PART 2

SERVICE AND MAINTENANCE

B20D 6X4 & 6X6 ADT Mk III CHAPTER 10 872154

CHAPTER 10. MAINTENANCE SCHEDULES

Preventative maintenance is very important. It includes lubrication, checks and adjustments which the
operator can perform. Scheduled services are to be performed by BELL EQUIPMENT Product Support.

Operator to do only daily inspection as indicated on the RSG below and CHAPTER 11 in this manual.

Most of these service measures are simple to carry out and do not need any detailed explanation. The
instructions which require specific procedures are detailed in Chapter 11 of this manual.

Maintenance Schedule in Running Hours

Every Every Every Every Every Every As
Details Daily
150 500 1000 2000 3000 4000 Required

ENGINE

NOTE: For further maintenance and service procedure, Refer to the Mercedes-Benz )OM 502 Manual.

Change the oil and oil filters X (J) X

Drain water from the primary fuel filter X

(Check cold, drain before starting).

Change the primary fuel filter/water X (J) X

separator.

Change secondary fuel filter. (Situated X (J) X

on engine).

Clean/replace the primer pump fuel X

screen.

Clean crankcase breather filter. X

Check the coolant level. X X

Check the coolant mixture. X

(A)

Change the coolant. X (A)

Adjust the valve clearance. (Every X

second oil change).

Check Fan Belt Condition. X

Replace fan belts. X

Change the air cleaner primary filter. X

Change the air cleaner secondary filter. X

Clean the air intake pre-cleaner X

assembly.

Check the air cleaner service indicator. X

Check the oil level. X

Change jockey pulley bearing X

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Maintenance Schedule in Running Hours

Every Every Every Every Every Every As
Details Daily
150 500 1000 2000 3000 4000 Required

TRANSMISSION-ZF 6 HP 592C

Check for oil leaks. X X

Check transmission oil level. X X

Change the oil. X

(B)

Change the filters. X

Replace transmission breather filters. X

TRANSFER CASE

Change the oil filter. X

Check the oil level. (Sight Glass). X X

Change the oil. X

(B)

Check and clean transfer case breather. X

HYDRAULICS

Check the oil level. X X

Change the oil. X

(B)

Change the return filters. X X

(E) (D)

Change the breather filter. X X

(E) (D)

Replace the suction screens. X

Test the brake accumulator function. X

AXLES AND CHASSIS & SUSPENSION

Change the oil in all axles, wet disc X

brakes and clean debris from all (B)
magnets.

Check the service brake pads wear X

Check the park brake pads wear. X

Check and adjust bin shock pad X

clearance. (H)

Check conditions of all drive shafts. X

Check and clean breathers of all axles. X

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B20D 6X4 & 6X6 ADT Mk III CHAPTER 10 872154

Maintenance Schedule in Running Hours

Every Every Every Every Every Every As
Details Daily
150 500 1000 2000 3000 4000 Required

Check suspension strut height, oil leaks X

& gen. cond.

Change all axle driveline cross and X

rollers (K)

CAB, PNEUMATICS AND ELECTRICAL

Change the air drier filter. X

Check the operator controls, buzzers X X

and instruments.

Check the working lights, reverse buzzer X X

and horn.

Check the electrical connections and X

wire routing for chaffing.

Replace Pneumatic block breather filters X

(situated on block).

Record and clear fault codes found on X

the MDU.

Clean or replace air conditioner filters. X X

(C)

LUBRICATION

Grease the hinges. X

Grease all remaining lube points. (If X

applicable).

Grease PTO propshaft Slip-joint. X

GENERAL WALK ROUND

Check and clean coolers. X

General check of drive line & suspension X

fasteners.

Check for fuel, water and oil leaks. X

Check tyre pressures. X X

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NOTES:
A Refer to bulletin 2000/033 regarding water & coolant specification
B Change intervals can be extended by oil sampling. Use kit 261677 for sampling the Allison
transmission and axles and final drives. (B50D axle & final drive: Refer to service manual chapter
15 for draining and filling).
C Daily depending on site conditions.
D To be changed in wet & muddy conditions. (Note service kit applicable for this condition).
E To be changed in dry & dusty conditions. (Note service kit available for this condition).
F Refer to SIB 2004/1018.
G Grease should meet DIN 51825 KP2-R-20, and not contain any solids such as Graphite or
Molybdeendisulphide. (Preferred greases: Castrol Viscotemp NLGI 2, Castrol Firetemp XT2).
H See SIB 97/105/07 for details of thickness.
I See SIB 2003 / 1067 for details of procedure.
J To be changed as indicated when running on FAME / Bio-diesel. Refer Appendix A of SIB 2006/1001 for more information
on FAME use.
K Cross & Roller replacement on all machanic joints, when operating in submerged or dusty conditions and replace every
6000 hrs under normal conditions.

Torque all wheel nuts to 650 Nm. (480 ft lb.) after the first 5 hours of operation and again after 50 hours of
operation. Repeat the procedure if the wheels are changed.

The air conditioner internal filter should be cleaned every 50 hours (or as required, depending upon
conditions) and replaced if damaged.

The air conditioner external filter should be cleaned every 250 hours (or as required, depending upon
conditions) and replaced if damaged.

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B20D 6X4 & 6X6 ADT Mk III
CHAPTER 11. DAILY OR 10 HOURLY SERVICE CHECKS
SECTION 1. ENGINE
INTRODUCTION
The daily or 10 hourly service checks must be
performed by qualified service personnel.
It is recommended that the daily or 10 hourly
service checks are performed in conjunction with
the Walk Round Checks so that the operator can
assist in the service checks which require two
people.
SERVICE INSTRUCTIONS
Ensure that the machine is in the service
position. Refer to Pre-service Instructions,
Chapter 7.
Engine
NOTE: For further engine information or
details not shown in this manual, refer to the
Mercedes-Benz Manual OM 502LA.
Open the bonnet.
Check the bonnet catch for damage and ensure
that the bolts are secure.
Check the Oil Level
Remove the dipstick (1).
Wipe the dipstick clean with a lint free cloth.
Re-insert the dipstick, ensuring that it is properly
seated.
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CHAPTER 11 872154
Remove the dipstick and check that the oil level
reaches the upper mark (1) on the dipstick.
NOTE: When the oil is hot, the oil level must
be on the top mark (1) of the dipstick, but not
above it. When the oil is cold, ensure that the
level is between marks (1) and (2), but not
below mark (2).
Re-insert the dipstick, ensuring that it is properly
seated and fasten the dipstick clip.
If necessary, replenish the engine oil.
Check the Coolant Level
‹ WARNING
Check the coolant level when the engine is
cold. Whenever the cap on the expansion
tank needs to be removed, remember that the
system may be under pressure which could
cause hot coolant to be ejected.
‹ CAUTION
When coolant is drained from the cooling
system, it must be replaced with the
recommended coolant specified by the
manufacturer.
If the coolant level is not correct, top up with
coolant. Refer to Specifications, Chapter 1 -
Recommended Lubricants and Coolant
Additives.
NOTE: If there is too much coolant in the
tank, when cold, the tank will purge itself and
overflow with excess coolant.
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872154 CHAPTER 11 B20D 6X4 & 6X6 ADT Mk III

Check Coolant Level

The coolant must not be lower than the "Minimum

Cold" mark (1) when the when the engine is cold.

Check Engine Air Intake System

Check air cleaner assembly for damage to the

pre-cleaner (1) and air cleaner housing (2).

Check the service indicator (3) is not showing a

red flag. If red flag is shown; service air cleaner
and reset indicator. (See Service Engine Air
Intake System in Maintenance - As Required
Section).

Check rubber elbows (4), clamps (5) and pipes

(6) for tightness, cracks or damage.

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B20D 6X4 & 6X6 ADT Mk III CHAPTER 11 872154

CHAPTER 11. DAILY OR 10 HOURLY SERVICE CHECKS

SECTION 2. TRANSMISSION

CHECK THE TRANSMISSION

FOR OIL LEAKS
Check under the machine for oil leaks. Take
special care to check for oil leaks in the
transmission region.

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B20D 6X4 & 6X6 ADT Mk III CHAPTER 11 872154

CHAPTER 11. DAILY OR 10 HOURLY SERVICE CHECKS

SECTION 3. TRANSFER CASE

CHECK THE TRANSFER CASE

FLUID LEVEL
NOTE: The level must be in the centre of the
sight glass when hot and just be visible at the
bottom of the sight glass when cold.

Check the oil level in the sight glass.

When oil level is at mark (1), the transfer case is

full.

When oil level is at mark (2), the oil level is low

and oil must be added.

Drain or add oil as necessary. (See Change

Transfer Case Oil in 2000 hours service).

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B20D 6X4 & 6X6 ADT Mk III CHAPTER 11 872154

CHAPTER 11. DAILY OR 10 HOURLY SERVICE CHECKS

SECTION 4. HYDRAULICS, CAB AND ELECTRICAL

HYDRAULICS • Apply the service brakes repeatedly to make

the pump re-charge a few times. Discontinue
Check the Hydraulic Fluid Level applying the brakes in a re-charge cycle while
the pump is still charging (to ensure the brakes
NOTE: Check the hydraulic fluid level in the are not consuming oil after the pump stops,
sight glass (1). wait 4 seconds while listening to the engine.
Engine revolutions must go up after pump
stops).
• Switch off the engine.
• Switch the ignition on an wait until the warning
lights extinguishes.
• Fully apply the service brakes and count the
number of applications before the accumulator
low pressure light illuminates.
NOTE: 1. If less than two full applications,
have the system checked by a BELL
EQUIPMENT serviceman.

Cab and Electrical

Check the Operator’s Controls and

The fluid level must be on the mark (2) with the Instruments
engine shut down and the machine parked on
level surface and oil hot. Carry out a functional check on all controls and
instruments daily. Refer to Chapter 2 - Operator
If necessary replenish the fluid in the hydraulic Control and Instruments.
tank. Refer to Specifications, Chapter 1 -
Recommended Lubricants and Coolants. Inspect, Clean / Replace Cab Air Filter
Service Brake Accumulator Routine
Test

• Start engine. Wait until main pump has fully

charged the accumulators (Listen to the tone
of the engine, while charging the engine
revolutions will be lower).

Turn latches (1) 1/4 turn counter clockwise. Open

the access door (2).

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872154 CHAPTER 11 B20D 6X4 & 6X6 ADT Mk III

Remove element (1). Inspect element for dust,

debris, moisture and damage.

Replace element if damaged.

Ensure that the reverse buzzer (1) is securely
mounted.
‹CAUTION
Use compressed air to 207kPa (30psi) to
clean filter element. Do not use high pressure
air, element may be damaged or personal
injury may result.

Clean element if necessary. Remove large debris

by hand. Blow compressed air through element
from opposite direction of normal air flow.

If element is moist, allow to dry before

re-installing. Do not apply heat to element.
Functionally test the horns and ensure that they
Install element. Ensure that “Air Flow” decal is
are securely mounted.
at top and arrows point towards front of machine.
Check the Head lights - Bright and dip to ensure
Close access door. Turn latches 1/4 turn
bulbs are working.
clockwise and ensure latches are locked.
Check rear lights - tail, brake and indicators.
Close parts catalogue compartment door.
Check bin switch for damage.
Check all Working Lights, Reverse Buzzer
and Horn

Two people are needed to perform this check.

One person inside the cab to control the switches
and the other outside to ensure all the lights are
working. Refer to Specifications, Chapter 1 -
Recommended Lubricants and Coolants.

• Switch all the lights on in turn, including

headlight (dipped and high beam), indicators,
hazard and brake lights.
• Make sure the path is clear behind the
machine, and then reverse to ensure the
buzzer and reverse lights are working.

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