily on the cab, bin and
chassis to ensure that it is structurally sound and has
not suffered any damage during use.
870966 91
October 17, 1997
Grease Points for Machines Built Before October 1996
The following figure details the points that require greasing daily.
1 2
4 5
B20B
7
14
s002208
13 12 11 10 9 8
1. Walking beam pivot points 8. Steering cylinder pivot points

2. Oscillation tube 9. Front axle suspension pivot points
3. Upper articulation joints 10. Steering cylinder pivot pins
4. Lower articulation joints 11. Oscillation tube
5. Door hinge pins 12. Lower tip cylinder pivot pins
6. Battery box lid hinge pins 13. Upper tip cylinder pivot pins
7. Bonnet hinge pins 14. Bin pivot pins
92 870966
October 17, 1997
Prop shaft Grease Points for Machines Built Before October 1996
The following figure details the prop shaft grease points for machines built before October 1996. All prop shafts
are greased at both ends.
These prop shafts must be greased every 250 hours.
B20 B
.
.
S002227
1 2 3 4
1. Center to rear differential 4. Transmission to front differential

2. Oscillation tube to center differential 5. Engine to transmission
3. Drive knuckle joint
Drive Knuckle Joint

1 2
The following figure details the grease points on the
drive knuckle joint for machines built before October
1996.
This drive knuckle joint requires greasing every 250

hours.
3 s0002194
The drive knuckle joint must be greased through

grease nipples (1, 2 and 3).
870966 93
October 17, 1997
Grease Points for Machines Built After October 1996
The following figure details the points that require greasing daily.
1 2
4 5
B20B
7
14
s002208
13 12 11 10 9 8
1. Walking beam pivot points 8. Steering cylinder pivot points

2. Oscillation tube 9. Front axle suspension pivot points
3. Upper articulation joints 10. Steering cylinder pivot pins
4. Lower articulation joints 11. Oscillation tube
5. Door hinge pins 12. Lower tip cylinder pivot pins
6. Battery box lid hinge pins 13. Upper tip cylinder pivot pins
7. Bonnet hinge pins 14. Bin pivot pins
Note: On machines built after October 1996, the prop shafts are fitted with sealed universal joints and require no
greasing.
94 870966
October 17, 1997
Earthing points
The following figure details the earthing points on the machine.
FRONT CHASSIS
BATTERY TO CHASSIS
EARTH STRAP
ENGINE TO
CHASSIS
EARTH STRAP
CAB EARTH
(ELECTRICAL)
TRANSMISSION
TO CHASSIS
EARTH STRAP
CAB TO CHASSIS
EARTH STRAP
REAR CHASSIS
EARTH
S002200
870966 95
October 17, 1997
96 870966
October 17, 1997
CHAPTER 5. 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
Symptom Possible Cause Remedy

Starter motor turns engine too slowly Battery under charged Check the battery charge. Recharge
or replace the battery
Loose or dirty battery terminals Tighten or clean the battery terminals
Faulty engine earth connection R e p a ir , c le a n or se c u r e t h e
connection
Incorrect grade of engine lubrication C h a n g e t h e oi l. R e f e r t o
oil Recommended Fuel, Lubricants
and Coolant Chart
Engine hard starting when cold Engine starter motor turns engine too Check the battery charge. Recharge
slowly or replace the battery
Incorrect use of auxiliary starting aid Instruct operator on correct use
Engine turns but does not start Insufficient fuel in fuel tank Fill fuel tank and bleed fuel system
Engine difficult to start (hot or cold) Starter motor turns too slowly Check the battery charge. Recharge
or replace the battery
Air in the fuel system Bleed the fuel system
Restricted air inlet Service air filter system
Restricted exhaust system Locate and repair the restriction
Engine cuts out soon after starting Insufficient fuel in the fuel tank Fill the fuel tank and bleed the fuel
system
Air in the fuel system Bleed the fuel system
Blocked fuel tank air vent Clean out the air vent and bleed the
fuel system
Blocked fuel filters Replace the fuel filters
Air filter restriction Service the air filter system
Exhaust restriction Locate and repair the restriction
October 17, 1997 97

Engine Lacks Power

Engine overheating Water level too low Top up the radiator. Check for leaks
and repair
Drive belt slipping Inspect, adjust or replace the drive
belts
Radiator filler cap not sealing or worn Fit new radiator filler cap
Blocked radiator Clean radiator
Engine running too cold Temperature gauge faulty Check temperarture gauge. Contact
y o ur BELL P r o d u c t S u p p o r t
Representative.
Incorrect fan fitted Check the m a n u f a c t u r e r ’s
specification. Contact your BELL
Product Support Representative
Incorrect radiator fitted Check the m a n u f a c t u r e r ’s
specification. Contact your BELL
Engine knocking Incorrect fuel grade Drain and refill if necessary
Engine Difficult to Start

Loss of power Air filter restriction Service the air filter system
Engine does not attain the required Tachometer error R e - c a l i b r a t e t h e t a c h o m e te r .
speed during daily brake test Contact your BELL Product Support
Representative.
Loss of power Refer to “Loss of Power” in this table
Excessive Fuel Consumption

Excessive fuel consumption External fuel tank leak Check the fuel tank, fuel lines and
filter for leaks and/or damage
Too low operating temperature Check and repair cooling system
Air filter restriction Service the air filter system
Defective cold start function Contact your BELL Product Support
Representative
98 October 17, 1997

Low Engine Oil Pressure

Low Engine Oil Pressure Faulty pressure gauge Check gauge. Contact your BELL
Product Support Representative.
Incorrect grade of oil used R e f e r to Recommended Fuel,
Lubricants and Coolant Chart
Abnormal Oil Consumption

Abnormal Oil Consumption Engine overfilled Instruct operator on correct oil level
maintenance
Engine oil leaks Locate and repair oil leaks
Incorrect grade of engine oil R e f e r to Recommended Fuel,
Incorrect operating temperature Check the cooling system and repair
Abnormal Oil Consumption

Oil pressure too high Incorrect engine oil used Drain the engine sump. Refer to
Recommended Fuel, Lubricants
and Coolant Chart
Faulty pressure gauge Check gauge. Contact your BELL
Internal Engine Oil Sludge

Engine oil sludge Incorrect grade of oil used Drain the engine sump. Refer to
and Coolant Chart
Engine operating temperature too Check and correct cooling system
high or too low
Oil in service for too long Change the oil and the oil filtersRefer
to Recommended Fuel, Lubricants
and Coolant Chart
October 17, 1997 99

Engine Vibration

Excessive vibration at any speed Loose components (eg alternator Secure all components including the
etc.) engine mountings and exhaust
system
Worn or damaged engine mountings Check and replace the engine
mountings
Propshaft out of balance Balance and/or replace the propshaft
Exhaust Smoke Analysis

Black smoke from the exhaust Inlet system restricted Service and repair the inlet system
Incorrect grade of fuel Drain and refill the fuel tank. Refer to
and Coolant Chart
Blue smoke from the exhaust Engine oil level too high Correct the engine oil level
White smoke from the exhaust Engine running too cold Check the cooling system
Water in the fuel supply Clean out the fuel system
100 October 17, 1997

Transmission Trouble Shooting

Control pressure too low in all speeds Oil level is low Refill the transmission. Refer to
Recomended Fuel, Lubricants and
Coolants
Oil temperature is too high. The cen- Oil level is too low Refill the transmission. Refer to
t r a l w a r n in g lig h t is t h e c ab Recomended Fuel, Lubricants and
illuminates when the temperature ex- Coolants
ceeds 120oC (248oF)
Oil cooler partly or fully blocked Clean the oil cooler
Transmission will not function at any Oil level is too low Refill the transmission. Refer to
speed Recomended Fuel, Lubricants and
Coolants
P r o p s h a f t fr o m e n gi ne to Change the propshaft
transmission is defective
October 17, 1997 101

102 October 17, 1997
Axle Trouble Shooting

Final drive leaking oil Loose or damaged oil plugs Tighten or replace the oil plugs
Oil level too high Drain oil to the correct level
Final drive bolts loose Tighten the final drive bolts to the
correct torque
Axle breather blocked Clean the axle breather
Noisy final drive Low oil level in the final drive Refill the final drive. Refer to
and Coolant Chart
Final drive overheating Oil level too high Drain oil to the correct level
Oil level too low Refill the final drive. Refer to
and Coolant Chart
Differential assembly leaking oil Bolts loose on main housing Tighten bolts to the correct torque
Differential assembly noisy Oil level too low Refill the differential. Refer to
Specifications for t he
Recommended Fuels, Lubricants
and Coolants
Differential assembly overheating Oil level too high Drain the oil to the correct level
Oil level too low Refill the differential. Refer to
Specifications for t he
Recommended Fuels, Lubricants
and Coolants
Axle breather blocked Clean the axle breather
October 17, 1997 103

104 October 17, 1997
Wheel Trouble Shooting

Wheel misalignment Wheel bent or damaged Change the wheel
Wheel cracked Impact damage Change the wheel
Tire Trouble Shooting

Tires wearing in tread centre Tires over inflated Reduce the tire pressure to the
correct level
Tires wearing on both sides of the Increase the tire pressure to the
Tires under inflated
tread correct level
Tires loosing pressure Tire punctured Repair the puncture or change the
tire
Cracks, splits or bulges in the tire Impact damage Change the tire
sidewall
Defective tire Change the tire
Tire over inflated Change the tire
Tire under inflated Change the tire
Rapid tire wear Excessive speed Instruct the operator on proper
driving. Change the tire
Poor road surface conditions Recommend road surface
maintenance. Change the tire
Tire component heat separation Excessive speed Instruct the operator on proper
driving. Change the tire
Cracks in the tire tread grooves Incorrect tire pressure Change the tire if separation occurs.
Brakes Trouble Shooting

Increased stopping distances Worn brake pads Change the brake pads
Oil or grease on the brake pads Change the brake pads
Squealing noise from the brakes Brake pads glazed Change the brake pads
when applied
Brake discs warped or scored Inspect the brake discs for damage
Brakes do not fully release Brake caliper pistons sticking Change the brake caliper
October 17, 1997 105

106 October 17, 1997
Hydraulic System Trouble Shooting

Pump not delivering hydraulic fluid Hydraulic fluid in hydraulic tank is too Refill the hydraulic tank. Refer to
low Recommended Fuel, Lubricants
and Coolant Chart
Outlet pipe from the tank to the pump Check the suction strainer for
is blocked blockages. Clean if necessary
Hydraulic fluid viscosity and type is Drain and refill the hydraulic system.
incorrect R e f e r to Recommended Fuel,
Pump making noise Pump intake is partially blocked Clean the hydraulic tank strainer.
Check the hydraulic fluid condition, if
necessary drain and flush the system
and refill
Breather is blocked Replace the breather filter
October 17, 1997 107

108 October 17, 1997
Pneumatic System Trouble Shooting

System does not reach operating Drain valves are open Close the drain valves
pressure
Defective pressure gauge Install a new pressure gauge
Ineffective park brake Park brake caliper incorrectly Adjust the park brake caliper.
adjusted Contact your BELL Product Support
Representative
October 17, 1997 109

110 October 17, 1997
Instruments and Controls Trouble Shooting

Gauge not working properly Circuit breaker tripped Investigate the cause and rectify
Loose or broken connections Tighten or repair the connections
Gauge defective Change the gauge
Switch not working properly Circuit breaker tripped Investigate the cause and rectify
Warning light not working Warning light bulb defective Change the warning light bulb
Circuit breaker tripped Investigate the cause and rectify
Electrical Supply Trouble Shooting

Alternator charge warning indicator Indicator light bulb defective Change the light bulb
not illuminated when master switch is
in the ON position
Alternator charge warning indicator Alternator drive belt is loose or Adjust drive belt tension or fit new
illuminated when engine is on broken drive belt. Contact your BELL
Poor battery connections Clean and check the battery
connections
Batteries do not hold a charge Battery cells dry Check the battery electrolyte and top
up. Replace battery if sealed type
Short running time with lights on Remove the batteries and recharge
or fit new batteries
October 17, 1997 111

Electrical Equipment Trouble Shooting

Headlights do not work Circuit breaker tripped Investigate and rectify the cause
Headlight bulb defective Change the headlight bulb
Only high beam or low beam comes Headlight bulb defective Change the headlight bulb
on
Loose or broken connection Tighten or repair the connections
One headlight does not come on Headlight bulb defective Change the headlight bulb
(high or low beam)
High beam indicator light does not Indicator bulb defective Change the indicator bulb
come on when high beam is selected
Tail lights do not come on Bulb defective Change the bulb
Stop lights do not come on Bulb defective Change the bulb
Turn indicator and horn does not Circuit breaker tripped Investigate the cause and rectify
work
Right turn indicator does not work Bulb defective Change the bulb
Left turn indicator does not work Bulb defective Change the bulb
Windscreen wiper does not work Circuit breaker tripped Investigate and rectify the cause
Starting System Trouble Shooting

Starter motor does not turn or turns Batteries are flat Recharge or charge the batteries
very slowly
Batteries defective or damaged Change the batteries
Battery terminals loose or damaged Tighten or clean the battery terminals
112 October 17, 1997

EST 25 Trouble Shooting

NN is displayed but the engine does Gear shift not in neutral Move gear shaft to neutral
not start
EE is displayed and the engine does Electrical system charge too low Recharge or renew the batteries
start but the machine does not move
F1 is displayed (flashing) upshifting Kick down switch is activated Change to the next gear using the
to 1st is not possible gear shift. Contact your BELL
F is displayed (with four lines) and Engine speed too high Reduce engine speed.
machine does not move
F is displayed (selected gear flash- Selected gear is too low and machine Reduce machine speed
ing) speed is too high
CODE 10 (with flashing spanner) is Downshift inhibitor is defective Contact your BELL Product Support
displayed Representative
October 17, 1997 113

114 October 17, 1997
Articulation and Oscillation Assembly Trouble Shooting

Excessive play in the oscillation tube Incorrect adjustment of the oscillation Tighten the retaining nut on the
tube oscillation tube to the correct torque.
Contact your BELL Product Support
Representative
Oscillation tube does not accept Grease nipple blocked or damaged Change the grease nipple
grease
Rear Frame and Walking Beam Assembly Trouble Shooting

Blocked grease nipple Change the grease nipple, pins and
bushes. Contact your BELL Product
Support Representative
Cab and Bonnet Assembly Trouble Shooting

A smear remains in the windshield Oil or grease on the windshield Clean the windshield
when the windshield wiper is in op-
eration
Wiper blade damaged Change the wiper blade
Seat is difficult to adjust Lack of lubrication Lubricate the seat runners
Excessive movement of the wing mir- Loose or missing retaining bolts Tighten or replace the retaining bolts
rors while the machine is in operation
Mirror difficult to view Damaged mirror arm Replace the mirror arm
Incorrect adjustment Readjust the mirror
Mirror is cracked Replace the mirror
Excessive noise while the fan rotates Obstruction near the fan blades Remove the obstruction
Engine over heating Air intake is blocked. Clean as necessary. Refer to Engine
Trouble Shooting if the engine still
over heats
Bin Assembly Trouble Shooting

Excessive play in the pivot pins and Blocked grease nipple Change the grease nipple, pins and
bushes bushes. Contact your BELL Product
Support Representative
October 17, 1997 115

116 October 17, 1997

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TO THE OPERATOR

WARNING AND CAUTION

CALIFORNIA PROPOSITION 65 WARNING

BELL B20B 6X4 PROMOTIONAL VIDEO

Document Part Number 870966

Issue : OCTOBER 1997

This manual conforms in-full or in-part to the following specifications:-

The following address list was correct as at 31 July 1996.

Richards Bay (Head Office):

Richards Bay (Training):

Johannesburg (Jet Park):

Johannesburg (Used/Rebuild Division):

Johannesburg (National Distribution):

Garden City (Head Office):

New Zealand (Bell Equipment (NZ) Ltd):

Australia (Bell Equipment):

Pacific Rim Region (Western Australia):

South America (Bell Equipment Chile SA):

South East Asia (Bell Equipment (SEA) Ltd):

Bell France SARL:

Please supply your dealer details here:

YOUR COMMENTS, SUGGESTIONS, OR QUERIES:

DOES THE MANUAL MEET YOUR NEEDS ? YES NO

Thank you for your co-operation.

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

ADE Atlantic Diesel Engines JIC Joint Industry Conference Standards

October 17, 1997 i

ii October 17, 1997

Unauthorised Modifications of the Operator Protective Structure (OPS)

Noise Emission Levels

October 17, 1997 iii

Mounting and Dismounting the Machine

Avoid Power Lines

Keep Riders Off the Machine

Prepare for Emergencies

Handle Flammable Fluids Safely

Clean the Machine Regularly

iv October 17, 1997

Do not smoke in areas where batteries are being charged.

Avoid the hazard by:

• Filling the batteries in a well ventilated area.

• Wearing eye protection and rubber gloves.

• Avoid breathing fumes when electrolyte is added.

• Avoid spilling or dripping electrolyte.

• Flush your skin with water.

• Apply baking soda or lime to help neutralise the acid.

• Drink large amounts of water or milk.

• Then drink milk of magnesia, beaten eggs, or vegetable oil.

• Get medical attention immediately.

Wear Protective Clothing

Use the Seat Belt

Avoid High Pressure Fluids

October 17, 1997 v

Use a safety cage if available

vi October 17, 1997

WORKING UNDER RAISED BIN TO CONNECT ARTICULATION LOCK BEFORE LIFTING,

Located on the front of the cab

Located on the bonnet.

October 17, 1997 vii

Located on the hydraulic tank

CALIFORNIA PROPOSITION 65 WARNING