OMM B25L & B30L 4X4 ADT MK II May 2003

B25L & B30L Mk II 4 X 4
ARTICULATED DUMP TRUCK
OPERATOR’S MANUAL
Document Part Number 872120
LEFT BLANK INTENSIONALLY
TO THE OPERATOR
WARNING
Do not operate the machine unless you have read this manual and fully understand how to operate
the machine properly.
The safe operation of your BELL EQUIPMENT machines very important to prevent any personal injury and/
or damage. This manual must be read and fully understood before operating or carrying out any
maintenance on your BELL EQUIPMENT machine.
SAFETY SYMBOL
The following safety symbol is used for all safety messages. When you see the safety symbol, follow the
safety message to avoid personal injury or death.
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 SYMBOL
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.
LEFT BLANK INTENTIONALLY
B25L and B30L Mk II 4X4
ARTICULATED DUMP TRUCK
OPERATOR’S MANUAL
THIS MANUAL IS APPLICABLE TO
B25L Mk II 4X4 (411829)

B30L Mk II 4X4 (411828)
Document Part Number 872120
Issue:0
(Released: June 2003)
Technical Documentation
BELL EQUIPMENT COMPANY
Richards Bay
IMPORTANT
Due to BELL EQUIPMENT’S policy of continuous product improvement, the information contained in this
manual was correct up to the time of printing (Revised 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.
Photographs and illustrations may show optional equipment.
Amendment Record Sheet
The table below is a record of amendments made to this manual after the publication date.
Authorisation for Page/Pages No’s. Amended Page/

Date
Amendment Replaced Pages Inserted By
7
8
INTRODUCTION
This manual has been produced to assist you in the correct operation, maintenance and care of your BELL
EQUIPMENT machine.
This manual is divided into chapters. The information contained in the manual is in logical sequence, with
the instructions written in step by step format.
Effective maintenance on your BELL EQUIPMENT 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 endeavour 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 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 EQUIPMENT Product Support Representative
whenever you have a query on your BELL EQUIPMENT product or this manual.
The following address list was correct at 2 May 2001.
GROUP OPERATIONS LISTING
RICHARDS BAY (HEAD OFFICE)

Carbonate Cell .................................... Tel: (035) 907 9111 ..................................Private Bag X20046
Alton.................................................... Fax: (035) 907 4323 .................................EMPANGENI
RICHARDS BAY ................................. Web site: www.bellequipment.com ...........3880
3900
LOCATION OF OPERATIONS
EUROPEAN REGION
FRANCE
Bell France Sarl
Z.A. Route díArgenton-sur-Creuse ..... Tel: +33 55589 2356
23800 Dun-Le-Palestel ....................... Fax: + 33 55589 2324
FRANCE ............................................. e-mail: bell-france@inext.fr
GERMANY
Bell Equipment (Deutschland) GmbH
Am Ringofen 24 / 14B......................... Tel: +49 - 6631 911 30
D-36304 Alsfeld .................................. Fax: +49 - 6631 911 313
GERMANY.......................................... e-mail: dickv@bell-germany.de
9
UNITED KINGDOM
Bell Equipment U.K.
Unit 6C ................................................ Tel: +44 1283 712862 (Direct)
Graycar Business Park ....................... Tel: +44 1283 716777 (Parts Direct)
Barton Turns ....................................... Fax: +44 1283 712687
Barton-under-Needwood..................... e-mail: general@bellequipment.co.uk (General)
Burton-on-Trent................................... e-mail: sales@bellequipment.co.uk (Sales)
DE13 8EN ........................................... e-mail: colinw@bellequipment.co.uk (Customer Support)
UNITED KINGDOM............................. e-mail: cliffa@bellequipment.co.uk (Parts)
NORTH AMERICA
United States
Bell Equipment North America Inc.
2843 HWY 80...................................... Tel: +1 912 966 2615
Garden City ......................................... Fax: +1 912 964 1594
GEORGIA ........................................... e-mail: billr@bellequipment.com
GA 31408
USA
SOUTHERN AFRICA REGION
CAPE REGION
CAPE TOWN:
Bell Equipment Co SA (Pty.) Ltd.
Milan Street ......................................... Tel: 021 386 2252 .................................... P.O. Box 162
Airport Industria................................... Fax: 021 386 2260 ................................... EPPINGDUST
CAPE TOWN ...................................... e-mail: fionaj@bell.co.za.......................... 7475
7525
EAST LONDON
25 Ray Craib Crescent........................ Tel: 043 748 6622/3 ................................. c/o P.O. Box 3443
Beacon Bay ........................................ Fax: 043 748 6624 ................................... North End
Industria .............................................. e-mail: pierred@bell.co.za ....................... PORT ELIZABETH
EAST LONDON .................................. ................................................................. 6001
5200
GEORGE
Pioneer Road ...................................... Tel: 044 878 0930/1 ................................. P.O. Box 1697
Pacaltsdorp ......................................... Fax: 044 878 0932 ................................... GEORGE
GEORGE ............................................ e-mail: karino@bell.co.za ........................ 6530
6534
PORT ELIZABETH
349 Kempston Road ........................... Tel: 041 451 3202 .................................... P.O. Box 3443
Korste, Port Elizabeth ......................... Fax: 041 451 3208 ................................... NORTH END
6056 .................................................... e-mail: lynneo@bell.co.za........................ 6056
10
SPRINGBOK
Drive Inn Road .................................... Tel: 027 712 1124/30 ................................P.O. Box 618
Industrial Park ..................................... Fax: 027 718 1314....................................SPRINGBOK
SPRINGBOK....................................... e-mail: laurencedv@kingsley.co.za ..........8240
8240
WINDHOEK
37 LazaretT Street .............................. Tel: 264 61-22 6021/2/3............................Private Bag 12018
Ausspann Platz ................................... Fax: 264 61-22 8330.................................Auspann Platz
WINDHOEK ........................................ ..................................................................WINDHOEK
NAMIBIA ............................................. ..................................................................NAMIBIA
CENTRAL REGION
BLOEMFONTEIN
109 Fritz Stockenstrom Street ............ Tel: 051 432 7855 .....................................P.O. Box 1878
Ooseinde............................................. Fax: 051 432 3740....................................BLOEMFONTEIN
BLOEMFONTEIN................................ e-mail: karenm@bell.co.za .......................9300
9300
GAUTENG
Bell Jet Park........................................ Tel: 011 928 9700 to 22 ............................P.O. Box 25391
Griffiths Road ...................................... Fax: 011 928 9730....................................EAST RAND
JET PARK ........................................... e-mail: bokkiec@dc.bell.co.za ..................1462
1459 .................................................... e-mail: pamj@dc.bell.co.za
KIMBERLEY
26 South Circular ................................ Tel: 053 832 1078/9 ..................................P.O. Box 2927
KIMBERLEY ....................................... Fax: 053 832 1135....................................KIMBERLEY
8300 .................................................... e-mail: cornell@bell.co.za.........................8300
KURUMAN
8 Acacia Street.................................... Tel: 053 712 0698 .....................................P.O. Box 1396
KURUMAN .......................................... Fax: 053 712 0697....................................KURUMAN
8460 .................................................... e-mail: charld@bell.co.za .........................8460
SWAZILAND
Bell Equipment Swaziland
Shop No. 4 .......................................... Tel: +268 - 51 - 87 496/7 ..........................P.O. Box 134
Second Street ..................................... Fax: +268 - 51 - 87 498 ............................Matsapha
Matsapha ............................................ ..................................................................SWAZILAND
SWAZILAND
11
MIDDELBURG
9 Celcius Street................................... Tel: 013 246 1169 .................................... P.O. Box 2821
Building B ............................................ Fax: 013 246 1229 ................................... MIDDELBURG
Industrial Area ..................................... e-mail: bellmid@intekom.co.za ................ 1050
MIDDELBURG
1050
NELSPRUIT
3 Christie Crescent.............................. Tel: 013 755 2110/6 ................................. P.O. Box 1672
Vintonia 2 ............................................ Fax: 013 755 2117 ................................... NELSPRUIT
NELSPRUIT ........................................ e-mail: boeriev@bell.co.za ...................... 1200
1200
RUSTENBURG
16 Vanadium Street ............................ Tel: 014 538 1003/4 ................................. P.O. Box 3701
Border Industrial.................................. Fax: 014 538 1005 ................................... RUSTENBURG
RUSTENBURG ................................... e-mail: bellrust@intekom.co.za................ 0300
0300
TZANEEN
8 Impala Street.................................... Tel: 015 307 4812 .................................... P.O. Box 2102
Industrial Sites..................................... Fax: 015 307 3095 ................................... TZANEEN
TZANEEN ........................................... e-mail: tinas@bell.co.za........................... 0850
0850
WOLMARANSSTAD
80 Kruger Street.................................. Tel: 018 596 2319 .................................... P.O. Box 587
WOLMARANSSTAD ........................... Fax: 018 596 2855 ................................... WOLMARANSSTAD
2630 .................................................... ................................................................. 2630
COASTAL REGION
EMPANGENI
No.1 Irvine Bell Drive .......................... Tel: 035 792 6517 .................................... P.O. Box 7332
Old Mill Industrial................................. Fax: 035 792 6516 ................................... EMPANGENI RAIL
EMPANGENI....................................... e-mail: shelleyb@bell.co.za ..................... 3910
3880
PIET RETIEF
14 Smith Street ................................... Tel: 01782 61523 ..................................... c/o P.O.Box 1221
PIET RETIEF ...................................... Fax: 01782 61580 .................................... VRYHEID
2380 .................................................... ................................................................. 3100
12
PIETERMARITZBURG
7 Van Eck Place.................................. Tel: 033 386 9319 .....................................P.O. Box 100436
MKONDENI......................................... Fax: 033 386 1837....................................SCOTTSVILLE
3201 .................................................... e-mail: carlaf@bell.co.za ..........................3209
PONGOLA
Akasia Street....................................... Tel: 034 413 1720 .....................................P.O. Box 681
PONGOLA .......................................... Fax: 034 413 1735....................................PONGOLA
3170 .................................................... ..................................................................3170
PORT SHEPSTONE
Shop 5 Industrial Park......................... Tel: 039 685 4124 ..................................P.O. Box 560
Cnr. Main Harding and Izotsha Road.. Fax: 039 685 5155.................................PORT SHEPSTONE
PORT SHEPSTONE ........................... ...............................................................4240
4240
RICHARDS BAY (Training Centre)

Carbonate Cell .................................... Tel: (035) 907 9111 ..................................Private Bag X20046
Alton.................................................... Fax: (035) 797 3196 .................................EMPANGENI
RICHARDS BAY ................................. e-mail: veronicab@bell.co.za....................3880
3900
UMHLALI
Lot 81 .................................................. Tel: 032 947 0696 / 947 1637...................P.O. Box 39
Shakas Head Industrial Park .............. Fax: 032 947 2141....................................UMHLALI
Shakas Head ...................................... ..................................................................4390
UMHLALI
4390
VRYHEID
Bloekom Street ................................... Tel: 034 981 5541 .....................................P.O. Box 1221
VRYHEID ............................................ Fax: 034 980 9752....................................Ausspann Platz
3100 .................................................... ..................................................................3100
NORTHERN REGIONS
MALAWI
Bell Equipment (Malawi) Ltd.
10/338 Mtendere Street ...................... Tel: +265 78 3293
Area 10 ............................................... Fax: +265 78 3293
Lilongwe
MALAWI
13
MOZAMBIQUE
Bell Equipment (Mozambique) LTD
Avenida da Oau 121 ........................... Tel: +258 - 1 - 403 137/403 706 .............. Caixa Postal 2510
Maputo ................................................ Fax: +258 - 1 - 401 949 ........................... Maputo
MOZAMBIQUE.................................... e-mail: BellEquipment@mail.garp.co.mz . MOZAMBIQUE
Contact: Eddy Fischer......................... Cel: +258-1-(0)82301894
ZAMBIA
Bell Equipment (Zambia) Ltd.
Plot 4675 ............................................. Tel: +260 221 8113/121/123.................... P.O. Box 20367
Kitwe Chingola Road........................... Fax: +260 221 3516 ................................. Kitwe
Kitwe ................................................... e-mail: bell@zamnet.zm .......................... ZAMBIA
ZAMBIA
ZIMBABWE
Bell Equipment (Zimbabwe) Ltd.
16 Erith Road ...................................... Tel: +263 4 661 048/061 .......................... P.O. Box 2980
Willowvale .......................................... Fax: +263 4 621 026................................ Harare
ZIMBABWE ......................................... e-mail:bellzimb@iafricaonline.co.zw ........ ZIMBABWE
DEALER
Please supply your dealer details here:
14
B25L & B30L Mk II 4X4 872120
ABBREVIATION LIST
The table below lists the abbreviations used in this manual:
Abbreviation Meaning Abbreviation Meaning
ºC degrees Celsius m metre
cubic metre
ºF degrees Fahrenheit m3
A ampere N Neutral
ADT Articulated Dump Truck m.p.h. miles per hour
Ah ampere hours MSDS Material Safety Data Sheet
CB circuit breaker Nm Newton metre
d diagnostic psi pounds per square inch
D drive PTO Power Take-Off
DNS Do Not Shift R Reverse
ECU Electronic Control Unit rev/min. revolutions per minute
FOPS Falling Objects Protective ROPS Roll Over Protective

Structure Structure
ft foot (feet) SMR Service Meter Reading
ft lb foot pound USGAL United States Gallon
HP Horsepower V Volt
ISO International Standards cubic yard

Organisation yd 3
kg kilogram
km kilometre
km/hr kilometres per hour
kPa kilo pascal
kW kilowatt
lb pound
LCD Liquid Crystal Display
LED Light Emitting Diode
ISSUE 0 15
872120 B25L & B30L Mk II 4X4
16 ISSUE 0
TABLE OF CONTENTS
SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5
SAFETY FEATURES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Material Safety Data Sheets (MSDS) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
General Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
SAFETY DECALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12
CHAPTER 1. SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -19

MACHINE SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
CHAPTER 2. OPERATOR CONTROL AND INSTRUMENTS - - - - - - - - - - - - - - - - -29
SECTION 1. OPERATOR CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29

INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
SEAT BELT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
SECTION 2. INSTRUMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -33

INDICATORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
SECTION 3. SWITCHES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -41

LIGHTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
MISCELLANEOUS EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
CHAPTER 3. PROCEDURES BEFORE STARTING - - - - - - - - - - - - - - - - - - - - - - - -47
SECTION 1. SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47

Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
SECTION 2. BEFORE STARTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -49

Safety Rules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
CHAPTER 4. OPERATING INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51
SECTION 1. SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51

SAFETY RULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51
SECTION 2. STARTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -53

BEFORE STARTING THE ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
SHUTTING DOWN THE ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
USING BOOSTER BATTERIES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55
SECTION 3. RUNNING-IN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -57

RUNNING-IN INSTRUCTIONS - - - - - - - - -- --- -- -- -- --- -- -- -- --- -- -- -- --- -- -- -- - 57
SLOWING AND STOPPING - - - - - - - - - - -- --- -- -- -- --- -- -- -- --- -- -- -- --- -- -- -- - 61
BRAKING - - - - - - - - - - - - - - - - - - - - - - - -- --- -- -- -- --- -- -- -- --- -- -- -- --- -- -- -- - 61
Operating with Inter-axle Differential Lock - -- --- -- -- -- --- -- -- -- --- -- -- -- --- -- -- -- - 62
SECTION 4. OPERATING THE MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - -63

LOADING THE MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
STEERING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
OPERATING INDOORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
ISSUE 0 1
TABLE OF CONTENTS
CHAPTER 5. OPERATING TECHNIQUES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65

Safety Rules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
Gear Pre-selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
Transport Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
CHAPTER 6. RECOVERY AND TRANSPORTATION - - - - - - - - - - - - - - - - - - - - - - 71
SECTION 1. TOWING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71
SAFETY RULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71
BRAKES RELEASE PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71
SECTION 2. LIFTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73
Machine Lifting Points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73
Machine Tie-down Points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 74
Transporting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75
CHAPTER 7. PRE-SERVICE INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
SECTION 1. SERVICE POSITION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77

Install the Bin Prop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
Install the Articulation Safety Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
Lower and Raise the Belly Plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 79
SECTION 2. RULES WHEN SERVICING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81

GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81
DIESEL FUEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81
CONTAMINATED OILS AND FLUIDS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82
CHAPTER 8. MAINTENANCE SCHEDULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87
CHAPTER 9 . AS REQUIRED SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
SECTION 1. ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
Service Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
SECTION 2. HYDRAULICS CAB AND ELECTRICAL - - - - - - - - - - - - - - - - - - - - - 95

CLEAN AND CHECK THE BREATHER, HOSES AND CONNECTIONS - - - - - - - - - - - - - - - - - - 95
CHECK THE STEERING CYLINDERS, HOSES AND CONNECTIONS - - - - - - - - - - - - - - - - - - - 95
CHECK THE TIP CYLINDERS, HOSES, PIPES AND CONNECTIONS - - - - - - - - - - - - - - - - - - - 95
CHECK THE MAIN HYDRAULIC PUMP, HOSES AND CLAMPS - - - - - - - - - - - - - - - - - - - - - - - 96
CHECK THE EMERGENCY STEERING PUMP, HOSES AND CLAMPS - - - - - - - - - - - - - - - - - - 96
AXLES AND CHASSIS AND WHEELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96
LUBRICATE ALL HINGES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96
CHANGE ENGINE COOLANT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96
CHAPTER 10 . DAILY OR 10 HOURLY SERVICE CHECKS - - - - - - - - - - - - - - - - - 99
SECTION 1. ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
SERVICE INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
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TABLE OF CONTENTS
SECTION 2. TRANSMISSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101

CHECK THE TRANSMISSION FLUID LEVEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101
SECTION 3. HYDRAULICS, CAB AND ELECTRICAL - - - - - - - - - - - - - - - - - - - - 103

HYDRAULICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103
CHAPTER 11 . FIRST 100 HOUR SERVICE CHECKS - - - - - - - - - - - - - - - - - - - - - 105
SECTION 1. ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 105

INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 105
SERVICE INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 105
ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 105

Check for fluid leaks at the filter covers. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110
SECTION 3. HYDRAULICS, CAB AND ELECTRICAL - - - - - - - - - - - - - - - - - - - - 113

HYDRAULICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 113
SECTION 4. AXLES AND FINAL DRIVES - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115

CHANGE AXLE & FINAL DRIVE OIL AND FILTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115
CHAPTER 12 . 500 HOURS SERVICE AND CHECKS - - - - - - - - - - - - - - - - - - - - - 117
SECTION 1. ENGINE, AXLES AND SUSPENSION - - - - - - - - - - - - - - - - - - - - - 117

INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117
SECTION 2. CLEAN, CHECK AND REPLACE BREATHERS - - - - - - - - - - - - - - 119

FRONT AXLE BREATHER (LOCATED UNDER CAB) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119
REAR AXLE BREATHERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119
SECTION 3. CAB AND ELECTRICAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 121

CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS - - - - - - - - - - - - - - - - - - - - - - - - - - 121
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS - - - - - - - - - - - - - - - - - - - 121
SECTION 4. LUBRICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123

LUBRICATE BIN PIVOTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
OSCILATION TUBE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
ARTICULATION JOINT BOTTOM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
ARTICULATION JOINT TOP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
STEERING CYLINDERS REAR PIVOT POINTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 124
STEERING CYLINDERS FRONT PIVOT POINTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 124
TIP CYLINDERS TOP PIVOT POINTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 124
TIP CYLINDERS BOTTOM PIVOT POINTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 124
GREASE PROPSHAFTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 125
CHAPTER 13 . 1 000 HOURS SERVICE AND CHECKS - - - - - - - - - - - - - - - - - - - 127
SECTION 1. DRIVE TRAIN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 127

INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 127
ISSUE 0 3
TABLE OF CONTENTS

TRANSMISSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 129
SECTION 3. HYDRAULICS AND LUBRICATION - - - - - - - - - - - - - - - - - - - - - - - 131

REPLACE HYDRAULIC RESERVOIR BREATHER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131
CHECK AXLE OIL LEVELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131
CHAPTER 14. 2 000 HOURS SERVICE AND CHECKS - - - - - - - - - - - - - - - - - - - - 133
SECTION 1. DRIVE TRAIN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 133

INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 133
SECTION 2. HYDRAULICS AND LUBRICATION - - - - - - - - - - - - - - - - - - - - - - - 135

CHANGE AXLE & FINAL DRIVE OIL AND FILTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 135
REPLACE PNEUMATIC SYSTEM DRYER FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136
CHAPTER 15. 4 000 HOURS SERVICE AND CHECKS - - - - - - - - - - - - - - - - - - - - 137
SECTION 1. HYDRAULICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 137

INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 137
CHAPTER 16. MISCELLANEOUS SERVICE AND CHECKS - - - - - - - - - - - - - - - - 139
SECTION 1. ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 139

INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 139
SECTION 2. ELECTRICAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141

USING BATTERY CHARGER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141
SECTION 3. OPERATIONAL CHECKOUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - 143

OPERATIONAL CHECK-OUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 143
CHAPTER 17. TROUBLE SHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 151

Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 151
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B25L & B30L Mk II 4X4 OMM 872120
SAFETY
SAFETY FEATURES
3 14 15
2 12
1 11
GLC0001CFM
5
6
7 8 13 10
6
1. Rock Canopy Protection. 8. Secondary Steering.

2. Cab Open. 9. Horn.
3. Dump Body Service Lock. 10. Sealed Beam Head Lights.
4. Stop/Back Lights. 11. Engine Fan Guard.
5. Backup Alarm. 12. Bypass Start Protection.
6. SAHR (Spring Applied Hydraulic Released) 13. Exhaust Brake & Engine Valve Brake.
Brakes On Each Wheel. 14. Safety Belt.
7. Articulation Lock Bar. 15. Exhaust Purifier.
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872120 OMM B25L & B30L Mk II 4X4
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).
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.
General Safety
Be sure all operators of this machine understand every safety message. Replace operator’s manual and
safety decals immediately if missing or damaged.
Safety Regulation
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.
Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of
grease, oil and foreign objects.
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B25L & B30L Mk II 4X4 OMM 872120
Prepare for Emergencies

Avoid Work Site Hazards
GD0017CFM
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.
Avoid Backing Over Accidents
GD0014CFM
Avoid Overhead 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.
Operate Only On Solid Footing

GD0016CFM
Operate only on solid footing with strength
sufficient to support machine. Be alert working Make sure all persons are clear of machine path
near embankments, excavations and with bin before moving the machine. Where conditions
raised. Avoid working on surfaces that could permit, raise bin for better visibility to the rear. Use
collapse under machine. mirrors to assist in checking all round machine.
Use caution when backing up to berms before Keep windows, mirrors and backup alarm clean
dumping load. and in good condition.
Use a signal person when backing if view is

Keep Riders Off the Machine obstructed and/or in close quarters. Keep signal
person in view at all times.
Use prearranged hand signals to communicate.
Handle Chemical Products And Flam-

mable Fluids Safety
Exposure to hazardous chemicals can cause
serious injury. Under certain conditions,
GD0015CFM lubricants, coolants, paints and adhesives used
with this machine may be hazardous.
Do not allow unauthorised personnel on the
machine.
ISSUE 0 7
872120 OMM B25L & B30L Mk II 4X4
If uncertain about safe handling or use of these

chemical products, contact your authorized dealer
Clean the Machine Regularly
for a Material Safety Data Sheet (MSDS). 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.
Prevent Battery Explosions and Acid

Burns
GD0019CFM
GD00!*CFM The standard battery supplied with the machine is

Handle fuel with care, as it is highly flammable. Do a sealed type that does not need maintenance.
not smoke or go near an open flame or sparks keep sparks and flames away from the batteries.
while refuelling. Always stop the engine before If a non-sealed battery is subsequently installed,
refuelling the machine and fill the fuel tank keep sparks and flames away from the batteries.
outdoors. Use a flashlight to check the battery electrolyte
Keep all fuels and lubricants in properly marked level. Use a voltmeter or hydrometer to check
containers and away from all unauthorised battery charge. Never place a metal object across
persons. Do not smoke in the storage areas. the posts. Always remove the grounded (Negative
-) battery clamp first and replace it last.
Store oily rags and other flammable material in a
protective container, in a safe place. Do not smoke in areas where batteries are being
charged.
Do not weld or flame cut pipes or tubes that have
contained flammable fluids. Clean them Sulphuric acid in battery electrolyte is poisonous
thoroughly with nonflammable solvent before and is strong enough to burn skin, eat holes in
welding or flame cutting them. clothing and cause blindness if splashed into the
eyes.
Starting fluid is highly flammable. Keep all sparks
and flames away when using it. To prevent Avoid the hazard by:
accidental discharge when storing the pressurised • Filling the batteries in a well ventilated area.
can, keep the cap on the can and store it in a cool • Wearing eye protection and rubber gloves.
protected place. Do not burn or puncture a starting • Avoid breathing fumes when electrolyte is
fluid container. added.
• Avoid spilling or dripping electrolyte.
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B25L & B30L Mk II 4X4 OMM 872120
If you spill acid on yourself: Avoid High Pressure Fluids

• Flush your skin with water.
• Apply baking soda or lime to help neutralise Escaping fluid under pressure can penetrate the
the acid. skin causing serious injury. Relieve the pressure
• Flush your eyes with water for 10 - 15 minutes before disconnecting hydraulic or other lines.
and get medical attention immediately. Tighten all connections before applying pressure.
Keep hands and body away from pinholes and
If acid is swallowed: nozzles which eject fluids under high pressure.
Use a piece of cardboard or paper to search for
• Drink large amounts of water or milk.
leaks.
• Then drink milk of magnesia, beaten eggs, or
vegetable oil. If any fluid is injected into the skin it must be
• Get medical attention immediately. surgically removed within a few hours by a doctor
who is familiar with this type of injury or gangrene
Wear Protective Equipment may result.
Stay Clear Of Moving Parts

Entanglements in moving parts can cause serious
injury.
Stop engine before examining, adjusting or

maintaining any part of the machine with moving
parts.
Keep guards and shields in place. Replace any

guard or shield that has been removed for access
GD0013CFM
as soon as service or repair is complete.
Wear a hard hat, protective glasses and other
protective equipment as required by the job
Beware of Toxic Fumes
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. Wear a suitable hearing protective
device such as earmuffs or earplugs. Wear gloves
when handling wire rope cable.
Use the Seat Belt GD0020CFM
Use a seat belt at all times to minimise the chance Prevent asphyxiation. Engine exhaust fumes can
of injury in an accident. cause sickness or death.
The seat belt must not be altered or modified in Operate only in well ventilated indoor areas. Avoid
any way. Such changes can render the belt hazardous fumes by first removing paint on
ineffective and unsafe. painted surfaces before welding.
The seat belt is designed and intended for the Wear an approved respirator when sanding or
seat’s occupant to be of adult build and for one grinding painted surfaces.
occupant of the seat only.
If a solvent or paint stripper is used, wash surface
with soap and water. Remove solvent or paint
containers before welding and allow at least 15
minutes before welding or heating.
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872120 OMM B25L & B30L Mk II 4X4
Use extra care when bin is raised. Machine

Dispose of Waste Properly stability is greatly reduced when bin is raised.
Drive slowly, avoid sharp turns and uneven
Improper disposal of waste can threaten the ground.
environment. Fuel, oils, coolants, filters and
batteries used with this machine may be harmful if Do not over load the machine.
not disposed of properly.
Before operating machine after it has tipped,
Never pour waste onto the ground, down a drain or carefully inspect all hydraulic and electrical lines.
into any water source.
Operating on Slopes
Air conditioning refrigerants can damage the
atmosphere. Government regulations may require
using a certified service centre to recover and
recycle used refrigerants.
If uncertain about the safe disposal of waste,

contact your local environmental centre or your
dealer for more information.
Start Only From Operator’s Seat
GD0023CFM
Avoid side slope travel whenever possible.
Check neutral and emergency brakes frequently

when operating on slopes
The maximum slope will be limited by the ground

conditions.
Welding Repairs
NOTE:Disable electrical power before welding.
Turn off main battery switch or disconnect
positive battery cable. Separate harness
connectors to engine, alternator and vehicle
microprocessors.
GD0022CFM
Avoid unexpected machine movement. Start

engine only while sitting in operator’s seat. Ensure
all controls and working tools are in proper position
for a parked machine.
Never attempt to start engine from the ground. Do

not attempt to start engine by shorting across the
starter solenoid terminals.
Lower bin during work interruptions, apply park

brake and be careful not to accidentally actuate
controls when co-workers are present. GD0021CFM
Avoid welding near fluid lines. Do not let heat go

Operating The Machine beyond work area near fluid lines.
Avoid Tip Over Remove paint properly. Wear eye protection and
protective equipment when welding.
Use safety belt at all times. Do not jump from
machine if it tips. Do not inhale dust or fumes.
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B25L & B30L Mk II 4X4 OMM 872120
Tyre Information
Welding or heating of the rim components, external fire or excessive use of brakes can cause overheating
of the tyres, which could cause a tyre explosion.
This explosion can propel the tyre, rim and final drive components approximately 500 metres (1 640ft) from
the machine, which may cause personal injury or death and/or property damage.
If the tyre 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 tyres. Use a safety
cage if available. Do not stand over the tyre.
15 m
(49'3")
Use a safety cage if available
Do not stand over the tyre, use a clip-on chuck and extension hose
500 m
(1 640 ft)
GC0002FM
NOTE:It is recommended that only trained personnel service and change tyres and rims.
Inspect and Maintain Canopy And Cab

A damage canopy should be replaced, not reused.
If the canopy and cab was loosened or removed for any reason, inspect it carefully before operating the
machine again.
To Maintain:
• Replace missing hardware using correct grade hardware.
• Check hardware torque.
• Check isolation mounts for damage, looseness or wear; Replace if necessary.
• Check canopy for cracks or physical damaged.
Drive Metal Pins

Always wear protective goggles or safety glasses and other safety equipment.
Use soft hammer or a brass bar between hammer and object to prevent chipping.
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872120 OMM B25L & B30L Mk II 4X4
SAFETY DECALS
There are several safety decals on your BELL EQUIPMENT machine. Their exact location and description
of the hazard are reviewed in this section. Please take the time to familiarise yourself with these safety
decals.
Keep the decals clean by using a soft cloth, water, and soap. Do not use solvent, gasoline, etc. You must
replace a decal if it is damaged, missing or cannot be read. If a decal is on a part that is replaced, ensure a
new decal is installed on the replacement part. Contact your BELL EQUIPMENT Representative for new
decals.
CAUTION
AVOID DEATH OR SERIOUS INJURY
*READ AND UNDERSTAND OPERATOR’S MANUAL BEFORE OPERATING
*THIS MACHINE.
*OPERATE ONLY FROM THE OPERATOR’S SEAT.
*BEFORE LEAVING SEAT: LOWER BODY TO FRAME REST.
PLACE TRANSMISSION IN NEUTRAL.
APPLY PARK BRAKE.
STOP ENGINE (TURN KEY SWITCH TO OFF).
*DO NOT PERMIT RIDERS.
*AVOID CONTACT WITH OVERHEAD OBSTACLES WHEN OPERATING OR
*HAULING THE TRUCK.
*USE EXTRA CARE TO AVOID TIP-OVER WHEN DUMPER BODY IS RAISED.
207307FM
Located inside the cab
Located inside
the cab next
to the park brake
WARNING
COMPRESSED AIR
RESERVOIR
Avoid injury, drain
completely before carrying
out maintenance.
Typical working pressure:
800 kPa (116 PSI).
207349-AFM
Located on the air reservoir
WARNING WARNING
HIGH PRESSURE
HYDRAULICS
See manual for correct
AVOID INJURY
maintenance procedure. Ensure propshaft
Typical working guards are in
pressure: 8000 kPa place at all times
(1160 PSI). 207329FM
207330FM
Located inside the battery box Located on the inside of the front chassis GLC0007CFM
12 ISSUE 0
B25L & B30L Mk II 4X4 OMM 872120
WARNING
THIS MACHINE IS FITTED WITH
A NEUTRAL PARK BRAKE FUNCTION
ANY ATTEMPT TO FREE WHEEL

IN NEUTRAL GEAR
WILL APPLY THE PARK BRAKE
203967-FM
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872120 OMM B25L & B30L Mk II 4X4
WARNING
NO ETHER
Electrical pre-heater built in.
Personal injury may result.
207290FM
207306FM
Located on the front chassis front plate.

Located on the air cleaner.
207310FM
THIS TAG MUST ONLY BE
REMOVED BY THE PERSON Located at the rear lifting points on the bin.
SERVICING THE MACHINE.
PART No. 870050
207409-AFM
Located inside the PM pack wallet.
Located inside the cab, at the tip lever on the right
hand control panel
14 ISSUE 0
B25L & B30L Mk II 4X4 OMM 872120
GREASE
POINTS
207304FM
GREASE Located on the rear chassis.
EVERY
500HRS
207380FM
Located at the rear of the truck on the rear chassis.
ISSUE 0 15
872120 OMM B25L & B30L Mk II 4X4
16 ISSUE 0
PART 1
OPERATOR’S INSTRUCTIONS
AND
MACHINE INFORMATION
B25L & B30L Mk II 4X4 CHAPTER 1 872120
CHAPTER 1. SPECIFICATIONS
MACHINE SPECIFICATIONS
The specifications for the B25L & B30L ADT 4X4 are as follows:
Engine
Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - DC Om906 LA Tier 2
Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 In Line
Aspiration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Turbo Charged
Injection type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Direct
Gross power B25L - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 205 kW (274 HP) @ 2 200 rev/min
Gross power B30L - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 205 kW (274 HP) @ 2 200 rev/min
Gross Torque B25L - - - - - - - - - - - - - - - - - - - - - - - - - - 1 000 Nm (737.6 pd. f) @ 1050 - 1 900 r.p.m.
Gross Torque B30L - - - - - - - - - - - - - - - - - - - - - - - - - - -1 100 Nm (811.3 pd. f) @ 1200 - 1 600 r.p.m.
Idle speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 700 ± 20 rev/min
Oil Pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0,5 Bar @ Idle
Oil Pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2.5 Bar @ High Idle
Transmission
Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ZF 6 WG 210
Axles
Front
Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BELL
Rear
Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BELL
Brakes
Service Brakes
Type - - - - - - - - - - - - - - - - - - - - - SAHR - Spring Applied, Hydraulic Released units on all four wheels
Park Brake/Emergency Brakes

Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -SAHR
Type - - - - - - - - - - - - Spring applied, hydraulic released with neutral brake and engine switch off brake
Wheels
Tyre size Front - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20,5 R 25
Tyre size Rear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18.00 R 25
Wheel nut torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -650 Nm (480 ft lb.)
Suspension System
Front
Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Air bag suspension with hydraulic shock absorbers.
Rear
Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Fixed axle.
ISSUE 0 19
872120 CHAPTER 1 B25L & B30L Mk II 4X4
Hydraulic System
Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Load sensing
Pump
Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H A10 VO 71 65 CC Side Port
Pump Emergency Steering System

Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -#52 A10 VO 28
Steering System
Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Articulated with two double -acting, hydraulic cylinders
Number of turns lock to lock- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.7
Pneumatic System
Reservoir capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20 litres (5.28 USGAL)
Electrical System
Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 V
Battery Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 X 12 V, maintenance-free
Battery capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 X 100Ah
Starter motor capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 kW
Alternator voltage rating- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28 V
Alternator amperage rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 A
Power Ratings (bulbs)

Headlight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 V 60 W
Stop/tail light- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 V Diode Light Unit
Reverse light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 V 60 W
Frame and Body

Cab
Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BELL Open Cab Side Or Forward Facing
Bin
Type - - - - - - - - - - - - - - - - - - - - Manufactured from high tensile wear and impact resistant alloy steels
B25L
Rated payload - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23 000 kg (50 600 lb.)
Capacity Struck- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9.4 m³ (12.2 yd.³)
Capacity Heaped (SAE 2:1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12.00 m³ (15.7 yd.³)
B30L
Rated payload - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27 000 kg (59 524 lb.)
Capacity Struck- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12.00 m³ (15.7 yd.³)
Capacity Heaped (SAE 2:1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14.5 m³ (18.76 yd.³)
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B25L & B30L Mk II X4 CHAPTER 1 872120
Tip Cylinders
Tip cylinders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 X Single stage, double acting
Tipping angle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65°
Bin raise time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15 seconds
Bin lower time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10 seconds
Mass
B25L
Total mass, empty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18 920 kg (41 711 lb.)
Total mass, fully laden - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41 970 kg (92 418 lb.)
B30L
Total mass, empty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19 520 kg (43 034 lb.)
Total mass, fully laden - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46 520 kg (102 559 lb.)
Fluid Capacities
Fuel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 220 litres (89.82 USGAL)
Engine oil (including filter) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29 litres (7.661 USGAL)
Engine coolant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28 litres (7.4 USGAL)
Transmission fluid (initial fill) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -26 litres (6.9 USGAL)
Transmission fluid (refill) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16 litres (4.2 USGAL)
Hydraulic reservoir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85 litres (22.5 USGAL)
ISSUE 0 21
Machine Dimensions
The following figure details the dimensions of the B25L ADT 4X4:
4 730 (15’6”)
B25L
2 280 (7’6”)
2 750 (9’)
1 925 (6’4”)
ALL DIMENSIONS SHOWN ARE IN MILLIMETRES (FEET)
3 070 (10’)
25LC0001CFM
22 ISSUE 0
ISSUE
The following figure details the dimensions of the B30L ADT 4X4:
2 530 (8’4”)
ALL DIMENSIONS SHOWN ARE IN MILLIMETRES (FEET)
3 070 (10’)
30LC0001CFM
ISSUE 0 23
Recommended Lubricants and Coolant Additives

The following chart details the recommended lubricants and coolant additives:
BELL EQUIPMENT RECOMMENDED LUBRICANT AND FLUID CHART

B25L, B30L, 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
ENGINE - M-BENZ SAE 15W-40

OILS TO MEET M-BENZ 228.5
SPECIFICATIONS
PREFERRED: - CASTROL DYNAMAX 10W-40 SAE 10W-40
- CALTEX XLD 10W-40
COOLANT: - M-BENZ
EXTENDED LIFE COOLANT PRE-MIX 50/50 EXTENDED LIFE COOLANT PRE-MIX 50/50
PREFERRED: - CALTEX EXTENDED LIFE COOLANT PRE-MIX 50/50
TRANSMISSION - ZF 6WG 210

USE ONLY CASTROL
TRANSMAX-Z OR S/TRANSYND CASTROL TRANSMAX-Z OR S (SAE 70W-80W)
DRIVE AXLES - BELL

SAE 50
HYDRAULIC and BRAKING SYSTEM

OILS TO MEET
VICKERS M-2952-S
ATF
ATF DEXRON III ISO 32
SPECIFICATION
ISO 46
ISO 68
RECOMMENDED SERVICE FILLS o

(FOR AMBIENT TEMPERATURES BETWEEN -5 C TO 45 oC)
COMPONENT OIL DESCRIPTION BELL EQUIPMENT PART No.
ENGINE CALTEX XLD (SAE 10W-40) 910276

COOLANT Extended Life Pre-mix 50/50 910245
CASTROL TRANSMAX-Z/S 910208
TRANSMISSION
Transynd 915043
DRIVE AXLES CALTEX TORQUE FLUID 454 910337
HYDRAULIC & ATF : CALTEX TEXAMATIC Type G 910083

BRAKING SYSTEMS
GENERAL (PINS, BUSHES, ETC) : 910336

GREASE CALTEX ULTRA DUTY GREASE 2
BEARINGS (DRIVE TRAIN): CALTEX 910026
MULTIFAK EP2
GL0001- CFM
CAUTION
1. Caltex Texamatic Type-G is only to be used in the hydraulic system and must NOT be used in the
transmission.
2. Failure to use only Castrol Transmax-S or Z in the transmission may render warranty claims
invalid.
3. Failure to use Caltex Torque Fluid 454 in the axles may reduce the life of the gears.
24 ISSUE 0
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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 / BELL Equipment 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 is 90% of the yield load.
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% permanent set) at 0.2% permanent set) at 0.2% permanent set)
METRIC NUT GRADE INTERPRETATION 1 lb ft = 1.35582 Nm 1 Nm = 0.737561lb ft
CURRENT STANDARD : 1 lb in = 0.112985 Nm 1 Nm = 8.85073 lb in
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
Nuts which are 1.0xD high. 800 MPa (51.80 tsi) 8.8 Grade
ISO Grade 4.6 Manufacturer's ISO Grade 10.9 Manufacturer's

Mark
Mark
400 MPa (25.90 tsi) 4.6 Grade (Optional) 1000 MPa (64.75 tsi) 10.9 Grade
ISO Grade 6.9 Manufacturer's ISO Grade 12.9 Manufacturer's

Mark
Mark
600 MPa (38.85 tsi) 6.9
Grade (Optional) 1200 MPa (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
2
T/Stress area (mm ) 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
GD0001CFM
ISSUE 0 25
Imperial Sizes - BS Grades

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
T/Stress area (mm2) 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
T/Stress area (mm2) 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
Manufacturer's
46.9 tsi (724 Mpa) 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 Drawing Number 700999/2 rev A 24/6/96
GD0002CFM
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Serial Number Plates

The following figure identifies and locates the main serial number plates for the machine, engine and
transmission of the B25L & B30L Mk II 4X4.
Engine
Specification
Plate
AEB XXXXXX XR XXXXXX ARTICULATED HAULER

MACHINE BUILD No.
Vin Number MACHINE MODEL

ENGINE MODEL
(On Left Hand Side of Truck) TRANSMISSION MODEL

FRONT DIFF MODEL
MID DIFF MODEL
REAR DIFF MODEL
AXLE FRONT MID REAR TOTAL

TARE kg
GROSS kg
PAYLOAD kg
LUBRICATION SCHEDULE - FACTORY FIRST FILL
-
-
-
-
-
-
-
CONSULT THE OPERATOR AND MANUFACTURED BY:

MAINTENANCE MANUAL FOR BELL EQUIPMENT CO. (PTY) LTD
LUBRICATION SPECIFICATIONS ALTON, RICHARDS BAY
AND SAFETY PRECAUTIONS. P/N 200181 SOUTH AFRICA
GLC0002CFM
ISSUE 0 27
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CHAPTER 2. OPERATOR CONTROL AND INSTRUMENTS
SECTION 1. OPERATOR CONTROLS
INTRODUCTION
The following figure details the layout of the controls and instruments in the side cab:
5
12
9
11
2 10 6
1. Main Warning Light. 7. Brake Pedal.

2. Park Brake Lever. 8. Accelerator Pedal.
3. Main Instrument Panel. 9. Brake Pressure Gauges.
4. Steering Column. 10. Tip Control Lever.
5. Shift Lever. 11. Safety Belt.
6. Battery Isolator Switch. 12. Operator’s Seat
ISSUE 0 29
The following figure details the layout of the controls and instruments in the front cab:
1 2
3 13
10
4 8
11
6
12
5
7
9
1. Brake Pressure Gauges. 7. Brake Pedal.

2. Warning Light Cluster. 8. Accelerator Pedal.
3. Main Instrument Panel. 9. Ignition.
4. Steering Column. 10. Tip Control Lever.
5. Shift Lever. 11. Park/Emergency Brake.
6. Battery Isolator Switch. 12. Operator’s Seat
30 ISSUE 0
ISSUE
Accelerator And Brake Pedals SEAT BELT

A lap seat belt is an integral part of the seat.
The seat belt is designed to fit firmly across the

front of the pelvis.
Seat belt and mounting hardware must be

inspected before operating the machine. If belt or
2 1 mounting hardware are worn, replace complete
seat belt assembly.
A date label, to determine the age of the belt is

attached to each belt.
Fastening
The accelerator pedal (1) and the brake pedal (2)

are located on the cab floor.
Both pedals are progressive and spring loaded to 1

an up, neutral position. 2
Steering Wheel
NOTE:There is no self-centring action on • Pull the seat belt out and push the buckle (1)
the steering. The machine must be into the fixed clasp (2) until it clicks into
returned to the straight ahead position.
position by turning the steering • Ensure that the connection is secure and that
wheel. the belt fits tightly across the pelvis.
• Ensure that the strap of the belt is not twisted.
Releasing
1
Press down the red push button on the fixed clasp.
WARNING
1. Always wear a seat belt when operating
the machine. In an accident it may save your
life.
2. Check the condition of the seat belt and
mounting hardware before operating the
machine. Replace the seat belt at least every
three years, regardless of the condition.
NOTE:Clean the seat belt regularly with a

soap and water solution.
The steering wheel (1) to steer the truck.
ISSUE 0 31
Park Brake Control Lever Gear Shift Control
1
1
The gear shift control (1) is located on the right

hand side in a forward facing cab and on the left
The park brake lever is located on the left hand hand side of a side facing cab.
side of the operator in a forward facing cab and on
the right hand side in a side facing cab. The gear selector options are as follow:
• To release park brake lever (1), turn the lever • V (Forward), to select a forward gear.
in a clockwise direction towards the driver. • N (Neutral), to select neutral gear.
• To apply park/emergency brake, turn the lever • R (Reverse), to select reverse gear.
in an anti-clockwise direction.
Tip Control Lever
WARNING
Under normal circumstances the operator
must not leave the machine unattended with 1
the engine running. If the circumstances are
such that the operator must leave the engine
running, the operator must not leave the ma-
chine until he has:
-Select and ensure that the transmission is
in N.
-Applied the park brake and ensured that it
is properly engaged.
-Chocked the wheels and taken all other
steps necessary to prevent the machine
from moving.
The tip control lever (1) is located on right hand
• When the ignition is turned off the park brake side and is used to raise and lower the bin.
will automatically be applied.
• When the truck is started, the park brake will • To tip the bin: pull the control lever towards the
automatically applies. operator.
• To lower the bin: push the tip control lever
away from the operator.
NOTE:The tip control lever is spring-loaded

to the central (holding) position.
The bin raised warning light on the instrument

panel illuminates as soon as the bin is raised off
the chassis and only extinguishes when the bin is
fully lowered onto the chassis.
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SECTION 2. INSTRUMENTS
The following figure details the Operator Instruments on the dashboard:
1 13 2 12 3 4 8
15
10
7 7 8 16
6 5
9 11 14/17
1.
1. Transmission Temperature Gauge. 9. Ignition.

2. Engine Temperature Gauge. 10. MFA 10 Warning Light Cluster.
3. Engine Oil Pressure Gauge. 11. Tachometer.
4. Air Pressure Gauge. 12. Hydraulic Accumulator Pressure Gauge.
5. Hour Meter. 13. Hydraulic Brake Pressure Indicator.
6. Hooter. 14. Transmission Display Screen.
7. Flip Switch For Difflock And Headlights. 15. Overspeed Warning Indicator.
8. Blank Cover. 16. Main Warning Indicator.
17. Gear Indicator.
ISSUE 0 33
Engine Oil Pressure Gauge Engine Temperature Gauge
This gauge is located on the dash. This gauge

indicates if the engine oil pressure is in the
specified range. This gauge is located on the dash. This gauge
indicates if the engine coolant temperature is in
When the machine is idling at operating the specified range.
temperature, the engine oil pressure gauge
needle must be above 0.5 bar (50kPa) (7.25 If the needle is on the red bar, the temperature is
P.S.I). out of limits and machine must be stopped and the
fault rectified.
If it is below 0.5 bar (50kPa) (7.25 P.S.I), stop the
machine and rectify the fault. The maximum operating temperature of the
engine is 105 °C (221 °F).
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ISSUE
Air Pressure Gauge If the needle is above 100 °C (212 °F), the
temperature is out of limits and machine must be
stopped and the fault rectified.
Tachometer

indicates if the air pressure is in the specified
range.
Transmission Oil Temperature Gauge The tachometer is located on the centre of the left
side instrument panel.
The tachometer monitors the engine speed in

revolutions per minute (rev/min).
CAUTION
A maximum engine overspeed of 2600 rev/
min must not be exceeded or serious
damage will be caused to the engine.
Hour Meter (SMR Meter)

indicates if the transmission oil temperature.
The operating temperature range of the

transmission is between 60 °C and 100 °C (140 °F
and 212 °F). The hour meter (SMR meter) is located on the left
hand panel of the dashboard.
ISSUE 0 35
The gauge displays the service meter readings Accumulator Pressure Gauge
(SMR) for the machine service life.
Speedometer CAUTION
If the machine is operating with the needle in
the red zone, Contact your BELL
EQUIPMENT Representative, as it will effect
the brake system.
The speedometer measures the machine speed to

the ground.
The gauge also includes a odometer and trip

meter.
The accumulator pressure gauge is a hydraulic

gauge that reads the hydraulic pressure available
to the brakes (Before the brake pedal).
When the engine is running, the needle must be

within the green band of 10 - 15 MPa. (1450.4 -
2175.6 lb. in).
When the brake is applied and released, the

needle will drop by small increments. When the
needle reaches 10 MPa (1450.4 lb. in.) the pump
will recharge the system.
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Brake Pressure Gauge INDICATORS
WARNING Main Warning Indicator

If the needle moves over 10 MPa. (1450.4 lb.
in.), stop the imachine immediately, as dan- CAUTION
mage can be caused to the axle/seals. Continued operation of the machine with the
main warning indicator illuminated will
cause serious damage to the engine,
transmission or the bin.
The main warning indicator (1) is located on the

centre panel of the dashboard.
• The main warning indicator flashes to warn the

operator of one of the following conditions or
problems with the machine system:
• Engine Fault
The brake pressure gauge is a hydraulic gauge • Transmission Fault
that reads the hydraulic pressure in the brake • Bin In Raised Position
circuit. This is the pressure that acts to release the
brakes at each wheel. If the main warning indicator flashes, stop the
machine immediately and investigate the cause.
The needle must operate within the green band of
0 - 10 MPa. (0 - 1450.4 lb. in). If one or more of the above faults occur, the
respective warning indicator on the dashboard will
When the machine is moving (brakes released), also flash when the main warning indicator
the needle will read 10MPa. (1450.4 lb. in.). When flashes.
the brakes are applied, the needle will drop to 0
Mpa. A warning buzzer also sounds when the main
warning indicator flashes if the engine is running.
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Engine Overspeed Warning Indicator Engine Fault Warning Light
CAUTION
If the engine fault warning light flashes, the
machine must be stopped and the engine
shut down immediately. Engine damage
may result if this caution is ignored.
The engine overspeed warning indicator (1) is

located on the centre panel of the dashboard.
1
CAUTION
If the engine overspeed warning indicator If a fault on the engine occurs the warning light will
illuminates, the engine speed must be be illuminated.
reduced immediately, using the service
brake. Stop the machine as soon as it is safe.
Check the fault codes and required action to rectify

If the operator continues to overspeed and the the fault.
engine speed exceeds 2 900 rev/min the following
occurs: NOTE:The main warning light and the
warning buzzer are also activated
• The engine overspeed warning indicator with the engine warning light.
ceases flashing but stays illuminated.
• A louder buzzer sounds. Battery (Charge) Warning Light (14)
• The ADM cuts the fuel to the engine.
CAUTION
If the battery charge warning light
illuminates, the fault must be rectified or the
batteries will be discharged.
The warning light illuminates if the alternator is not

charging the batteries or if the engine is not
running and the ignition switch is ON.
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The normal operating voltage is between 25.5V Bin Raised Warning Light (17)
and 29.5V while engine is running.
The balance between the two batteries are also

WARNING
monitored and if a difference of greater than 1.2V As a safety precaution it is recommended

occurs, the battery light is illuminated. that the operator should not drive the ma-
chine when the bin up light is illuminated as
This must be rectified immediately, or damage this may cause serious damage to the ma-
to both batteries will occur. chine and/or injury to personnel. Refer to
Tip Control Lever in this Chapter for special
Transmission Fault Warning Light instructions regarding driving the machine
while the bin is raised.The bin raised warn-
CAUTION ing light will illuminate when the bin is
raised.
If the transmission fault warning light
illuminates, the machine must be stopped
immediately using only the service brake NOTE:Gear restriction will occur while the
and NOT the gear shift control. bin is up.
1 1
The electronic control system is programmed to When the bin is not fully lowered, this indicator will
inform the operator of a problem with the illuminate.
transmission system and automatically take action
to protect the operator, machine and transmission. Inter-axle Differential Lock Light (18)

When the Electronic Control Unit (ECU) detects a
“Do Not Shift” (DNS) condition, the ECU restricts CAUTION
shifting, turns on the DNS warning light and Do not operate the machine on hard
registers a diagnostic code. surfaces with the inter-axle differential lock
engaged. Damage to the drive train may
CAUTION
result if this caution is not observed.
For some problems, diagnostic codes may

be registered without the ECU activating the
DNS warning light. BELL EQUIPMENT
Product Support should be consulted
whenever there is a transmission related
concern.
The inter-axle differential lock light illuminates

when the longitudinal differential lock is engaged.
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SECTION 3. SWITCHES
The switches and their functions are as follows:
Ignition Switch
The Light Switch
The light switch (1) is used to switch the head

lights, rear lights and the dash lights on or off.
The ignition switch (1) is located on the right hand
The switch has two positions: side on the dashboard.(Shown in the “ON”
position).
• OFF; switch in the normal position.
• ON Headlights and tail lights ON. The ignition switch is key operated and has four
positions, OFF, Accessory, ON and IGNITION.
InterAxle differential Lock Switch
NOTE:The ignition switch will only operate
if the battery disconnect switch is
ON.
1
CAUTION
Do not stop the engine immediately after
bringing the machine to a halt. Allow the
engine to idle for two minutes before
switching off the ignition. This protects the
turbocharger bearings and allows all
temperatures to stabilise.
This switch is used to activate the inter-axle

differential lock (IDL). When switched “ON” the
inter-axle differential lock light will also be
illuminated on the dash board.
To actuate the Diff Lock (IDL):Stop the machine

and move the gear shift lever into the neutral
position. Move the IDL switch into the “ON”
position. Ensure that the IDL light on the switch
and warning display has been illuminated before
releasing the park brake and moving forward.
The switch has two positions:
• OFF; Normal position.

• ON; Inter-axle differential lock switched on.
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Battery Disconnect Switch Battery Circuit Breaker Box
WARNING
The battery circuit breaker box is located inside
the battery box.
Never switch off the engine using the bat-
tery disconnect switch as this will log errors
on the ECU and my damage the engine.
1
CAUTION
1. Always switch OFF the battery disconnect
switch when the engine is shut down and
the machine is left unattended. If the switch 2
is left ON for long periods while the engine
is shut down, the batteries may become
discharged. There are two circuit breakers located in the
2. Always switch OFF the battery disconnect battery box. One circuit breaker rated 60A and one
switch before any maintenance or repair is rated 20A.
performed on the machine’s electrical
system or any welding work is performed. The 60A circuit breaker (1) protects the machine’s
primary electrical circuits (24V) from a possible
overload condition or fault from the batteries.
The 20A circuit breaker (2) protects the machine’s

12V circuits.
The battery disconnect switch (1) is located inside

the cab and is of the removable key type.
The battery disconnect switch is used to isolate

the electrical power from the batteries to the
machine.
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LIGHTS Rear Lights
Front Lights
1
The rear of the machine is equipped with two stop/

tail lights (1).
The stop light illuminates when the brake pedal is

depressed.
The park lights operates from the lights switch on

the dashboard.
Reverse Lights
The front of the machine is equipped with four front

The machine is equipped with two white lights (1)
head lights, two on each side of the machine.
as reverse lights.
The headlights are operated from the lights switch
The reverse lights illuminate and a warning buzzer
on the dashboard.
sounds when the reverse gear is selected.
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Circuit Breaker Panel
The following figure details the circuit breaker box located under the inspection cover:
7 6 5
4
3
2
1
1. 15A - ADM; EST 37. 5. 15A - ADM; PLD Engine.

2. 20A - Front Lights. 6. 15A - IDL Switch.
3. 20A - Reverse Lights. 7. 20A - Horn; Beacon.
4. 15A - Brake Lights.
Push in a circuit breaker to reset a circuit that has tripped.
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MISCELLANEOUS EQUIPMENT
Electrical Horn
Two electrical horns (1) are fitted.
Reverse Warning Buzzer
When reverse gear is selected, the reverse lights

illuminate and a warning buzzer (1) sounds at the
rear of the machine.
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CHAPTER 3. PROCEDURES BEFORE STARTING
SECTION 1. SAFETY
Safety Instructions
Before operating the machine the following safety
instructions must be observed:
• Read and fully understand this manual, before

you start operating the machine.
• Never operate the machine while under the
influence of alcohol, medication or any other
drugs.
• Wear the required protective clothing for safe
machine operation.
• When mounting or dismounting the machine
always face the machine and use the hand
rails and steps provided. Never jump off the
machine.
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CHAPTER 3. PROCEDURES BEFORE STARTING
SECTION 2. BEFORE STARTING
Safety Rules
1. Check the transmission oil level.
Operator Duties 2. Check the condition and tension of the
The operator must know the rules and safety alternator belts.
aspects of the site. The operator must study the
3. Check for loose, frayed or corroded
following rules and become aware of how to avoid
connections in the wiring harness.
serious injury and/or machine damage.
4. Check the engine mountings and cab
• It is the operator’s duty to report all damage mountings are secure and the rubber
and wear which may endanger the operator or elements are not damaged.
cause damage to the machine.
• Only trained personnel may operate the 5. Ensure that all the hose connections are
machine. tight and inspect for leaks, cracks or
• Check that a “DO NOT OPERATE” tag is not chafing damage.
attached to the steering wheel. If the tag is
6. Check that the exhaust connections,
attached, do not operate the machine.
exhaust brake valve and actuator are
• Complete the Walk Round Check (refer to next
secure.
instruction). If any defects are found, do not
operate the machine. Attach the “DO NOT 7. Check that the batteries are secure and the
OPERATE” tag to the steering wheel and connections are tight.
remove the machine key.
• Report all defects and problems encountered 8. Check the compressed air drier assembly
during the Walk Round Check to the service and unloader valve for security and
personnel. damage.
Daily Walk Round Check 9. Check the cooling pack for cleanliness and
ensure there are no restrictions to the
The Daily Walk Round Check must always be cooling function.
carried out before operating the machine at the
beginning of a work shift or after a change of 10. Check the security of the cooling pack
operator during a shift. assembly and inspect for leaks.
11. Inspect the air cleaner assembly for

The operator starts his check at the left of the
damage and security.
machine and walks around the machine in a
clockwise direction. 12. Clean the pre-cleaner bowl if required.
NOTE:The machine must be parked in the 13. Check the service indicator and service the
straight ahead position on firm, level filter elements if required.
ground with the bin down and the
park brake applied. 14. Reset the service indicator. Check that the
vacuator valve is not restricted and is
It is recommended that the machine is thoroughly undamaged
washed before starting the Walk Round Check.
The following is a list of the tasks required in the

Daily Walk Round Check. For a more detailed
description of the tasks refer to the Daily or 10
Hourly Service Checks in Chapter 11.
ISSUE 0 49
15. Check the engine oil level. 25. Ensure that the drive shaft assemblies are
secure.
16. Check the engine coolant level.
26. Check the wheels, wheel nuts and
17. Check the condition and the tension of the
components for damage and security.
drive belt.
27. Check the tyres for cuts and damage.
18. Drain the fuel/water separator filter.
28. Check the tyre pressures.
19. Drain the air reservoir and change the air
drier element if required. 29. Check the fuel level.
20. Check that the steering cylinders are 30. Ensure that there are no obstructions
secure. around the machine before moving off.
21. Check the transfer case oil level. 31. Ensure that there are no obstructions in the
cab, especially under and around the
22. Ensure that the transfer case mountings
pedals and controls before moving off.
are secure and undamaged.
32. Ensure that the seat belt is in proper
23. Check the hydraulic fluid level.
working order and fasten the seat belt
24. Check the axles and components (cradle before start-up.
pins, air bags and SAHR brake units) for
leaks, damage and security.
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CHAPTER 4. OPERATING INSTRUCTIONS
SECTION 1. SAFETY
CAUTION
SAFETY RULES
Read and understand all of the operator Always wear the seat belt when operating the
related chapters in this manual before machine.
performing any of the following procedures
and obey all Warnings and Cautions Check that no personnel are near the machine.
contained in the sections. Refer to the
Adapt the machine speed to road conditions, load
detailed procedures in the relevant chapter.
and visibility.
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SECTION 2. STARTING
BEFORE STARTING THE ENGINE

Ensure that the Daily or 10 Hourly Service Checks
have been completed.
Adjust the operator’s seat for the best operator

comfort and easy access to the machine controls.
1
Fasten the seat belt and adjust the seat belt to fit
firmly across the front of the pelvis.
WARNING
Do not start the machine by shorting across
starter terminals. Never start machine while
standing on the ground. Always start ma-
• Insert the ignition key into the ignition switch
chine from operator’s seat with park brake
(1).
applied.
• Turn the ignition switch clockwise to the ON
Never turn the key OFF and direct ON again
position.
if the engine has not start the first time. Wait
• Apply the horn for two seconds, wait for five
2 minutes before next attempt.
seconds.
Turn the key one step further to start engine.

Starting the Engine in Warm Weather
Starting the engine in warm weather does not CAUTION
require any special procedures. 1. Do not run the engine at high speed
(r.p.m.) or heavy loading until the engine oil,
The following procedure must be used to start the
transmission fluid and hydraulic fluid have
engine in warm weather:
warmed up to normal operating
• Ensure the battery disconnect switch is turned temperatures.
ON. 2. Do not hold the key in the start position
• Ensure the park brake is applied. for more than seventeen seconds. If the
• Ensure the gear shift is in the neutral position. engine does not start, wait one minute
before attempting to restart the engine to
NOTE:The engine cannot be started when allow the battery to stabilise. If the engine
any gear is selected. does not start after two attempts investigate
the cause.
ISSUE 0 53
Starting the Engine in Cold Weather CAUTION
The following procedure must be used to start the 1. Do not run the engine at high speed
engine in cold weather: (r.p.m.) or heavy loading until the engine oil,
transmission fluid and hydraulic fluid have
• Ensure the batteries disconnect switch is warmed up to normal operating
turned ON. temperatures.
• Ensure the park brake is applied. 2. Do not hold the key in the start position
• Ensure the gear shift is in the neutral position. for more than 17 seconds. If the engine does
not start, wait 1 minute before attempting to
WARNING restart the engine to allow the battery to
Do not use starting fluid in machine. Dam- stabilise. If the engine does not start after
age to the engine may result. two attempts investigate the cause.
3. Engine will not start by towing or pushing.
Permanent damage to the transmission will
NOTE:The engine cannot be started when result.
any gear is selected.
SHUTTING DOWN THE ENGINE

• The following procedure must be used to shut
down the engine:
1
CAUTION
Never stop the engine from high idle. This
will cause damage to the turbocharger and
the engine.
i. Stop the machine in the straight ahead

position.
ii . Apply the park brake.
iii . Select neutral (N).
• Insert the ignition key into the ignition switch
(1). iv . Allow the engine to idle for 2 minutes to
allow the engine temperature to
• Turn the ignition switch clockwise to the ON stabilise.
position.
v . Turn the ignition switch counter-
NOTE:The cold start function of the clockwise to the OFF position.
machine is automatic. The cold start vi . If the machine is stopped overnight
function will only operate when the ensure the battery disconnect switch is
outside temperature drops below turned to the OFF position and that the
o o
15 C (59 F ). park brake is ON.
• Wait until the cold start indicator light WARNING

extinguishes (approx. 20 seconds). Never use the isolator switch the shut down
• Apply the horn for two seconds, wait five the engine. Doing this will cause damage to
seconds. the engine control unit and the engine.
• Turn the ignition key to the start position to
start the engine.
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USING BOOSTER BATTERIES

Before boost starting, machine must be properly
shut down and secured to prevent unexpected
machine movement when engine starts.
CAUTION
An explosive gas is produced while
batteries are in use or being charged. Keep
flames or sparks away from battery area.
Make sure the batteries are charged in a well
ventilated area.
NOTE:The machine electrical system is a

24-Volt negative (-) ground system.
Connect two 12-Volt booster
batteries together in series as shown
for 24-Volts.
GD1025CFM
Connect one end of the positive cable to the

positive terminal of the machine batteries and the
other end to the positive terminal of the booster
batteries.
Connect one end of the negative cable to the

negative terminal of the machine batteries and the
other end to the machine as far away from the
batteries as possible.
Start the engine (See Starting Engine in this

section).
Remove the cables immediately after engine has

started. (Disconnect negative cable first from the
machine and then from the negative terminal on
the booster batteries.
Disconnect positive cable.
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56 ISSUE 0
ISSUE
SECTION 3. RUNNING-IN
RUNNING-IN INSTRUCTIONS
Gear Shifting
The machine’s run-in period is the First 100 SMR
of operation. The machine MUST be serviced at
100 SMR to ensure maximum machine service
CAUTION
life. 1. Do not allow the machine to free wheel
(coast in neutral) as this will cause the
The 100 SMR service MUST ONLY be done by brakes to be applied and damage caused to
BELL EQUIPMENT Service Personnel. the transmission.
2. Do not continually select from 1st forward
Driving to 1st reverse as this will cause damage to
the transmission.
Safety Rules
CAUTION The transmission has 4 forward gears and 1

1. Never maintain a stall condition for more reverse gear with automatic lock-up in all gears.
than 30 seconds at any one time because of The transmission can be operated as a fully
the rapid rise in fluid temperature. Do not automatic transmission. All automatic gear shifting
allow the converter-out fluid temperature to will be controlled by the machine’s electronic
o
exceed 120 C (248 F ).
o control unit.
2. Never permit a stall condition to arise if
Gear shifting in automatic is dependent upon
the converter-out fluid temperature (as
engine speed (rev/min) and operating conditions
displayed on the driver’s instrument panel)
o o (on site conditions)
is below 45 C (113 F ) or if the sump fluid
temperature (as displayed on the Pro-Link R The position of the gear shift lever in the gear shift
o o
9000 diagnostic tool) is below 30 C (86 F ). gate is represented by the plate.
3. Serious transmission damage will be
caused if the CAUTIONS above are ignored. The driving direction is selected by the horizontal
tilting of the gear shift lever.
Check that all the gauges and indicators are The following procedure must be used in gear
operational. Ensure the readings are correct. shifting:
Refer to Chapter 2, Operator’s, Controls and
Instruments for the correct readings. • Start the engine.
• Ensure that the park/emergency brake is
Wait until there is sufficient air pressure {810kPa applied.
(117psi)} before driving the machine. • Apply the service brake.
Check that there are no personnel on or around Forward Selection (Automatic)

the machine before driving the machine. • Press in the function knob and select Forward
(V) by moving the gear shift lever forward.
Check the steering and brake functions and
confirm that the reverse alarm sounds when NOTE:If the gear shift lever is moved
reverse is selected. without depressing the function
knob, Neutral will remain selected.
Sound the horn before moving off.
• Release the park/emergency brake.
• Release the service brake and increase the
engine speed (rev/min).
As the machine speed increases, the transmission

will select (sequentially) the next gear.
ISSUE 0 57
The inhibitor will not allow a lower gear to be Transmission Display Screen Symbols
selected until the engine speed has been reduced and Characters
sufficiently to prevent overspeeding of the The following shows the symbols and characters
transmission. displayed on the transmission display screen.
Manual Gear Shifting The symbols are as follows:
• While driving in automatic, move the gear shift
lever to the right (+) to select a higher gear or 2 3
to the left (-) to select a lower gear.
• The gear shift lever is spring-loaded to the 4
central position and either + or - will have to be
selected to keep shifting gears.
1
• To revert back to automatic gear selection,
depress the function knob once.
• To change to a lower gear, decrease the
engine speed and move the gear shift lever to
the next lower gear. 2 30C1003CFM
All selected forward gears will be indicated on the

transmission display screen as follows:
NOTE:When driving in manual gear shift 1. Lines indicated gear number selected.
mode the arrows will not be 2. Arrows indicating automatic gear selection.
displayed on the screen. 3. Indicates gear selected and/or error code.
4. Error in the system
Reverse Selection
WARNING
NOTE:There is no automatic function on
If the spanner symbol (error code) appears
reverse gear selection. The three
on the transmission display screen, DO NOT
reverse gears can only be
OPERATE THE MACHINE. Consult your
individually selected manually
BELL EQUIPMENT Product Support Repre-
sentative for advice.
• From Neutral (N), select Reverse (R) on the
gear selector.
• Release the park/emergency brake. Description of Error Codes
• Release the service brake and increase the
engine speed (rev/min).
• As the machine speed increases, decrease First Meaning of Character
the engine speed slightly and move the gear
Character
shift lever to the right (+) to the next gear. 1 Digital Input Signal
As the machine speed decreases, decrease the 2 Analog Input Signal
engine speed and move the gear shift lever to the
left (-) to the next gear. 3 Speed Signals
Gear Shifting Safety Functions 4 Speed Signals

The inhibitor will not allow a gear to be selected 5 CAN Signal Errors
until the engine speed has been reduced below
750 rev/min. 6 CAN Signal Errors
7 Analog Current Output

Error Warning
Signals
WARNING 8 Analog Current Output
If the transmission display screen shows an Signals
error symbol, a spanner, the machine must 9 Digital Output Signals
be stopped immediately, as serious damage
and/or injury may result. A Digital Output Signals
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First Meaning of Character Error Definition of Error Not

Character Code Code e
B Transmission Faults, Clutch 35 Short Circuit To Ground At
Errors Turbine Speed Input
C Logical Errors 36 Logical Error At Turbine

Speed Input
D Power Supply
37 Short Circuit To Battery
E High Speed Signals Voltage Or Open Circuit At
F General Errors Internal Speed Input
38 Short Circuit To Ground At

List of Error Codes Internal Speed Input
39 Logical Error At Internal

Error Definition of Error Not Speed Input
Code Code e
3A Short Circuit To Battery
11 Logical Error At Gear Range
Voltage Or Open Circuit At
Signal
Output Speed Input
12 Logical Error At Direction
3B Short Circuit To Ground At
Select Signal
Output Speed Input
Voltage At Load Sensor Input 3C Logical Error At Output
Speed Input
24 Short Circuit To Ground Or
3E Output Speed Zero Doesn’t
Open Circuit At Load Sensor
Fit To Other Speed Signals
Input
Voltage At Clutch K1
Temperature Sensor Input 72 Short Circuit To Ground At
26 Short Circuit To Ground At Clutch K1
Temperature sensor Input 73 Open Circuit At Clutch K1
27 Short Circuit To Battery 74 Short Circuit To Battery
Voltage Or Open Circuit At Voltage At Clutch K2
Retarder Temperature
Sensor Input 75 Short Circuit To Ground At
Clutch K2
Retarder Temperature 76 Open Circuit At Clutch K2
Sensor Input
31 Short Circuit To Battery Voltage At Clutch K3
Engine Speed Input 78 Short Circuit To Ground At
Clutch K3
79 Open Circuit At Clutch K3
Engine Speed Input
33 Logical Error At Engine
Voltage At Clutch K4
Speed Input
34 Short Circuit To Battery 82 Short Circuit To Ground At

Voltage Or Open Circuit At Clutch K4
Turbine Speed Input 83 Open Circuit At Clutch K4
ISSUE 0 59
Error Definition of Error Not Error Definition of Error Not

Code Code e Code Code e
84 Short Circuit To Battery 9F Short Circuit To Battery
Voltage At Clutch KV Voltage At Retarder Solenoid
85 Short Circuit To Ground At A1 Short Circuit To Ground At

Clutch KV Difflock Solenoid
86 Open Circuit At Clutch KV A2 Short Circuit To Battery

Voltage At Difflock Solenoid
Voltage At Clutch KR A3 Open Circuit At Difflock
Solenoid
Clutch KR A4 Short Circuit To Ground At
Warning Signal Output
89 Open Circuit At Clutch KR
A5 Open Circuit At Warning
91 Short Circuit To Ground At Signal Output
Relay Reverse Warning
Alarm A6 Short Circuit To Battery
Voltage At Warning Signal
92 Short Circuit To Battery Output
Voltage At Relay Reverse
Warning Alarm B1 Slippage At Clutch K1
93 Open Circuit At Relay B2 Slippage At Clutch K2

Reverse Warning Alarm
B3 Slippage At Clutch K3
94 Short Circuit To Ground At Not
Relay Starter Interlock Used B4 Slippage At Clutch K4
95 Short Circuit To Battery Not B5 Slippage At Clutch KV

Voltage At Relay Starter Used B6 Slippage At Clutch KR
Interlock
B7 Overtemp Sump
96 Open Circuit At Relay Starter Not
Interlock Used B8 Overtemp Retarder
97 Short Circuit To Ground At B9 Overspeed Engine

Park Brake Solenoid
BA Differential Pressure Oil Filter Not
98 Short Circuit To Battery (Change Filter) Used
Voltage At Park Brake
Solenoid D1 Short Circuit To Battery
Voltage At Power Supply For
99 Open Circuit At Park Brake Sensors AU1
Solenoid
D2 Short Circuit To Ground
9A Short Circuit To Ground At AtPower Supply For Sensors
Convertor Clutch AU1
9B Open Circuit At Convertor D3 Low Power At Battery

Clutch
D4 High Power At Battery
9C Short Circuit To Battery
Voltage At Convertor Clutch D5 Error At Switch 1 For Valve
Power Supply VPS1
9D Short Circuit To Ground At
Retarder D6 Error At Switch 2 For Valve
Power Supply VPS2
9E Open Circuit At Retarder
F1 General EEPROM Fault
60 ISSUE 0
ISSUE
Error Definition of Error Not When machine is fully loaded or slope is steep, it
Code Code e may be desirable to pre-select a lower gear before
F3 Application Error reaching the slope.
When exhaust brake is engaged, the transmission

Accelerator Control automatically starts to down shift to a lower gear.
The digital display will indicate “2” while this
CAUTION happens.
To avoid injury or property damage caused When second gear is attained and machine has
by sudden movement of the machine, do not slowed, the exhaust brake will be disengaged and
make shift from neutral (N) to drive (D) or the digital display will return to the previous value
reverse (R) while pressing accelerator. shown.
BRAKING
NOTE:Shifting from neutral to drive or
reverse is inhibited when engine
Service Brakes and Park Brake
speed is above 900r.p.m.
During normal operation the machine must be
The position of the accelerator pedal influences stopped using the service brakes. When the
the timing at which automatic shifting will occur at machine is stopped for more than a few seconds
fast engine speeds. the park brake must be applied.
A partially depressed accelerator pedal position Service Brakes

will cause upshifts at slow engine speeds.
Stopping the machine with the service brakes is
done as follows:
SLOWING AND STOPPING
• Release the accelerator.
During normal operation, machine must be
stopped using the service brakes. If a machine is NOTE:1. When the accelerator is released
stopped for more than a few seconds, the the engine retarder will be activated.
parkbrake must be applied. 2. It is recommended that the
retarder brake function is used to
Retarders slow the machine down and the
service brakes used to stop the
Engine Retarder
machine.
The engine retarder system is fully automatic and
will be activated when the accelerator pedal is fully • While driving the machine normally the brake
released. pedal must be pressed.
On down hill operation, if engine governed speed NOTE:The transmission will automatically
is exceeded in the lower gear, the transmission select the lowest pull-off gear.
may upshift to the next higher gear. This will
reduce braking. Apply service brakes to prevent Park/Emergency Brake
exceeding engine governed speed in lower gear When the machine is to be stopped for more than
selected. a few seconds the following must be done:
NOTE:Down shifting to a lower gear • Stop the machine using the service brake.
increases the effectiveness of the • Apply the park brake.
engine braking. • Select Neutral (N).
• Release the service brake.
ISSUE 0 61
Emergency Braking Inter-axle Differential Lock Control

WARNING Engaging the Inter-axle Differential Lock
Only in the case of an emergency, apply the The following procedure must be used to engage
park/emergency brake while machine is the inter-axle differential lock:
moving. Applying the emergency brake at
high speed may cause the wheels to lock up • Stop the machine before entering poor ground
and possible damage to the transmission. conditions.
Never use the neutral brake to stop the ma- • Apply the park/emergency brake.
chine while moving. Use the service brakes • Select Neutral (N).
to stop the machine in normal situations. • Switch the differential lock switch ON.
• The inter-axle differential lock indicator will
illuminate.
To actuate the Emergency Brake, move the park • Select Forward (V).
brake lever into the apply position. • Release the park/emergency brake.
• Drive off slowly.
The machine is fitted with a NEUTRAL and engine
Disengaging the Inter-axle Differential Lock
switch OFF brake in case of an emergency.
When the ground conditions improve the inter-axle
Always check the neutral brakes before operating differential lock must be disengaged.
on steep inclines. If the brakes take longer than 3
seconds to apply, contact Your BELL The following procedure must be used to
EQUIPMENT Product Support Team. disengage the inter-axle differential lock:
Operating with Inter-axle Differential • Stop the machine when on the improved
Lock ground surface.
• Apply the park/emergency brake.
NOTE:It is recommended that the inter-axle • Select Neutral (N).
differential lock is only engaged • Switch the inter-axle differential lock switch
when the machine is operating on OFF.
very poor ground conditions. • The inter-axle differential lock indicator will
extinguish.
• Release the park/emergency brake.
CAUTION • Drive off normally.
The differential lock must not be engaged
when the machine is operating on tar or
graded surfaces. This will cause damage to
the differential.
The inter-axle differential lock switch operates the

differential lock in the transmission.
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SECTION 4. OPERATING THE MACHINE
LOADING THE MACHINE

NOTE:If the bin is not fully lowered (the bin
The following procedure must be used to load the raised warning indicator is
machine: illuminated), the transmission will
only select 1st gear, neutral and
• Position the machine in a straight ahead reverse. As soon as the bin raised
position. warning indicator is extinguished,
• Apply the park brake. normal transmission gear selection
• Select Neutral (N). will resume.
When the loading operator signals that the bin is • Select Drive (D).
fully loaded the following must be done: • Release the park brake and drive off slowly.
Select Drive (D). NOTE:The tip control lever is spring-loaded
to the central position (holding
Release the park brake and drive off slowly. position).
Raising the Bin STEERING
WARNING Normal Steering
Do not operate the bin tip lever unless the
The machine’s normal steering system is
transmission is in neutral (or dumping in 1st
operational when the engine is operating.
or reverse). This practice can over-ride the
safety functions and could cause damage to
the machine and/or personal injury. WARNING
There is no self-centring function on the ma-
• Position the machine in a straight ahead chine steering. After turning the steering,
position. the machine must be straightened by turn-
• Apply the park brake. ing the steering wheel to the straight ahead
• Select Neutral (N). position.
• Increase the engine speed to approximately
1 500 r.p.m.
• Move the tip control lever towards the Emergency Steering
operator. It will be kept automatically in this
position until the bin is fully lowered and then
automatically return to the central position. WARNING
• Reduce engine speed as the bin reaches If there is an engine or main pump failure,
maximum travel. the ground driven emergency steering sys-
• Release the tip control lever. tem will enable the operator to steer the ma-
chine to a safe stop. In this event the
NOTE:The tip control lever is spring-loaded machine must be stopped as quickly as pos-
to the central position (holding sible.
position).
Lowering the Bin

• Move the tip control lever away from the
operator.
• Ensure that the bin raised warning indicator is
extinguished.
ISSUE 0 63
The machine’s emergency steering system is Overnight Parking

ground driven and will be operational until the
machine is stationary. When the machine is to be parked overnight the
following must be done:
NOTE:There is no self centring function
with the machine steering. The • Ensure the machine is unloaded.
machine must be straightened by • Park the machine on firm level ground.
turning the steering wheel to the • Move all the switches to the OFF position.
straight ahead position. • Ensure the transmission is in Neutral (N).
• Ensure the park brake is applied.

• Switch the ignition OFF and remove the key.
CAUTION • Lock the cab door.
If the engine fails the machine must be • Move the battery disconnect switch to the OFF
steered to safety as soon as possible. position.
OPERATING INDOORS
Machines may only be operated in buildings
approved by site management.
When operating the machine indoors ensure that

there is sufficient ventilation for the exhaust fumes
to escape.
Do not exceed the maximum floor load when

operating indoors.
64 ISSUE 0
ISSUE
CHAPTER 5. OPERATING TECHNIQUES

The following information details suggested
techniques to obtain the safest and most efficient However knowledge of the ranges and when to
use of your machine. select them will make machine control and the
operator’s job easier.
Safety Rules
The following table is a brief summary of the range
Ensure there is sufficient space for the machine selections covered in this manual.
before entering confined areas.
R Completely stop the machine before
NOTE:The bin is wider than the mud shifting from a forward gear to R or from
guards. R to a forward gear.

Accidents and injuries must be reported
immediately. Site management must also be WARNING
informed of any "narrow escapes" and areas and Do not allow the machine to coast in N,
situations which could present an accident risk. this will apply the neutral brake. Coasting
in neutral will also cause transmission
If possible, after an accident, the machine must be damage.
left in its position.
Do not do anything to the machine that may N Use N to start the machine and for
hamper an investigation into the accident. periods of engine idle operation. N is
selected by the ECU at start-up. Always
Follow the instructions given by the site
select N before turning off the engine.
management.
The shift from N to V or R is inhibited when the
Gear Selection engine speed is above idle. N must be re-
selected and the idle speed reduced before
the shift will occur.
V The transmission will initially attain 2nd

gear when V is selected. As machine
speed increases, the transmission will
upshift automatically through each gear.
as the machine slows, the transmission
will downshift automatically. The shift
selector will display the highest range
available.
Even though V is selected, gear selection

may not be attained due to active inhibit
The transmission makes it unnecessary to select functions such as high throttle or engine
the right moment to up shift or down shift during idle speeds. Check for active diagnostic
changing travelling conditions. codes if V is not attained.
ISSUE 0 65

R Reverse operation of the machine is not
WARNING affected by the bin raised condition (as
If the operator just downshifts or just described above).
uses the service brakes while going
2 When retarding, (i.e. The operator takes
downhill, he may lose full control of the
his foot off the accelerator) the
vehicle.
transmission will start downshifting from
the current gear, down to 2nd gear to
To help in keeping full control on down-hills, maximise engine braking.
use a combination of downshifting and The Transmission Display will show “2”
braking. as long as retardation is in progress and
Downshifting to a lower gear increases engine will revert back to the original displayed
braking and helps the operator maintain full value when:
control. - 2nd gear is attained and the machine
The transmission has a feature which prevents has slowed down almost to a stop
automatic upshifting above the lower gear - or when the operator applies the
selected. However during downhill operation, if accelerator to cancel retardation.
engine governed speed is exceeded in the
lower gear, the transmission may shift to the The engine exhaust brake is
next higher gear. This will reduce braking and automatically applied and the exhaust
may cause loss of control. brake warning indicator is illuminated
during the above retardation period.
Apply service brakes to prevent exceeding
engine governed speed in the lower gear
selected. Gear Pre-selection
3 Occasionally road conditions, load or Gear pre-selection means selecting a lower gear
traffic conditions will make it desirable to to match driving conditions which the operator
2 restrict automatic shifting to a lower gear. encounters or expects to encounter.
1 Lower gears provide greater engine
breaking for going down grades (the Learning to take advantage of pre-selected shifts
lower the gear; the greater the braking will give the operator better control on slick or icy
effect). surfaces and on downgrades.
Even though a lower gear was selected, Downshifting to a lower gear increases engine
the transmission may not down shift until braking.
machine speed is reduced.
The selection of a lower gear often prevents
1 Use this gear when pulling through mud cycling between that gear and the next higher gear
and deep snow, when manoeuvring in on a series of up-and-down gradients.
tight spaces or while driving up/down
grades. Transport Operation
1st gear provides the machine with When operating the machine in ideal conditions
maximum driving torque and maximum (e.g. level graded surfaces) normal driving and
engine braking effect. gear selection must be used.
1 When selecting V from N and the bin is The machine may be operated at maximum speed
raised (bin raised warning indicator is in accordance with the site and road regulations.
illuminated), the transmission will limit
gear selection to 1st gear. The display on Always adapt the machine speed to the road and
the shift selector will show “1”. traffic conditions.
As soon as the bin is fully lowered (bin When driving through a bend do not drive too fast.
raised warning indicator is extinguished), The machine’s centre of gravity is changed which
the transmission will automatically revert may cause the machine to tip or roll if the road is
to normal gear selection. slippery or cambered the wrong way.
66 ISSUE 0
ISSUE
The machine load must not be allowed to fall off During icy or other slippery conditions, utilise the
the machine at any time. inter-differential lock to improve traction and
braking effect.
Do not use the inter-axle differential lock when
operating on smooth graded surfaces. Using the Engine to Slow the Machine

Due to the mass of the machine allow for long
braking distances, especially on slippery roads. WARNING
If the operator just down shifts or just uses
Uphill Operation the service brakes while going downhill, he
If the machine is operating in full automatic mode, may lose full control of the machine.
transmission will select the correct gear for
travelling uphill.
To help in keeping full control on down hills, use a
When operating on slippery roads the inter-axle combination of down shifting, braking and the
differential lock must be applied to allow for even retarder.
traction on all the driving wheels.
Downshifting to a lower gear increases engine
The engine speed must be kept constant at all braking and helps the operator maintain full
times when driving uphill. control.
NOTE:Shift cycling or "gear hunting" on The transmission has a feature which prevents
certain uphill applications can be automatic up shifting above the lower gear
eliminated by driving in manual selected. However during downhill operation, if
gearshift mode. engine governed speed is exceeded in the lower
gear, the transmission may up shift to the next
“Gear Hunting” higher gear. This will reduce braking and may
cause a loss of control.
Under certain conditions, the transmission may
start shift cycling or “gear hunting” i.e. The Apply the service brakes retarder to prevent
transmission changes up and down between two exceeding engine governed speed in the lower
gears at short intervals. This is because the power gear selected.
is insufficient for operating in the higher gear but is
To use the engine as a braking force, the operator
sufficient for up shifting from the lower gear.
must:
When the range hold switch is ON the
• Take his foot off the accelerator.
transmission will hold the gear that it is in at the
• The transmission will start to down shift and
time of the switch being activated. Normal down
the exhaust brake will be applied.
shifting will occur, but the transmission will not up
shift to a higher gear until the switch is switched If the machine is exceeding the maximum speed
OFF. for this gear, use the service brakes and/or
retarder to slow the machine.
When level ground is reached the machine must
be operated normally. When a lower speed is reached, the ECU will
automatically down shift the transmission.
Downhill Operation
Engine braking provides good speed control for
When driving downhill the exhaust brake and
travelling downhill. When the machine is fully
retarder must be utilised to assist the service
loaded, or the gradient is steep, it may be
brakes and to reduce brake pad wear.
desirable to pre-select a lower gear before
If necessary, slow down before the downhill slope reaching the gradient.
begins so that the transmission automatically
If engine-governed speed is exceeded, the
selects a low gear.
transmission will up shift automatically to the next
gear.
ISSUE 0 67
Off-road Operation Ensure that the bin is fully lowered so that the load
is not dumped into a bin which is supported on the
Do not operate too close to quarry edges, ramp tip cylinders.
edges, quay edges and soft edges that may
collapse under the machine weight. Do not overload by exceeding the rated capacity of
the machine. The operator of the dump truck is
Always use the inter-axle differential lock and six- responsible for the size and mass of the load.
wheel drive during off-road operation when there
is a risk of wheels slipping. Ensure the machine is loaded evenly. An uneven
load will cause tyre and axle damage.
Always engage the inter-axle differential lock
before any of the wheels begin to slip. Before moving off with a load ensure that it is
safely contained in the bin and no part of it can fall
off. Ensure that no parts of the load are protruding
from the bin.
Unloading
GD0003CFM
Ensure there is sufficient space for the machine
To cover difficult areas (e.g. soft mud) use the
articulation steering combined with the inter-axle Do not operate or stop too close to quarry edges,
differential lock to move through the area in the so ramp edges, quay edges and soft edges that may
called “duck waddle”. collapse under the machine mass. The use of
stopping chocks or other safety devices is
Where the ground is particularly soft and there is
recommended.
no space restriction, choose a new track for each
approach to avoid making deep tracks. Reverse up to the unloading site in a single,
straight manoeuvre so that you can maintain eye
Loading contact at all times with the spotter and have all-
Ensure there is sufficient space for the machine round vision from the machine.
If a spotter is present follow only his instructions.
Ensure that no personnel are near the machine or
loading area. Steer the machine so that it is straight and on level
ground. The operator must have clear and
Do not operate too close to quarry edges, ramp unobstructed vision through his rear view mirrors.
edges, quay edges and soft edges that may If the machine is articulated and not in the straight
collapse under the machine’s weight. ahead position the operator may find it difficult to
observe the spotter and the dumping action.
Be aware of other machines and personnel when
entering or leaving the loading area. When raising the bin ensure that when the bin is
fully raised it is no less than 4 metres (13’) away
If a spotter is present follow only his instructions. from any power lines.
Reverse up to a loading machine in a single, Ensure that no personnel are near the machine or
straight manoeuvre so that you can maintain eye dumping area.
contact at all times with the operator of the loader.
Be aware of other machines and personnel when
Steer the machine so that it is straight. The entering or leaving the dumping area.
operator must have clear and unobstructed vision
through his rear view mirrors. If the machine is
articulated and not in the straight ahead position
WARNING
the operator may find it difficult to observe the Do not operate the bin tip lever unless the
spotter and the loading machines. transmission is in Neutral (or dumping in 1st
or Reverse). This practice can over-ride the
Stop the machine on a firm level surface. safety functions and could cause damage to
the machine and/or personal injury.
68 ISSUE 0
ISSUE
Stuck Machine Full power for more than 30 seconds under the
above conditions will cause the transmission to
NOTE:If the ground is soft with deep wheel overheat.
tracks constant attention must be
given to the rear chassis angle. If the transmission overheats, shift to N and
operate the engine at 1 500 rev/min until it cools
If the rear chassis starts to lean sideways (2-3 minutes).
excessively, stop the machine immediately and try
another route. If the machine is stuck in deep sand, snow or mud,
it may be possible to rock it out as follows:
If the machine becomes stuck the following must
be done: • Shift to V and apply steady, light throttle (never
full throttle).
• Select Neutral (N). • When the vehicle has rocked forward as far as
• Engage the inter-axle differential lock. it will go, apply the service brakes.
• Select Forward (D). • Allow the engine to return to idle.
• Check that the inter-axle differential lock • Select R.
indicator illuminates. • Release the service brakes and apply a
• Drive off slowly keeping the engine speed (rev/ steady, light throttle and allow the machine to
min) constant and not too high. rock in R as far as it will go.
• To assist with traction, turn the steering wheel • Again apply and hold the service brake and
one way and then the other alternately causing allow the engine to return to idle.
the machine to adopt a “duck waddle”. • This procedure may be repeated in V and R if
• Continue with this movement until the machine each directional shift continues to move the
is free and can be operated normally. machine progressively further.
NOTE:If the machine does not move, get a
towing vehicle to move the machine
from the soft soil.
Rocking Out
WARNING
To help in avoiding injury or property dam-
age caused by sudden movement of the ma-
chine, do not make shifts from N to V or R
when the throttle is open.
If the operator shifts while the throttle is open too

much, the transmission will engage only if the
throttle is closed in the next three seconds. That
can cause a sudden movement of the machine.
Leaving the throttle open longer than three
seconds causes the transmission to remain in N.
Avoid this condition by making shifts from N to V or
R only when the throttle is closed.
CAUTION
Do not make N to V or directional shift
changes when the engine speed is above
idle. Also if the wheels are stuck and not
turning, do not apply full power for more
than 30 seconds in either V or R.
ISSUE 0 69
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ISSUE
CHAPTER 6. RECOVERY AND TRANSPORTATION
SECTION 1. TOWING
SAFETY RULES
If the disabled machine is to be articulated
Always consult your BELL EQUIPMENT Product (manoeuvred) a towing machine with an A-frame
Support Representative before towing a disabled must be attached to the front of the machine for
machine. manoeuvring and a machine attached to the rear
for controlling.
Always chock the machine before releasing the
brakes and/or disconnecting the driveshafts. Minimum towing capacity is required for towing on
smooth level surfaces and maximum towing
Only use a rigid A-frame when towing a machine capacity is required for towing on gradients and
The A-frame must be securely fastened to both poor ground conditions.
towing eyes and must distribute the towing force
evenly on both towing eyes when towing or turning
the machine. CAUTION
Failure to lift the wheels off the road or
Ensure the A-frame is strong enough to tow a disconnect the drivetrain can cause damage
machine at least 1.5 times the gross weight of the to the transmission.
towed machine, when towing from mud or on a
gradient.
The engine can not be started by pushing or
Never exceed 2 km/h (1.2 m.p.h.) when towing a towing.
disabled machine for short distances.
BRAKES RELEASE PROCEDURE
Load a disabled machine onto a suitable
breakdown vehicle or remove the driveshafts
between the transmission and transfer case when WARNING
moving it long distances. This procedure must be performed by a
BELL EQUIPMENT Product Support Repre-
Shielding must be provided on the towing machine
sentative only.
and the disabled machine if the operator can
possibly be injured due to the tow bar breaking.
Do not allow any unauthorised personnel on the

WARNING
disabled machine. 1. Once the brakes have been released us-
ing the hand pump the only way the brakes
Gradual smooth movement is necessary for safe can be applied is by turning the hand pump
towing. Quick movements will overload the A- lever to the “OFF” position.
frame and cause it to break. 2. Never over pressurize the system.
3. After machine has been towed to the de-
The towing machine must be the same size or sired location, always turn hand pump lever
larger than the disabled machine. Ensure the to “OFF” position.
towing machine has sufficient brake capacity,
mass and power to control both machines. Take
account of the ground conditions and gradient
when towing a disabled machine.
CAUTION
Chock wheels before performing this
A larger machine and a solid tow bar is required procedure.
when towing a disabled machine downhill. An
additional machine connected to the rear may also • Attach the towing machine to the stationary
be required to prevent the disabled machine from machine at lifting/tie down points with an A
rolling away. Frame.
• Ensure that the emergency/park brake is
applied on the towing machine to prevent
vehicles from moving.
ISSUE 0 71
• Open the park brake cover plate on the main

inspection cover. With the engine stopped the machine hydraulic
• Turn the hand pump lever located on the lower and pneumatic systems are not operative. This
front side of the SAHR block to the “ON” means there is no steering.
position.
Before towing disconnect the transmission-to-front
• Position a second person in the cab to turn the
axle and the transmission-to-rear axle driveshafts.
lever “OFF” again if the machine starts rolling,
to stop the machine.
If the machine must articulate while being towed
• Pressurize the brake system by using the
disconnect as follows:
hand pump.
• While the second person is watching the brake • Remove the supply hoses from the T-pieces
pressure gauge. The brakes will start to on the left hand steering cylinder.
release at 8 MPa. (1160.3 lb. in.). • Block off the two supply hoses using suitable
• Do not pressurize the brakes higher than 10 plugs.
MPa (1450.77 lb. in.) on the brake pressure
gauge. If this is done, the seals on the brakes NOTE:Some oil spillage will be
can be damaged. unavoidable. Clean up any oil
spillage as soon as possible.
Towing a Machine with Inoperable Engine,
Failure In Transmission Or Hydraulic Loop the two steering cylinder T-pieces together
System using a suitable hose.
WARNING
With the brakes released and the drive shafts
disconnected, the towing machine must be
1. Before releasing the brakes, always chock capable of steering and stopping the complete
the wheels to prevent the machine from roll- mass of the disabled machine.
ing.
2. Ensure the brake system of the towing NOTE:1. Given the danger in towing a
machine is sufficient to hold the combined vehicle without an effective braking
mass of the towing machine and the disa- system it is recommended that the
bled machine. machine is transported on a suitable
breakdown vehicle.
2. Road speed must not exceed 2 km/
hr. (1.2 m.p.h.) and the steering
disconnected.
72 ISSUE 0
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CHAPTER 6. RECOVERY AND TRANSPORTATION
SECTION 2. LIFTING
Machine Lifting Points
The following figure details the machine lifting points:
~8090 MM
ONLY USE NYLON SLINGS

IN FRONT TO PREVENT
DAMAGE TO BONNET
CRANE
Minimum
4000mm
B25L
CRANE
GLC0004CFM
NOTE:Ensure that the articulation bar is installed.
ISSUE 0 73
Lifting the Machine • Lift the lifting beam until all the play in the
chain is removed.
NOTE:The machine lifting points are • Lift the machine until it is clear of the
indicated with decals on the transporting vehicle’s trailer.
machine.
NOTE:The crane must be moved slowly to
• When lifting the machine the following must be prevent excessive swinging of the
done: lifted machine.
• Park the transporting vehicle next to the
machine being lifted. • Move the machine over the transporting
• Install the articulation safety lock bar. vehicles trailer slowly.
• Attach the chains to the machine lifting points • When the machine is directly over the
and the lifting beam. transporting vehicle’s trailer lower the machine
onto the trailer slowly, following the
NOTE:The lifting beam must be longer than instructions of the spotters.
the machine length to avoid • Lower the lifting beam until the chain can be
damaging the machine and must be removed from the machine.
able to carry the total machine • Lift the lifting beam and move it away from the
weight. machine.
• Chock all the machine’s wheels.
• Attach the lifting beam to the crane. • Secure the machine to the transporting
vehicle’s trailer with chains.
NOTE:The crane must be able to carry total
machine weight.
Machine Tie-down Points

The following figure indicates the machine tie-down points:
GLC0005FM
NOTE:Ensure that the articulation bar is

installed.
74 ISSUE 0
ISSUE
Transporting Driving the Machine onto a Transporting

Vehicle
Transporting the Machine on Other To drive the machine onto the transporting vehicle
Vehicles the following must be done:
The machine can be loaded onto the transporting • Position the transporting vehicle’s trailer
vehicle by two methods: against the loading ramp.
• Drive the machine onto the trailer very slowly
• Lifting the machine (refer to Lifting the following the instruction of the spotter.
Machine and Machine Lifting Points; previous • Install the articulation safety bar.
procedure). • Chock all the machine wheels.
• Driving the machine. • Secure the machine to the transporting
vehicle’s trailer with chains.
Safety Rules • Drive the transporting machine away slowly.
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 bar until the machine is secured.
When the machine is lifted onto the transportation

vehicle the articulation safety bar must be
installed.
Always chock the machine when securing it to the

transportation vehicle.
ISSUE 0 75
76 ISSUE 0
ISSUE
CHAPTER 7. PRE-SERVICE INSTRUCTIONS
SECTION 1. 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.
2
1 6
WARNING
DO NOT
OPERATE
THISTAG MUST ONLY BE
REMOVED BY THE PERSON
SERVICING THE MACHINE
HOT
COLD
4 3 5
GLC0003CFM
Park the machine in the straight ahead position

and prepare for servicing as detailed below: WARNING
When servicing the machine and one of the
WARNING axles of the machine is raised off the ground
using jacks, the wheels on at least one of the
If the following steps are not observed it other axles must be chocked. This is be-
could result in injury or death. cause there is a risk that the machine may
roll off the jacks, even if the park brake is ap-
• Shut down the engine and apply the park plied.
brake.
• Remove the keys from the ignition switch and • Install wheel chocks to ensure that the
attach the “DO NOT OPERATE” warning sign machine cannot move backwards or forwards
to the steering wheel. during the service.
• Install the articulation safety bar.
WARNING
Beware of hot fluids and components. Do
not work on a hot machine.
ISSUE 0 77
5.
• Allow the machine to cool down.

• Relieve all pressure in the relevant system
before any lines, fittings or related items are
disconnected or removed, as follows:
1
i . The air pressure is relieved by holding
open the drain valve on the air reservoir.
ii . The cooling system pressure can only be
safely relieved by allowing the engine
coolant to cool down until it is safe to
remove the filler cap.
iii . The hydraulic, fuel and air conditioner
system pressures should only be
relieved by qualified personnel.
• Lower the bin until the bin prop is located
Install the Bin Prop safely in the holder (1)
WARNING WARNING
Check to ensure that the bin prop is located
When the bin is raised to perform mainte-
safely inside the holder.
nance tasks, the bin prop must be installed.
The following procedures must be used to install Install the Articulation Safety Bar
the bin prop:
The following procedures must be used to install
• The operator, in the cab, must control the bin the articulation safety bar:
operation.
• Park the machine in the straight ahead
position.
• Shut down the engine and apply the park
1 brake
• Remove the keys from the ignition switch and
attach the “DO NOT OPERATE” warning sign
to the steering wheel.
• Raise the bin high enough to allow the bin

1
prop (1) to be hinged up to the vertical position
by another person.
• Raise the bin prop.
• Remove pin (1).

• Swing articulation lock bar out.
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WARNING
The Belly Plate is very heavy. Be careful
when lowering the belly plate as it can cause
1 injury or even death.
NOTE:Closing is the reverse of opening.
Raise the Belly Plate Assembly

The following procedures must be used to raise
• Fit the pin (1) through the holes to secure in the belly plate:
position. The steering wheel must be turned so
•
that the articulation allows the holes to align.
Secure the articulation safety bar back in the WARNING
travelling position after the service. Be careful when raising the belly plate as it
can cause injury or even death if it slips off
Lower and Raise the Belly Plate the trolley jack.
To perform some maintenance tasks it is • Manoeuvre a trolley jack under the belly plate
necessary to lower the belly plate for access. so that the belly plate can be safely raised.
• Install the bolts and remove the trolley jack.
The belly plate assembly has two access hatches
that allow access to certain areas.
The complete assembly can be lowered if it is

required.
Lower the Belly Plate Assembly

The following procedures must be used to lower
the belly plate:
1
2
• Loosen the three Belly Plate securing bolts (1).

• One person should support the belly plate.
• A second person should help supporting the
belly plate while removing the bolts (1). Lower
the Belly Plate Assembly (2) to the ground.
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CHAPTER 7. PRE-SERVICE INSTRUCTIONS
SECTION 2. RULES WHEN SERVICING
GENERAL • Switch OFF the batteries disconnect switch or

disconnect the battery before performing
Do not carry out any work on the machine unless maintenance on the machine.
you are trained and have the knowledge to carry • Relieve the pressure in the relevant system
out the work. gradually before starting to work on a system
component or assembly.
Service which is not carried out in the correct way • All pressurised vessels must be opened very
may be dangerous. Make sure that you have carefully.
sufficient knowledge, the correct information, the • When checking for leaks, use a piece of paper
correct tools and the right equipment in order to or wood, do not use your hands.
carry out the service in the correct way. • Never set a pressure limiting valve to a higher
pressure than that recommended by the
Repair or change broken tools and faulty manufacturer. Only qualified personnel must
equipment. Read all plates and decals on the adjust any valve settings.
machine and in the manual before you start • Before starting the engine indoors, make sure
servicing the machine. Each of the instructions that the ventilation is sufficient to cope with the
contains important information about handling and exhaust gases.
servicing. • Do not stand behind the machine while the
engine is running.
Do not wear loose fitting clothing or jewellery when
working on the machine.
DIESEL FUEL
Always wear a hard hat, safety glasses, gloves,
Consult your local fuel distributor for properties of
shoes and other protective articles as the job
the diesel fuel available in your area.
requires.
In general, diesel fuel are blended to satisfy the
When carrying out service work in the articulation
temperature requirements of the geographical
area, ensure that the articulation safety bar has
area in which they are marketed.
been installed.
Diesel fuel specified to EN 590 or ASTM D975 are
Always stop the engine to service the machine,
recommended.
unless otherwise instructed in this manual.
In all cases, the fuel shall meet the following
When changing oil in the engine, fluid in the
properties:
hydraulic system or transmission, remember that
the oil and fluid may be hot and can cause burns.
Cetane Number of 40 Minimum
When lifting or supporting components, use Cetane number greater than 50 is preferred,
equipment with a lifting capacity which is at least especially for temperatures below -20°C (-4°F) or
as great as the components. elevations above 1500m (5000ft).
All lifting devices, for example slings and ratchet Cold Filter Plugging Point
blocks, must comply with national regulations for
lifting devices. BELL EQUIPMENT COMPANY Cold filter plugging point below the expected low
will not accept any responsibility if any lifting temperature or Cloud point at least 5°C (9°F)
devices, tools or working methods are used other below the 4 expected low temperature.
than those described in this manual.
Fuel Lubricity
• Stop the engine before removing engine Fuel lubricity should pass a minimum of 3100gram
covers or similar. load level as measured by the Bocle scuffing test.
• Make sure that no tools or other objects which
can cause damage are left in or on the Sulphur Content
machine.
• Sulphur content should not exceed 0.5%.
Sulphur content less than 0.05% is preferred.
ISSUE 0 81
• If diesel fuel with sulphur content greater than

0.5% sulphur content is used, reduce the CONTAMINATED OILS AND FLUIDS
service interval for engine oil and filter by 50%.
• Do Not use diesel fuel with Sulphur content Whenever the engine oil or transmission or
greater than 1%. hydraulic fluid is changed always inspect the old
oil and fluid for any signs of contamination (water
Bio-diesel fuels may be used ONLY if the fuel and foreign matter etc.) The presence of
properties meet DIN 51606 or equivalent contamination could indicate a fault in the system.
specification.
The old oil and hydraulic fluid filters must also be
DO NOT mix used engine oil or any other type of checked for the presence of foreign matter.
lubricant with diesel fuel.
Always use new, clean oil, fluids and filters when
Low Sulphur Diesel Fuel Conditioner replenishing the systems.
When possible, use existing fuel formulations for
engines used off-highway. This fuel will not require Measures to Prevent Fires
any additives to provide good performance and
There is always a risk of fire.
engine reliability. However, many local fuel
distributors will not carry both low and regular Find out which type of fire extinguisher to use,
sulphur diesel fuels. where it is kept and how to use it.
Handling and Storing Diesel Fuel Any fire fighting equipment stored on the machine
must be maintained in working order.
CAUTION
At the slightest sign of fire, and if the situation
1. Handle diesel fuel carefully. Do not fill the allows, take the following steps:
tank when engine is running.
2. DO NOT smoke while you fill the tank or • Move the machine away from the danger area.
service the fuel system. • Stop the engine and turn the ignition to the
3. The fuel tank is vented through the filler OFF position.
cap. Always replace the cap with an original • Leave the cab.
filler cap. • Start putting out the fire and notify the fire
brigade if required.
Fill the tank at the end of each day’s operation to Do not smoke or have a naked flame near a
prevent condensation and freezing during cold machine when filling with fuel or when the fuel
weather. system has been opened.
When fuel is stored for an extended period or if Diesel fuel oil is flammable and should not be used
there is a slow turn over of fuel, add a fuel for cleaning, use an approved solvent.
conditioner to stabilize the fuel and prevent water
condensation. Remember that certain solvents can cause skin
rashes and are usually flammable. Do not inhale
Contact your fuel supplier for recommendations. solvent vapour.
Lubrication Storage Store flammable starting aids in a cool, well

ventilated location. Remember that such aids
Use clean containers to handle all lubricants. (starting gas) must not be used in connection with
preheating of the induction manifold.
Whenever possible, store lubricants and
containers in an area protected from dust, Keep the work place clean. Oil and/or water on the
moisture and other contamination. Store floor makes it slippery.
containers on their side to avoid water and dirt
accumulation. Oil and/or water in close proximity to electrical
equipment or electrically powered tools are
Mark all containers properly. Dispose of all old dangerous and any spills should be cleaned up
containers and any residual lubricants they may immediately.
contain.
Oily clothes are a serious fire hazard.
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Check daily that the machine and equipment are

free from dirt and oil. In this way the risk of fire is Avoid breathing in the air conditioner refrigerant
reduced and it is easier to detect faulty or loose and lubricant vapour or mist. Exposure may irritate
components. the eyes, nose and throat.
The refrigerant is under high pressure and the

CAUTION system must be serviced by qualified personnel
If a high pressure jet is used for cleaning, only. Improper service methods may cause injury.
take great care as the insulation of electrical
If accidental system discharge occurs, ventilate
leads can become damaged even at a
the work area before resuming work.
moderately high pressure and temperature.
Additional health and safety information may be
WARNING
obtained from your refrigerant and lubricant
manufacturers.
Do not point the high pressure jet at person-
nel. Working on Painted Surfaces
When welding and cutting, the paint must first be
Check if the electric leads have been damaged by removed up to a distance of 100 mm (4") from the
chafing which could lead to a short circuit and fire. welding or cutting point. Paint which is heated
gives off unhealthy gases.
Check that there is no damage to hydraulic and
brake hoses caused by chafing. Ideally paint should be removed using sand
blasting. If the paint cannot be removed using

sand blasting, it must be removed in some other
CAUTION way for example using paint stripper or a high
Switch OFF the battery disconnect switch or speed grinder.
disconnect the batteries, when welding on
the machine. NOTE:When using paint stripper or a high
speed grinder, you must use a
portable air extractor, safety glasses
Welding and grinding may only be done on the and protective gloves.
machine when it is placed in a clean area where
there are no fuel tanks, hydraulic pipes or similar Working with Polymer Material
lying around. Take extra care when welding and
grinding near flammable objects. A fire Polymer materials, such as rubber and certain
extinguisher should be kept handy. kinds of plastics, can give off gases when
heated.These gases can be dangerous to your
health and to the environment.
The following protective measures should be

taken:
• Protect the polymer material from heat before

welding or cutting near the material.
• Do not burn polymer materials when disposing
of them.
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84 ISSUE 0
PART 2
SERVICE AND MAINTENANCE
ISSUE
CHAPTER 8. MAINTENANCE SCHEDULES
Preventative maintenance is very important. It includes lubrication, checks and adjustments which the
operator can perform. Procedures which require BELL EQUIPMENT Product Support to perform are noted
in the instructions.
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 this Chapter.
Maintenance Schedule in Running Hours

First Every Every Every Every As
Details Daily
100 500 1000 2000 4000 Required
ENGINE
NOTE: For further maintenance and service procedures, refer to the Mercedes-Benz OM 501 Manual.
Adjust the valve clearance. (Every second oil

X
change)
Change the primary fuel filter/water separator. X X
Change the final fuel filter. (Every second oil

X X
change).
Drain the primary fuel filter X
Change the oil and oil filters X
Check the oil level X
Clean pre-cleaner assembly X
Check the air cleaner service indicator X
Change the air cleaner primary filter X (C)
Change the air cleaner secondary filter X (D)
Change the coolant X (A)
Check the coolant level X
Check the coolant mixture X (A)
TRANSMISSION-ZF 6WG 210
Change the filters X X
Change the oil X X
HYDRAULICS
Change the oil X (B)
Change the return filters X
ISSUE 0 87
Maintenance Schedule in Running Hours
Details Daily First Every Every Every Every As

100 500 1000 2000 4000 Required
Change the breather filter X
Test the brake accumulator function. X
AXLES AND CHASSIS
Change the oil in the differentials and final

X X
drives
Check the oil level in the differentials and final

X
drives
CAB, PNEUMATICS AND ELECTRICAL
Change the air drier filter X
Check the operator controls, buzzers and

X
instruments
Check the working lights, reverse buzzer and

X
horn
Check the electrical connections and wire

X
routings for chaffing.
LUBRICATION
Grease the hinges X
Grease all remaining lube points. (If

X
applicable).
GENERAL WALK ROUND
Check and clean coolers X
Check and clean breathers axles X
Check tyre pressures X
NOTES:
A Refer to bulletin 2000/033 regarding water & coolant specification
B Change intervals can be extended by oil sampling.
C Replace yearly or as per indicator, whichever occurs first.
D Replace yearly or every third primary air filter change, whichever occurs first.
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.
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B25L & B30LMk II 4X4 CHAPTER 9 872120
CHAPTER 9 . AS REQUIRED SERVICE
SECTION 1. ENGINE
Introduction
This chapter details services which are described
in the maintenance schedule as tasks which are
performed as required.
Some unscheduled maintenance tasks are also

included in this chapter.
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 Check the alternator for security.
OM 906 LA Tier 2
Check the Engine Compartment

Components
Perform a general, visual check on the engine and
components in the engine compartment as
follows:
1
1
Ensure that the starter motor (1) is mounted
securely and not damaged.
Ensure that the pipes and hoses and all linkages

are secure and not damaged.
Inspect the alternator and water pump drive belt

for cracks, fraying, wear and tension.
ISSUE 0 89
2 1
3
2
Check the exhaust brake valve (1) and linkage (2)

for damage and security.
1
Check the air hose (3) on the exhaust brake valve
for security and leaks.
Check the manifolds for cracks, damage and

security.
Inspect the transmission mounting bolts (1) for
security.
Check that the rubber mountings (2) are secure

1
and not damaged.
Inspect the engine mounting bolts (1) for security.
Check that the rubber mountings (2) are secure

and not damaged.
3
Check the cooling pack (1) for damage and

security.
Check that the cooling pack mountings (2) are not

damaged and that the bolts (3) are secure.
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Check the radiator fins for damage and

cleanliness, if it is dusty and mud-packed, clean
with a pressure washer and mild, non caustic to
aluminium, soap and water solution, spraying from
the rear face. Ensure that there is no restriction to
the air flow.
1
Check and Clean Transmission Cooler
Open the battery box lid.
• Turn battery disconnect switch to OFF.
• Check the transmission cooler for damage and
security.
• Check the hoses and clamps for damage and
security. 2
Open The Belly Plate
Check the fan cowling (1) for damage and cracks.
Ensure that the mounting bolts and fan guard (2)

are secure.
Check for Oil and Fuel Leaks

Perform a visual inspection for oil and fuel leaks on
and around the engine and components inside the
engine compartment.
• Check the oil/water cooler, if it is mud-packed Check all Hoses and Clamps
clean with soap and water solution.
Visually inspect all the hoses in the engine
• Check all hoses and fasteners for security and
compartment for leaks, cracks, deterioration and
leaks.
chafing damage.
• Check hoses and clamps for damage and
security. Ensure that the hoses are routed correctly, all
NOTE:If there has been a failure in the securing straps are functional and undamaged.
retarder cooling system, the cooler
Check that the hoses are fastened in the correct
must be removed and tested.
position and no chafing can occur when the
Contact BELL EQUIPMENT Product
machine is in use.
Support.
Check all the clamps in the engine compartment to
ensure that they are secure.
Check all Electrical Components, Cables

and Connections
Visually inspect all the sender units and switches
in the engine compartment for damage.
Ensure that the electrical cables and wires are

routed correctly and that all securing straps are
functional and undamaged.
ISSUE 0 91
Check that the cables and wires are fastened in Check the rubber elbow (3), connecting pipes,
the correct position and no chafing can occur clamps (4) and mounting bolts for security and
when the machine is in use. damage.
Check all the electrical connections in the engine Check service indicator (5) for damage.
compartment to ensure that they are secure.
Check that the service indicator is not showing a
Check the Wiring red flag, re-set if necessary.
Check the wiring daily for security and to ensure

that no fraying has taken place.
Ensure that the connections are secure and that

the alternator, starter motor, air conditioner
compressor motor, buzzer and horn earth cables
are secure.
Visually inspect all the sender units and switches

for damage.
Check the Engine Components (External)

Check the exhaust pipes and mounting bolts and
clamps for security and damage.
Check that the vacuator valve (1) is undamaged

and free from obstruction.
Check the exhaust stack, mounting bolts and

clamps for security and damage as well as the
heat shields.
2
1
4
1
3
Check the level of the dirt in the bowl, if it reaches
the level (1) marked on the bowl, the bowl must be
5
cleaned.
Check the air cleaner assembly for damage to the

air cleaner (1) and pre-cleaner (2).
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Clean the Air Cleaner Pre-cleaner Bowl Change the Primary Filter Element
3
1
Remove the wing nut (1) securing the lid (2) to the
bowl (3).
Loosen the clips (1) and remove the end cover

from the air cleaner housing.
2
Remove the lid (1) and bowl (2) from the pre-
cleaner body (3). 1
Remove the dirt from the bowl and clean the bowl
with a lint-free cloth.
Install first the bowl then the lid onto the pre-
cleaner body and secure them with the wing nut.
Remove the primary filter element (1) from the air

cleaner housing.
Discard the primary filter element, do not re-use.
NOTE:At minimum, secondary element

must be replaced every third time
primary element is replaced.
ISSUE 0 93
Drain the Racor Fuel Filter
Remove and inspect secondary element (1).

Replace if necessary.
Clean the air filter housing inside and the end

cover with a damp cloth and inspect for damage. 2
Squeeze unloader valve to empty air cleaner

housing of dust and debris.
Install the new primary filter element into the air 1

cleaner housing and secure with the wing nut. Do
not over-tighten the wing nut.
Install the end cover and secure with the wing nut. Connect a pipe to the outlet (1) and hang the other
point in a container.
Check the end cover to ensure that it is fitted
correctly with the arrows pointing up. Loosen the nut (2) on the Racor fuel filter.
Check the Air Cleaner Service Indicator Drain the accumulated water.
Tighten the wing nut when fuel flows out water

free.
Remove the pipe.
Check the indication window (1) on the air cleaner

service indicator.
If the window shows a red flag, the air cleaner filter

element must be changed.
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CHAPTER 9 . AS REQUIRED SERVICE
SECTION 2. HYDRAULICS CAB AND ELECTRICAL
CLEAN AND CHECK THE BREATHER,

HOSES AND CONNECTIONS
Loosen the access panel on top of the hydraulic
tank and remove the cover.
2 1
CAUTION
DO NOT spray steam, water or cleaning
solution directly at hydraulic reservoir 2
breather. Spray could be forced into the
reservoir.
Hydraulic reservoir breather should be checked

daily in adverse working conditions. The amount of Check both of the steering cylinders for damage
dust and dirt encountered will determine the and leaks and ensure that the mountings (1) are
frequency of breather cleaning. secure.
Ensure that the hydraulic hoses and connections

(2) are secure and undamaged.
Check that the lubrication hoses are secure and

not damaged.
CHECK THE TIP CYLINDERS, HOSES,

1 PIPES AND CONNECTIONS
3 2
1
4
Check breather (1) for damage and security.
Replace breather if it appears damaged or cannot

be unclogged. (See Replace Hydraulic Reservoir
Breather in Maintenance every 4000 Hours
Section).
Check that the hoses and connectors are secure Check the tip cylinders (1) for damage and leaks.
and not damaged.
Ensure that the connections (2), pipes (3) and
Install access panel and cap screws. hoses (4) are secure and undamaged.
Install clamp and nuts to bin heater support and
pipe.
CHECK THE STEERING CYLINDERS,

HOSES AND CONNECTIONS
ISSUE 0 95
CHECK THE MAIN HYDRAULIC PUMP, Check all the axles for damage and security.
HOSES AND CLAMPS Check all the differentials for signs of leaks,
damage and security.
Check all the driveshafts for damage and security.
Check that the sandwich blocks are not damaged

and that the securing bolts are secure.
2 Ensure that the walking beam and joints are not
damaged and that the securing bolts are secure.
1
Check the tyres for wear and damage.
Check the tyre pressures.
LUBRICATE ALL HINGES
Check the main hydraulic pump mounting bolts , Lubricate cab door hinges, Battery compartment
connections (1) and hoses (2) for security. door hinges, hood hinges and bottom guard
hinges.
Check the hoses and connections for damage and
leaks. CHANGE ENGINE COOLANT
CHECK THE EMERGENCY STEERING Open the bonnet.

PUMP, HOSES AND CLAMPS Lower the access hatch upper. (See Lower the
Access Hatch Upper in Chapter 7).
3
1
Check the emergency steering pump (1) mounting

bolts, connections (2) and hoses (3) for security.
Remove fill cap (1) from expansion tank.
Check the hoses and connections for damage and
leaks.
AXLES AND CHASSIS AND WHEELS

Inspect all pipes, hoses, clamps and connections
on the axles and differentials for security.
Ensure that the hoses cannot chafe against

moving parts.
96 ISSUE 0
ISSUE
4
1
Attach hose and hose clamp to drain valve

nozzle (1).
Loosen nut (2) and valve stem (3) to open drain

valve (4).
Drain coolant into a container.
Tighten valve stem (3) and nut (2) to close drain

valve (4).
Add new engine coolant. (See Recommended

Coolants and Additives in CHAPTER 1).
Do Not install fill cap. Start engine and run engine

for 3 minutes at slow idle to purge air pockets from
engine cooling system. Stop engine.
Check for leaks at drain valve. Tighten only

enough to stop leaks.
Check coolant level in the expansion tank. Coolant

level should not be below the ADD mark. Hot
coolant should not be above FULL mark. Add if
necessary.
Replace fill cap.
Raise belly plate and access hatch front.
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CHAPTER 10 . DAILY OR 10 HOURLY SERVICE CHECKS
SECTION 1. ENGINE
INTRODUCTION
The daily or 10 hourly service checks must be 2
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 1

Refer to Pre-service Instructions, Chapter 7. Remove the dipstick and check that the oil level
reaches the upper mark (1) on the dipstick.
ENGINE
NOTE:When the oil is hot, the oil level must
NOTE:For further engine information or be on the top mark (1) of the dipstick,
details not shown in this manual, but not above it. When the oil is cold,
refer to the Mercedes-Benz Manual ensure that the level is between
OM 906LA. marks (1) and (2), but not below mark
(2).
Open the bonnet.
Re-insert the dipstick, ensuring that it is properly
Check the bonnet catch for damage and ensure seated and fasten the dipstick clip.
that the bolts are secure.
If necessary, replenish the engine oil.
Check the Oil Level
Check the Coolant Level
WARNING
Check the coolant level when the engine is
cold. Whenever the cap on the expansion
1 tank needs to be removed, remember that
the system may be under pressure which
could cause hot coolant to be ejected.
Remove the dipstick (1).
Wipe the dipstick clean with a lint free cloth.

seated.
The coolant must be between the maximum and

minimum marks on the tank.
ISSUE 0 99
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.
Check Air Intake System
5 4
3
2
4
6 5
4
Check air cleaner assembly for damage to pre-

cleaner (1) and air cleaner housing (2).
Check that the service indicator (3) is not showing

a red flag. If a red flag is shown, service air cleaner
and reset service indicator. (See Service Engine
Air Intake System in Chapter 9 - As Required
Service).
Check rubber elbows (4), Clamps (5) and air pipes

(6) for tightness, cracks or damage.
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ISSUE
SECTION 2. TRANSMISSION
CHECK THE TRANSMISSION FLUID

LEVEL
Transmission
1
Check the Transmission Fluid Level
Always check the fluid level at least twice. If the
readings are not consistent, check and clean the
transmission breather.
There are two methods for checking the

transmission fluid level, they are as follows: 30C3007FM
• The dipstick check when the transmission fluid • Unscrew and remove the dipstick (1) from the
is cold. tube and wipe clean.
• The dipstick check when the transmission fluid • Clean the end of the tube before inserting the
is hot. dipstick.
• Insert the dipstick into the tube and remove to
Dipstick Check - Transmission Fluid COLD check the fluid level.
(Cold Check) • Repeat the check procedure to verify the
The Cold Check determines if the transmission reading.
has sufficient fluid to be operated safely until a Hot
Check can be made.
30C3008FM
CAUTION
DO NOT start the engine until the presence 2 1
of transmission fluid has been confirmed.
• If the fluid level is within the “Cold (1) and Hot
(2)” band the transmission may be operated
A cold check must be performed before start-up
until the fluid is hot enough to perform a “Hot
and the presence of sufficient transmission fluid
Check”.
has been confirmed. The sump fluid temperature
o o o o • If the fluid level is not within the “Cold and Hot
is then typically 16 C to 49 C (60 F to 120 F )
“band, add or drain transmission fluid as
• Ensure that the transmission is in Neutral (N). necessary to bring it within the band.
CAUTION
1. The fluid level rises as the fluid
temperature increases. DO NOT fill above
the “Hot” mark if the transmission fluid is
below normal operating temperatures.
o
Normal operating temperature is 71 C to
o o o o
93 C (160 F to 200 F ). The oil level at 80 C
o
(176 F ) is valid and must not be exceeded.
2. The transmission must not be operated
for extended periods until a “Hot Check”
has verified proper fluid level.
ISSUE 0 101
Dipstick Check - Transmission Fluid HOT (Hot

Check)
The Hot Check verifies proper fluid level.
Ensure that the transmission fluid has reached

o o
normal operating temperature; 71 C to 93 C
o o
(160 F to 200 F )
NOTE:Check the transmission fluid

temperature on the master display
unit.
• Ensure that the machine is parked on a level

surface and the park/emergency brake is
applied.
• Allow the engine to run at idle (500 to 700 rev/
min.) in N (Neutral).
30C3007FM
• Unscrew and remove the dipstick (1) from the

tube and wipe clean.
• Clean the end of the tube before inserting the
dipstick.
• Insert the dipstick into the tube and remove to
check the fluid level.
• Repeat the check procedure to verify the
reading.
30C3008FM
2 1
• The safe operating fluid level is at the “Hot”

mark (2).
• If the fluid level is not at the “Hot” mark, add or
drain transmission fluid as necessary to bring
it to the mark.
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SECTION 3. HYDRAULICS, CAB AND ELECTRICAL
HYDRAULICS
Check the Hydraulic Fluid Level
Ensure that the bin is in the lowered position.
1
2
GC4018FM
Check the hydraulic fluid level in the sight

glass (1).
The fluid level must be on the mark (2).

Ensure that the reverse buzzer (1) is securely
If necessary replenish the fluid in the hydraulic mounted.
tank. Refer to Specifications, Chapter 1 -
Recommended Lubricants and Coolants.
Cab and Electrical

Check the Operator’s Controls and
Instruments
Carry out a functional check on all controls and
instruments daily. Refer to Chapter 2 - Operator
Control and Instruments.
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 - Functionally test the horns and ensure that they
Recommended Lubricants and Coolants. are securely mounted.
• Switch all the lights on in turn, including Check Brake Accumulators

headlight (dipped and high beam), indicators,
hazard and brake lights. Start engine and wait until main pump has fully
• Make sure the path is clear behind the charged the accumulators.
machine, and then reverse to ensure the
buzzer and reverse lights are working.
ISSUE 0 103
Press brake pedal repeatedly to make the main

pump recharge the accumulators several times.
Stop pushing pedal while in the middle of a
recharge cycle to ensure brakes are not
consuming oil after main pump stops.
Stop engine. Turn key switch to ON position.
Wait for bulb check.
While watching the accumulator pressure gauge,

press brake pedal repeatedly, counting the
number of strokes before the pump recharge the
accumulators. Machine must allow 8 strokes of the
brake pedal before the accumulator pressure
gauge needle rises again. The needle must be
always within the green zone. If it does not,
Contact your BELL EQUIPMENT Product Support
technician.
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CHAPTER 11 . FIRST 100 HOUR SERVICE CHECKS
SECTION 1. ENGINE
INTRODUCTION
The daily or 10 hourly service checks must be
performed by qualified service personnel. 1
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
Remove element (1).
Refer to Pre-service Instructions, Chapter 7. Install new element and ensure element is
properly seated.
ENGINE
Fill primary fuel fitter with clean fuel.
details not shown in this manual, Install lid and retaining screw.
refer to the Mercedes-Benz Manual
OM 906LA. Prime fuel system. (See prime fuel system in
Chapter 19).
Open the bonnet.
Start engine and let it run for 1 minute. Check for
Check the bonnet catch for damage and ensure leaks around lid. Tighten lid only enough to stop
that the bolts are secure. leaks.
Replace Primary Fuel Filter (Water Replace Final Fuel Filter

Separator) Open the bonnet.
Open the bonnet.
2
2 3
3
1
4
Clean dirt and debris from final fuel filter cap (1)
and surrounding area.
Clean dirt and debris from primary fuel filter (1)
and surrounding area. Remove the filter cap (1) and element (3). Lift
slowly to allow excess fuel to drain from element.
Remove retaining screw (2) and lid (3).
Remove element (3) and O-ring (2) from filter cap.
Discard element and O-ring.
Inspect filter cap and filter housing (4) for damage.

Replace if necessary. (Refer to BELL
EQUIPMENT Product Support).
ISSUE 0 105
Install new O-ring and element on filter cap. NOTE:When the oil is hot, the oil level must
be on the top mark (1) of the dipstick,
Apply a thin layer of fuel to O-ring. but not above it. When the oil is cold,
ensure that the level is between
Install element and filter cap. Tighten to
marks (1) and (2), but not below mark
specification.
(2).
Final filter cap tightening torque: 25Nm (18 ft.lb.).
Prime fuel system. seated and fasten the dipstick clip.
Start engine and let it run for 1 minute. Check for If necessary, replenish the engine oil.
leaks at filter cap. tighten only enough to stop
leaks. Check the Coolant Level
Check the Oil 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.
1
Remove the dipstick (1).
Wipe the dipstick clean with a lint free cloth.

seated.
The coolant must be between the maximum and
minimum marks on the tank.
2 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

1 coolant. Refer to Specifications, Chapter 1 -
Recommended Lubricants and Coolant
Additives.
Remove the dipstick and check that the oil level
reaches the upper mark (1) on the dipstick. 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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Check Air Intake System
5 4
3
2
4
6 5
4
Check air cleaner assembly for damage to pre-

cleaner (1) and air cleaner housing (2).
Check that the service indicator (3) is not showing

a red flag. If a red flag is shown, service air cleaner
and reset service indicator. (See Service Engine
Air Intake System in Chapter 11 - As Required
Service).
Check rubber elbows (4), Clamps (5) and air pipes

(6) for tightness, cracks or damage.
ISSUE 0 107
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CHANGE THE TRANSMISSION FLUID

Clean the drain plug and the sealing surface on
AND FILTERS
the housing.
Drain the Transmission Fluid
Install the drain plug with a new sealing ring.
o
normal operating temperature; 65 C to 93 C
o Tighten the drain plug to 25 to 32 Nm
o o
(116 F to 200 F ). (18 to 24 lb. ft.)
NOTE:Check the transmission fluid Inspect the drained transmission fluid for evidence
temperature on the master display of dirt, foreign matter or excessive water. (A small
unit. amount of condensation is normal during
operation). Report transmission fluid
contamination to BELL EQUIPMENT Product
Support.
1
Replenish the Transmission Fluid
Use a funnel in the dipstick tube (1) to replenish

the transmission fluid.
Place a 40 litre (10.5 USGAL) container under the Fill the transmission with the correct grade of fluid.
transmission drain plug (1). Refer to Specifications - Recommended
Lubricants and Coolant.
WARNING
Check the fluid with the dipstick at regular intervals
Be careful when draining the transmission during the filling procedure. Use the Cold Check
fluid, hot fluid can cause burns to unprotect- method initially, followed by one of the other two
ed skin. methods as detailed in Checking the
Transmission Fluid Level - Daily Checks.
Remove the drain plug with its sealing ring and Check for signs of fluid leaks at the drain plug.
allow the fluid to drain into the container.
Disconnect the pipes from the transmission fluid

cooler, allowing the cooler fluid to drain into the
container.
Reconnect the pipes to the transmission fluid

cooler.
ISSUE 0 109
Change the Transmission Fluid Filters Dipstick Check - Engine Off and
Transmission Fluid COLD (Cold Check)
Drain the transmission fluid.
CAUTION
Do not start the engine until the presence of
2 transmission fluid has been confirmed.
The Cold Check determines if the transmission

1 has sufficient fluid to be operated safely until a Hot
Check can be made.
A cold check must be performed before start-up

30C3015FM and the presence of sufficient transmission fluid
has been confirmed. The sump fluid temperature
o o o o
Unscrew and remove the filter (1) from the filter is then typically 16 C to 49 C (60 F to 120 F )
head (2).
Discard the filter do not re-use. surface and the park brake is applied.
• Ensure that the transmission is in Neutral (N).
Use a lint-free cloth to clean the filter head.
Smear a small amount of oil on the O-ring inside

the new filter. 1
Install the new filter by screwing in the filter until
contact is made with the sealing surface, then
tighten it manually a further 1/3 to 1/2 a turn.
Replenish the transmission fluid.
Check for fluid leaks at the filter covers.
Check The Transmission Fluid Level

Always check the fluid level at least twice. If the
• Unscrew and remove the dipstick (1) from the
readings are not consistent, check and clean the
tube and wipe clean.
transmission breather.
There are two methods for checking the dipstick.
transmission fluid level, they are as follows: • Insert the dipstick into the tube up to the stop
to check the fluid level.
• The dipstick check when the Engine Is Off • Repeat the check procedure to verify the
and the Transmission Fluid Is Cold. reading.
• The dipstick check when the Engine Is
Running and the Transmission Fluid Is Hot.
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2 1
• If the fluid level is on the mark (1) or above, the

transmission may be operated until the fluid is
hot enough to perform a “Hot Check”.
• If the fluid level is not on or above the mark (1)
STOP mark, add or drain transmission fluid as • Unscrew and remove the dipstick (1) from the
necessary to bring it to this mark. tube and wipe clean.
CAUTION dipstick.
1. The fluid level rises as the fluid • Insert the dipstick into the tube and remove to
temperature increases. DO NOT fill above check the fluid level.
the “Hot” mark if the transmission fluid is • Repeat the check procedure to verify the
below normal operating temperatures. reading.
o
Normal operating temperature is 80 C to
o o o o
95 C (176 F to 203 F ). The oil level at 85 C
o
(185 F ) is valid and must not be exceeded.
2. The transmission must not be operated
for extended periods until a “Hot Check”
has verified proper fluid level.
Dipstick Check - Transmission Fluid HOT 1

2
(Hot Check)
The Hot Check verifies proper fluid level. • The safe operating fluid level is between mark
(1) and mark (2).
Ensure that the transmission fluid has reached • If the fluid level is not between mark (1) and
o o
normal operating temperature; 80 C to 95 C (2), add or drain transmission fluid as
o o
(176 F to 203 F ) necessary to bring it to the mark.
NOTE:Check the transmission fluid
temperature on the Menu Display
Unit.

surface and the park brake is applied.
• Allow the engine to run at idle (600 to 700 rev/
min.) in N (Neutral).
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SECTION 3. HYDRAULICS, CAB AND ELECTRICAL
HYDRAULICS
Check all Working Lights, Reverse Buzzer and
Horn
Check the Hydraulic Fluid Level
Two people are needed to perform this check. One
Ensure that the bin is in the lowered position. person inside the cab to control the switches and
the other outside to ensure all the lights are
working. Refer to Specifications, Chapter 1 -
2 • 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
1 machine, and then reverse to ensure the
buzzer and reverse lights are working.
Check the hydraulic fluid level in the sight

glass (1).
The fluid level must be on the mark (2).
If necessary replenish the fluid in the hydraulic

tank. Refer to Specifications, Chapter 1 -
1
Cab and Electrical
Check the Operator’s Controls and
Instruments
Carry out a functional check on all controls and
instruments daily. Refer to Chapter 2 - Operator
Control and Instruments.
Ensure that the reverse buzzer (1) is securely

mounted.
ISSUE 0 113
Functionally test the horns and ensure that they

are securely mounted.
Check Brake Accumulators

Start engine and wait until main pump has fully
charged the accumulators.
Press brake pedal repeatedly to make the main

pump recharge the accumulators several times.
Stop pushing pedal while in the middle of a
recharge cycle to ensure brakes are not
consuming oil after main pump stops.
Stop engine. Turn key switch to ON position.
Wait for bulb check.
While watching the accumulator pressure gauge,

press brake pedal repeatedly, counting the
number of strokes before the pump recharge the
accumulators. Machine must allow 8 strokes of the
brake pedal before the accumulator pressure
gauge needle rises again. The needle must be
always within the green zone. If it does not,
Contact your BELL EQUIPMENT Product Support
technician.
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SECTION 4. AXLES AND FINAL DRIVES
CHANGE AXLE & FINAL DRIVE OIL Without starting the machine, remove lowest plug
AND FILTERS from final drives on both left and right hand side of
the axle and drain oil into a conrtainer.
Drain Axle And Brake Cooling Oil
Replace all drain plugs.
CAUTION Remove Pressure Filter

Do not drain oil from suction pipe between
the gear pump and suction check valve as
this will cause the cooling pump to cavitate
and fail.
NOTE:1. The brake cooling oil includes the

oil within the axle and final drive.
Cooling pumps on the engine PTO
transfer oil from the axle housing
onto the brake housing which then
fills the final drive and flows through
the brake unit and into the axle
housing via balancing hoses.
2. The front axle brake cooling circuit Remove old pressure filter (1).
operates independently to the rear
Clean sealing surface.
axle brake circuit.
3. Perform this procedure for both Fill new filter with oil.
axles.
4. Dispose of waste properly. Replace filter.
Remove Suction Filter
Clean axle housing at filter point (1) {where

balancing pipes are attached} and drain plug at
Remove old suction filter (1).
bottom of axle.
Clean sealing surface.
Remove balancing “T”-piece from axle housing.
Fill new filter with oil.
Place a container under the drain plug and remove
drain plug. Replace filter.
Drain oil into container.
ISSUE 0 115
Filling Axle And Brake Cooling Oil
Add oil through check and fill port (1). (See

Chapter 1 for recommended oils and
quantities).
Fill until oil starts to flow from port (1).
Replace balancing pipes.
CAUTION
If on start up the cooling pump begins to
cavitate or is not pumping, switch OFF
engine immediately and contact a BELL
EQUIPMENT Product Support
Representative.
Start engine and allow for ten minutes. This will

circulate oil through final drives.
Switch off engine and allow to stand for ten

minutes.
Remove balancing pipes from axle housing and

refill oil until oil begins to flow from port (1).
Start engine and release brakes.
Drive machine for twenty minutes allowing oil to

heat up and circulate properly.
Re-check oil level, filling if necessary.
NOTE:Repeat above procedure for front

axle.
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CHAPTER 12 . 500 HOURS SERVICE AND CHECKS
SECTION 1. ENGINE, AXLES AND SUSPENSION
INTRODUCTION
The 500 hours service and checks must be
SERVICE INSTRUCTIONS 1

2
Change Engine Oil And Replace Filter 3

Attach a hose to drain valve (1) with a hose clamp.
Place the end of the hose in a container.
refer to the Mercedes-Benz Manual
OM 906LA.
Loosen nut (2) and valve stem (3). Drain oil into
container.
WARNING
NOTE:Dispose of waste properly.
Be careful when draining hot engine oil. Hot
engine oil can cause burns to unprotected Tighten valve stem and nut. Remove hose clamp
skin. and hose. Wipe drain valve clean.
NOTE:The engine oil will drain easier when

the engine is warm.
1
Run engine to warm oil slightly. Stop engine.
Open the bonnet.
1 Remove engine oil filter cap (1) and element (2).
Lift slowly to allow residual oil to drain from

element.
WARNING
Do not clean inside surfaces of engine oil fil-
Remove engine oil filler cap (1). Clean and inspect ter housing.
the seal ring. Replace seal ring if necessary.
Lower belly plate. (See Chapter 7). Remove the oil filter cap from the element.
Remove the O-ring from engine oil filter cap.
Install new O-ring on oil filter cap. Install new oil

filter onto filter cap. Place filter element and cap
assembly into filter housing and tighten to
specification.
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WARNING Check Front Axle Air Bags

Do not overfill the engine with oil.
Start the machine. Allow to idle untill air pressure
reaches 8 KPa. (1.160 P.S.I.)
Add the new oil at the fill port. (See Chapter 1 for
Switch OFF the machine. Place “DO NOT
Service fill capacities).
OPERATE” tag onto the dash.
Replace engine oil filler cap.
Start engine and let it run at slow idle for 1 minute.

Stop the engine and check for leaks at filler cap
and drain valve. Tighten only enough to stop
leaks.
Check engine oil level. (See Check Engine Oil

Level in Chapter 12).
PHOTO TO FOLLOW
Raise and tighten belly plate. (See Chapter 7).
Brake Test
Test the brakes and emergency brakes operation
by following the following procedure:
Test 1
• Test on level open road with no one around or Climb under the machine and measure the height
near. between the cradle rubbers and the chassis.
• Start the machine and select forward gear.
• Release park brake and drive off. Measure height (3) from strut barrel shoulder (2) to
• Accelerate until in second gear. rubber stop (1).
• Move the gear shift level to neutral.
• Brakes must apply within 3 seconds. The height must be between: 70 - 80mm (2.756 -
• If Not: bring machine to a stand still and 3.15 in.).
contact your BELL EQUIPMENT Product
Support Representative. If height is not within specification, Refer to BELL
EQUIPMENT Product Support.
Test 2
• Test on level open road with no one around or
near.
• Start the machine and select forward gear.
• Release park brake and drive off.
• Accelerate until in second gear.
• Move the park brake level apply position.
• Brakes must apply within 3 seconds.
• If Not: bring machine to a stand still and
contact your BELL EQUIPMENT Product
Support Representative.
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SECTION 2. CLEAN, CHECK AND REPLACE BREATHERS
WARNING REAR AXLE BREATHERS

DO NOT spray steam, water or cleaning so-
lution directly at breathers. Spray could be Raise bin and install bin prop.
forced into housing.
NOTE:Breathers should be checked daily in 1

adverse conditions. The amount of
dust and dirt encountered will
determine the frequency of breather
cleaning.
Torque specification for breathers: 12 - 16 Nm

(106 - 142 lb.in.).
FRONT AXLE BREATHER (LOCATED

UNDER CAB)
Clean dirt and debris away from breather (1) and

surrounding areas.
1 Inspect breather for clogging, damage and proper
installation. If necessary, remove clogged
breathers from machine and clean with water. Dry
thoroughly before re-installing. Replace damaged
and breathers that can not be unclogged. Tighten
to specification.
Remove the cab floor plates.
Clean dirt and debris away from breather (1) and

and surrounding areas.
Inspect breather for clogging, damage and proper

installation. If necessary, remove clogged
breathers from machine and clean with water. Dry
thoroughly before re-installing. Replace damaged
and breather that can not be unclogged. Tighten to
specification.
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SECTION 3. CAB AND ELECTRICAL
CHECK BATTERIES, CLEAN AND

Check battery charge indicator (4) on each
TIGHTEN TERMINALS
battery. The colours are as follows:
• Green: - Battery is fully charged

• Black: - Battery charge is low and must be
1
charged. (See Using Battery Charger In
3
Chapter 19)
• Yellow: - Battery life has expired. Replace
3 battery. (See Replace Battery In Chapter 19).
Start engine. After bulb check, verify that battery

charge indicator on instrument panel is not lit.
Verify battery voltage on MDU. (See Chapter 8).
CHECK ELECTRICAL CONNECTORS,

2 HARNESSES AND LOOMS
Check for worn, frayed and damaged harnesses.
Open bonnet. Open side access door.
Check for loose, corroded and damaged electrical
Clean debris from battery compartment. connections.
Inspect circuit breaker box (1) for damage and

secure installation. Tighten mounting hardware if
necessary. Replace damaged components.
(Refer to BELL EQUIPMENT Product Support).
Inspect and clean terminals (3). Ensure that posts

are secure in battery housings. Ensure that cables
are securely installed on posts.
Ensure that mounting bracket assemblies (3) are

secure. Tighten nuts if necessary.
ISSUE 0 121
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SECTION 4. LUBRICATION
LUBRICATE BIN PIVOTS

ARTICULATION JOINT BOTTOM
Grease point (1) on left and right side (lower

Grease each point (1) left and right side until articulation joint) until grease escapes from joint.
grease escapes from joint.
ARTICULATION JOINT TOP
OSCILATION TUBE
PHOTO TO FOLLOW
Grease the oscilation tube through the grease

nipple located on the centre left hand side of the
oscilation tube.
Grease point (1) on left and right side (upper

articulation joint) until grease escapes from joint.
ISSUE 0 123
STEERING CYLINDERS REAR PIVOT TIP CYLINDERS TOP PIVOT POINTS

POINTS
1 1
Grease both tip cylinder top pivot points (1) until

Grease both steering cylinder rear pivot points (1) grease escapes from joint.
until grease escapes from joint.
TIP CYLINDERS BOTTOM PIVOT
STEERING CYLINDERS FRONT PIVOT POINTS
POINTS
1
1
Grease both steering cylinder front pivot points (1) Grease both tip cylinder bottom pivot points (1)
until grease escapes from joint. until grease escapes from joint.
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ISSUE
GREASE PROPSHAFTS
Grease the axle pivot point (1).
Grease the propshafts at grease nipples.
ISSUE 0 125
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CHAPTER 13 . 1 000 HOURS SERVICE AND CHECKS
SECTION 1. DRIVE TRAIN
INTRODUCTION
The 1 000 hours service and checks must be
performed by qualified service personnel. 1
Engine
Remove element (1).
refer to the Mercedes-Benz Manual Install new element and ensure element is
OM 906LA. properly seated.
Adjust Engine Valve Clearance Fill primary fuel fitter with clean fuel.
Refer to BELL EQUIPMENT Product Support for
Install lid and retaining screw.
engine valve clearance adjustment.
Prime fuel system. (See prime fuel system in
Replace Primary Fuel Filter (Water
Separator) Chapter 19).
Open the bonnet. Start engine and let it run for 1 minute. Check for
leaks around lid. Tighten lid only enough to stop
leaks.
Replace Final Fuel Filter

2 3 Open the bonnet.
1
1
Clean dirt and debris from primary fuel filter (1)

and surrounding area. 3
Remove retaining screw (2) and lid (3). 4
Clean dirt and debris from final fuel filter cap (1)
and surrounding area.
Remove the filter cap (1) and element (3). Lift

slowly to allow excess fuel to drain from element.
ISSUE 0 127
Remove element (3) and O-ring (2) from filter cap.

Discard element and O-ring.
Inspect filter cap and filter housing (4) for damage.

Replace if necessary. (Refer to BELL
EQUIPMENT Product Support).
Install new O-ring and element on filter cap.
Apply a thin layer of fuel to O-ring.
Install element and filter cap. Tighten to

specification.
Final filter cap tightening torque: 25Nm (18 ft.lb.).
Prime fuel system.
Start engine and let it run for 1 minute. Check for

leaks at filter cap. tighten only enough to stop
leaks.
128 ISSUE 0
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TRANSMISSION
WARNING
Change the Transmission Fluid and Be careful when draining the transmission
Filters fluid, hot fluid can cause burns to unprotect-
ed skin.
Drain the Transmission Fluid
o o
normal operating temperature; 65 C to 93 C Remove the drain plug with its sealing ring and
o o
(116 F to 200 F ). allow the fluid to drain into the container.
NOTE:Check the transmission fluid Disconnect the pipes from the transmission fluid
temperature on the master display cooler, allowing the cooler fluid to drain into the
unit. container.
Reconnect the pipes to the transmission fluid

cooler.
1
Clean the drain plug and the sealing surface on
the housing.
Install the drain plug with a new sealing ring.
Tighten the drain plug to 25 to 32 Nm

(18 to 24 lb. ft.)
Inspect the drained transmission fluid for evidence

of dirt, foreign matter or excessive water. (A small
amount of condensation is normal during
operation). Report transmission fluid
contamination to BELL EQUIPMENT Product
Support.
Replenish the Transmission Fluid
Place a 40 litre (10.5 USGAL) container under the

transmission drain plug (1).
1
Use a funnel in the dipstick tube (1) to replenish

the transmission fluid.
ISSUE 0 129
Fill the transmission with the correct grade of fluid.

Refer to Specifications - Recommended
Lubricants and Coolant.
Check the fluid with the dipstick at regular intervals

during the filling procedure. Use the Cold Check
method initially, followed by one of the other two
methods as detailed in Checking the
Transmission Fluid Level -Daily Checks.
Check for signs of fluid leaks at the drain plug.
Change the Transmission Fluid Filters

Drain the transmission fluid.
30C3015FM
Unscrew and remove the filter (1) from the filter

head (2).
Discard the filter do not re-use.
Use a lint-free cloth to clean the filter head.
Smear a small amount of oil on the O-ring inside

the new filter.
Install the new filter by screwing in the filter until

contact is made with the sealing surface, then
tighten it manually a further 1/3 to 1/2 a turn.
Replenish the transmission fluid.
Check for fluid leaks at the filter covers.
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SECTION 3. HYDRAULICS AND LUBRICATION
REPLACE HYDRAULIC RESERVOIR

BREATHER CHECK AXLE OIL LEVELS
NOTE:Hydraulic reservoir breather should NOTE:The procedure is the same for all
be replaced at scheduled intervals or axles.
whenever found to be damaged or
clogged.
Clean axle housing around “T”-piece(1).
Remove “T”-piece from axle housing.
Oil must be level with bottom of port.

Unscrew hydraulic reservoir breather (1) and
remove from machine. Add oil through check and fill port if necessary.
(See Change Axle Oil in Chapter 15).
Install new hydraulic reservoir breather. Hand-
tighten. Install “T”-piece.
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CHAPTER 14. 2 000 HOURS SERVICE AND CHECKS
SECTION 1. DRIVE TRAIN
INTRODUCTION
The 2 000 hours service and checks must be
1
Engine
refer to the Mercedes-Benz Manual Remove the filler cap and test the coolant in the
OM 906LA. coolant tank (1).
Check Coolant Conditioner In Radiator Use a 3-way heavy duty coolant test kit to test the
coolant. Follow the instructions on the kit.
NOTE:Check coolant every 500 hours or 6
months or when replacing 1/3 or
more of coolant. Ad coolant WARNING
conditioner as necessary. To prevent machine damage, ensure that all
coolant additives are compatible with cool-
Open the bonnet. ant that the system is currently filled with.
(See Chapter 1 for coolant specification).
WARNING
1. Explosive release of fluids from pressu- Add coolant conditioner or equivalent non-
rized cooling system can cause serious chromatic conditioner/rust inhibitor as necessary.
burns. Follow instructions on the container for amount.
2. Remove fill cap only when engine is cold
or when cool enough to touch with bare Install fill cap.
hands. Slowly loosen cap to first stop to re-
lieve pressure before removing completely.
ISSUE 0 133
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SECTION 2. HYDRAULICS AND LUBRICATION
CHANGE AXLE & FINAL DRIVE OIL

Without starting the machine, remove lowest plug
AND FILTERS
from final drives on both left and right hand side of
Drain Axle And Brake Cooling Oil the axle and drain oil into a conrtainer.
Replace all drain plugs.

CAUTION
Remove Pressure Filter
Do not drain oil from suction pipe between
the gear pump and suction check valve as
this will cause the cooling pump to cavitate
and fail.
NOTE:1. The brake cooling oil includes the

oil within the axle and final drive.
Cooling pumps on the engine PTO
transfer oil from the axle housing
onto the brake housing which then
fills the final drive and flows through
the brake unit and into the axle
housing via balancing hoses.
2. The front axle brake cooling circuit
Remove old pressure filter (1).
operates independently to the rear
axle brake circuit. Clean sealing surface.
3. Perform this procedure for both
axles. Fill new filter with oil.
4. Dispose of waste properly.
Replace filter.
Remove Suction Filter
Clean axle housing at filter point (1) {where

balancing pipes are attached} and drain plug at
bottom of axle. Remove old suction filter (1).
Remove balancing “T”-piece from axle housing. Clean sealing surface.
Place a container under the drain plug and remove Fill new filter with oil.
drain plug.
Replace filter.
Drain oil into container.
ISSUE 0 135
Filling Axle And Brake Cooling Oil REPLACE PNEUMATIC SYSTEM

DRYER FILTER
2
Add oil through check and fill port (1). (See
Chapter 1 for recommended oils and
quantities).
.Relieve pneumatic pressure.(See Relieve
Fill until oil starts to flow from port (1). pneumatic pressure in Chapter 7).
Replace balancing pipes. Remove old element (1) from head (2). Discard old
element.
CAUTION
Inspect O-ring on head for damage and wear.
If on start up the cooling pump begins to Clean or replace O-ring if necessary.
cavitate or is not pumping, switch OFF
engine immediately and contact a BELL Apply thin layer of oil to O-ring on head and O-ring
EQUIPMENT Product Support on new element.
Representative.
Install new element. Tighten until O-rings make
contact, then turn an additional 1/2 turn.
Start engine and allow for ten minutes. This will
circulate oil through final drives. Start engine and let it run. When pneumatic
system has reached operating pressure, stop the
Switch off engine and allow to stand for ten engine and check for air leaks at head and
minutes. element. Tighten element only enough to stop
leaks.
Remove balancing pipes from axle housing and
refill oil until oil begins to flow from port (1).
Start engine and release brakes.
Drive machine for twenty minutes allowing oil to

heat up and circulate properly.
Re-check oil level, filling if necessary.
NOTE:Repeat above procedure for front

axle.
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ISSUE
SECTION 1. HYDRAULICS
INTRODUCTION
Replace Hydraulic System Oil Return
The 4 000 hours service and checks must be Filter
Change Hydraulic Fluid 1 2

NOTE:The change intervals can be
extended by oil sampling.
GC4016FM Remove filter housings (1 & 2).
Clean top of tank from debris, dust and foreign

Place a 140 litre (37 USGAL) container under the
materials.
drain plug (1) on the hydraulic tank.
Remove the drain plug and allow the fluid to drain Change Hydraulic Reservoir Breather
into the container.
Remove the seal from the drain plug and discard.
Clean the drain plug and fit a new seal. 1
Install the drain plug into the hydraulic tank.
Remove hydraulic tank lid.
Replace old suction filter.
Replace lid gasket, replace lid and tighten.
Replenish the hydraulic tank with clean hydraulic

fluid. Refer to Specifications - Recommended
Lubricants and Coolant Additives. Unscrew hydraulic reservoir breather (1) and
remove from machine.
Install new hydraulic reservoir breather. Hand-

tighten.
ISSUE 0 137
NOTE:Use only recommended filters which

have the correct micron filtration
rating for the hydraulic system.
(Refer to BELL EQUIPMENT Product
Support).
NOTE:Dispose of waste properly.
138 ISSUE 0
ISSUE
CHAPTER 16. MISCELLANEOUS SERVICE AND CHECKS
SECTION 1. ENGINE
INTRODUCTION Wipe debris and moisture from sediment bowl with

a lint free cloth.
The miscellaneous service and checks must be
performed by qualified service personnel. Inspect sediment bowl for damage. Replace if
necessary.
Engine
WARNING
Do Not service control valves, cylinders,
1
pumps or motors. (Refer to BELL EQUIP- 2
MENT Product Support Teem.)
Remove fuel screen (2) and O-ring (1). Pull fuel

WARNING screen straight down.
Do Not service injection nozzles. (Refer to
Rins fuel screen and O-ring with clean diesel
BELL EQUIPMENT Product Support Teem)
fuel.Inspect fuel screen and O-ring for damage.
Replace if necessary.
Clean Fuel Screen
Install O-ring and fuel screen. Push fuel screen
NOTE:Dispose of waste properly. straight up. Ensure that O-ring and fuel screen are
properly installed.
Open the bonnet.
Install sediment bowl. Tighten until O-ring is firmly
CAUTION
compressed.
Avoid damage to components. Handle fuel Prime fuel system. (See Prime Fuel System
screen and O-ring with care. Do not twist or below).
squeeze fuel screen. Do not over-stretch or
cut O-ring. Prime Fuel System
The fuel system must be primed after performing
service procedure on the fuel system.
Even after priming, engine may start hard and run

1 rough for approximately one minute after
performing service procedure on fuel system. If
engine does not start or if engine run “rough” after
approximately one minute, stop the engine.
Correct the problem.
• Ensure that all filters and fittings are tight.

2 • Ensure that the air tank is at least 1/4 full.
Hold a container under sediment bowl (2).

Remove sediment bowl from primer (1). Empty
waste fuel into container.
ISSUE 0 139
1 Again apply force against spring tension and fit

serpentine belt.
Slowly release the ratchet to allow spring tension

to tension the serpentine belt.
Remove the ratchet and 1/2” square drive

extension.
WARNING
• Operate primer (1) using long, firm strokes Remove all loose objects from engine com-
until a significant increase in resistance is felt. partment and ensure that nothing is in the
• Check for leaks at all filters and fittings. way of the fan.
Tighten only enough to stop leaks. If leaks
cannot be stopped, Refer to BELL
EQUIPMENT Product Support. Start the engine and let it run while someone
checks the alignment of the serpentine belt.
Inspect Serpentine Belt
Stop machine.
Inspect serpentine belt for wear, fraying, splitting,
cracking, damage, dirt and debris. Replace the fan guard, bolts and washers.
Replace serpentine belt if necessary. Tighten bolts.
Replace Serpentine Belt Check clearance between fan and fan guard.
Remove the fan guard bolts and fan guard.
Check Wheels and Wheel Nuts
Fit a 1/2” square drive extension in the square of
the serpentine belt tensioner. Apply force with a WARNING
ratchet against spring torsion to slacken
Check wheels and wheel nuts daily during
serpentine belt.
walk around inspection.
Remove the serpentine belt.
Replace the serpentine belt with a new one. Ensure that wheel nuts are tight. Torque to
specification.
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SECTION 2. ELECTRICAL
USING BATTERY CHARGER
WARNING
1. Disconnect battery earth before you
charge the batteries in the machine to pre-
vent damage to the electrical components.
2. A frozen battery may explode when
charged. Warm battery to 16°C (60°F)before
charging. 5
Disconnect cables from terminals, beginning at

A battery charger may be used as a booster to the negative (-) terminal of outer battery. Move all
start the engine. cables aside.
Loosen battery clamp (5) and remove.

CAUTION
For each terminal, lift rubber terminal cover and
Do not use a battery charger as a booster if
remove the nut, washer and ring connector. Move
the battery has a 1.15 specific gravity
all cables aside.
reading or lower. Turn the charger off before
connecting or disconnecting the charger. Remove old batteries from machine.
Install new batteries.

Replace the batteries
Install all cables and tighten. Pull rubber terminal
covers over the terminals.
Turn battery disconnect switch ON.
Start engine after bulb check. Verify that battery

charge indicator on instrument panel is not lit.
Verify battery voltage on voltage gauge. (See
Chapter 8).
Replace Lights
NOTE:All lights, reverse; brake and head
lights are of the sealed beam type.
To remove a defect light;

Open bonnet. Open side access door (1).
• Disconnect dentz connector from behind light.
Clean debris from battery compartment. • Force light out of rubber casing.
• Force new light into rubber casing.
NOTE:Ensure that all cables are connected • Connect dentz connector.
properly. Note all connections while • If faulty light was a head light: re-set angle and
removing the batteries, to prevent alignment.
incorrect connections while
installing batteries.
ISSUE 0 141
142 ISSUE 0
ISSUE
SECTION 3. OPERATIONAL CHECKOUT
OPERATIONAL CHECK-OUT
A location will be required which is level and has
Use this procedure to check all systems and adequate space to complete the checks. No tools
functions on the machine. It is designed so you or equipment are needed to perform the check-
can make a quick check of machine operation out.
while performing specific checks from the
operator’s seat. Complete the necessary visual checks (oil levels,
oil condition, external leaks, loose hardware,
Should you experience a problem with the linkage, wiring, etc.) prior to doing the check-out.
machine, you will find helpful diagnostic The machine must be at operating temperature for
information in this check-out that will pinpoint the many of the checks.
cause. This information may allow you to perform
a simple adjustment which will reduce the down Start at the top of the left column and read
time of the machine. Use the table of contents to completely down column before performing check.
help find adjustment procedures. Follow this sequence from left to right. In the far
right column, if no problem is found, you will be
The information provided, after completing the instructed to go to next check. If a problem is
operational check-out, will allow you to pinpoint a indicated, you will be referred either to a section in
specific test or repair needed to restore the this manual for a specific procedure or to your
machine to design specifications. authorized dealer.
ISSUE 0 143
Checks Action Answer

Gauges and Turn battery disconnect switch ON YES: Go to next check.
Indicator Lights
Check. Turn key switch ON NO: Check circuit breakers. Reset if
tripped.
LOOK/LISTEN: Does the following
happen? IF OK: Check indicator bulbs. Replace if
necessary.
• All indicators light or flash.
• All gauges and speedometer move to IF OK: Refer to BELL EQUIPMENT
centre position. Product Support
• All segments of transmission control
LED display and mode button indicator
will light.
• Warning alarm sounds momenterily.
LOOK/LISTEN: After 3 seconds, do all

gauges, LCD and LED display return to
normal operating mode and cab warning
alarm will silence?
Do all indicators, except for emergency
steering, battery charge and park brake
indicators go out?
Air pressure indicator may also remain lit,
depending on system air pressure. Cold
start indicator may also remain lit,
depending on ambient temperature.
Key Switch Start Turn key switch to START position. YES: Go to next check.
Check

NO: Check battery disconnect switch.
WARNING
NO: Check batteries.
Do not hold switch in start position
for more than 17 seconds. If the en- NO: Refer to BELL EQUIPMENT Product
gine does not start during this peri- Support
od, turn switch to the OFF position.
Wait 2 minutes and try again.
Never turn key ON and direct OFF
and On again.
LISTEN: Starter will start the engine.
Run the engine for a few seconds, turn

the switch to OFF position.
LISTEN: Engine must stop immediately

when key switch is turned OFF.
144 ISSUE 0
ISSUE

Gauges And Start the engine. YES: Go to next check.
Indicators Check.
NOTE:Transmission temperature NO: Refer to BELL EQUIPMENT Product
gauge will not begin to Support
indicate temperature until
transmission temperature is
close to operating
temperature.
LOOK:
• Do all the indicators go out, except

park brake indicator light, after the
engine starts?
• Does engine oil pressure gauge
indicate pressure is increasing to
normal (green)?
• Does air pressure gauge indicate
pressure is increasing to normal
green)?
• Does coolant temperature gauge
indicate temperature is increasing to
normal (green)?
• Does accumulator pressure gauge rise
to 15Mpa (2175.6 P.S.I.) i.e. green
zone.
Brake Ensure brake accumulators are fully YES: Start machine and go to next check.
Accumulator charged by pressing brake pedal
Check. repeatedly to make pump recharge NO: Refer to BELL EQUIPMENT Product
accumulators several times. Support
Stop pumping during a recharge cycle to

ensure brakes are not using oil after pump
stops.
Stop engine.
Turn key switch to ON position and wait

until warning indicator goes out.
Press brake pedal repeatedly. Count the

number of applications the brake pedal is
pressed before brake pressure indicator
lights.
ISSUE 0 145

Service Brake NOTE:Perform this check in an open YES: Go to next check.
Check. area where machine can
travel at full speed. NO: Refer to BELL EQUIPMENT Product
Support
Drive machine slowly.
Push brake pedal to stop machine.
Release brake pedal.
LOOK/FEEL:
• Does brake pedal push easily without

binding?
• Does brake pedal return to the
released position so brakes are not
dragging?
• Do brakes stop machine in a
reasonable distance without pulling to
one side or making noises?
Operate machine at full speed.
Release accelerator and apply service

brakes to stop machine.
LOOK/FEEL: Do brakes stop machine in

a reasonable distance without pulling to
one side or making noises?

Park/Emergency YES: Continue with check.
brake check CAUTION
NO: Refer to BELL EQUIPMENT Product
Machine will stop abruptly during
Support
this check. Fasten seat belt. Perform
check in an open area.
Start engine.
Disengage park brake lever and move

forward.
Perform brake test (See “Brake Test” on

page 118).
Does brakes comply to specs?
YES: Go to next check.

Support.
146 ISSUE 0
ISSUE

Steering Check Move machine to an open area and park YES: Continue with check.
on a hard, level surface.
NO: If steering is jerky or steering wheel
Turn interaxle lock switch to OFF position. is hard to turn, Refer to BELL
EQUIPMENT Product Support.
Release park brake.
Release service brakes.
Run engine at slow idle.
Turn steering wheel fully left then fully

right.
FEEL: Does machine turn both directions

smoothly?
Run engine at fast idle.
Turn steering wheel fully left then fully

right.
FEEL: Does machine turn both directions

smoothly? YES: Go to next check.
NO: If steering is jerky or steering wheel

is hard to turn, Refer to BELL
EQUIPMENT Product Support
ISSUE 0 147

Dump Body YES: Continue with check.
Raise and Lower CAUTION
Checks NO: Refer to BELL EQUIPMENT Product
Ensure there is at least 7.6 m (25 ft)
Support.
clearance above machine. DO NOT
perform this check within 4 m (13.1
ft) of a high voltage power line.
Perform this check in an open area away

from other people.
Position the machine straight.
CAUTION
Clear all personnel from behind
machine. Some material may slide
out of dump body as it is raised.
WARNING
Ensure area above dump body is
clear of obstructions and power
lines. Height of raised dump body is
7226 mm (23 ft 8.5 in.).
Ensure the dump body is empty.
Operate the engine at 1500 rpm.
Pull dump body control lever rearward to

raise dump body.
When dump body is almost completely

up, reduce engine speed to slow idle.
LOOK: Does dump body raise to full

height smoothly?
Release dump body control lever.
LOOK/FEEL: Does dump body control YES: Continue with check.

lever return to neutral position? NO: Refer to BELL EQUIPMENT Product
Push dump body control lever to full Support.
forward detent dump body float position
and release lever.
LOOK/FEEL: Does control lever return to YES: Go to next check.

neutral position?
LOOK: Does dump body lower to full Support
down position smoothly?
148 ISSUE 0
ISSUE

Lights Check Push lower half of headlight switch to first YES: Continue with check.
ON position.
LOOK: Are front parking lights and tail/ Support.
brake lights ON?
Park brake ON.
Push and hold service brake.
Shift transmission into reverse.
Have a helper look at backup lights.
LOOK: Are backup lights ON? YES: Continue with check.

Support.
ISSUE 0 149
150 ISSUE 0
ISSUE
CHAPTER 17. TROUBLE SHOOTING
Introduction
It is important to properly operate and maintain the machine and its components and to immediately rectify
any faults which may occur.
Further information regarding the measures listed under “Remedy” can be obtained from the Service
Manual or your BELL EQUIPMENT Product Support Representative.
NOTE:These lists are not exhaustive. If in doubt contact your BELL EQUIPMENT Product
Support Representative.
Engine
Symptom Possible Cause Remedy
Starter pinion Battery insufficiently charged. Charge battery.
does not turn or
turns too slowly. Connecting cable to starter loose. Tighten cable at terminal; if necessary,
solder on a new terminal.
Carbon brushes shorting to earth, Clean carbon brushes with a clean cloth
jamming in guides, or poor contact. moistened in diesel (do not use emery
paper); have the brushes renewed if
necessary. Refer to BELL EQUIPMENT
Product Support.
Solenoid switch of starter faulty. Refer to BELL EQUIPMENT Product

Support.
Freewheel clutch of starter slipping. Refer to BELL EQUIPMENT Product

Support.
Engine does not Fuel tank almost or completely empty. Refuel and bleed system.
start, or stops
immediately. Fuel filter clogged. Clean filter; renew element, if necessary.
Fuel line, pre-cleaner or strainer Clean and bleed system.

clogged.
Seals bleed.
Leak in fuel system or in filter seals.
Wash off wax deposits on strainer and
Fuel with insufficient fluidity. filters, or renew filter element and use
winter-grade fuel matched to outside
temperature.
Observe measures for winter operation.

Outside temperature too low.
ISSUE 0 151
Engine
Engine runs Fuel tank almost or completely empty. Refuel and bleed system.
irregularly, cuts
out or has poor Fuel filter clogged. Clean filter; renew element, if necessary.
performance.
Fuel line, pre-cleaner or strainer Clean and bleed system.
clogged.
Seal, bleed.
Leak in fuel system or in filter seals.
Wash off wax deposits on strainer and
Fuel with insufficient fluidity. filters, or renew filter element and use
winter-grade fuel matched to outside
temperature.
Observe measures for winter operation.

Outside temperature too low.
Check, renew if necessary.
Bypass valves in fuel filter or in injection
pump do not maintain pressure.
Clean cap.
Vent in fuel tank filler cap clogged.
Check and adjust start of delivery.
Start of delivery of injection pump
incorrectly set.
Renew nozzles.
Injection nozzles jam or do not atomise.
Clean air filter.
Insufficient air at higher speeds
(because air filter fouled).
Check, set correctly if necessary.
Throttle linkage or control lever not at full
stop.
Check position of exhaust valves; clear
Exhaust valve for exhaust brake, one or jamming valves.
both cylinder banks, or valve at end of
exhaust line is closed or jammed.
Black exhaust. Injection nozzles are damaged or fouled Renew nozzles.

by carbon deposits.
Start of delivery of injection pump Set correctly.

incorrectly set.
Excessive fuel delivery. Check injection pump.
Air filter fouled. Clean.
Exhaust valve for exhaust brake, one or Check position of exhaust valves; clear
both cylinder banks, or valve at end of jamming valves.
exhaust line is closed or jammed.
152 ISSUE 0
ISSUE
Engine
Blue exhaust. Oil level in engine or in oil bath air filter Correct oil level.
too high.
Engine oil in combustion chamber Refer to BELL EQUIPMENT Product

(because piston rings jamming, cylinder Support.
liners are scored or excessive play in
valve guides, or valve stem seals
leaking).
White exhaust. Cylinder head or cylinder head gasket Measure compression pressure to
leaking, coolant in combustion chamber. determine defective cylinder and rectify
damage or refer to BELL EQUIPMENT
Product Support.
Engine pinking. Leak in nozzle holder or nozzles not Renew nozzles. Tighten nut of nozzle
properly atomising. holder.
Start of delivery of injection pump Check and adjust start of delivery.

incorrectly set.
Engine Bearing damage to crankshaft or Switch off engine immediately and refer
knocking. damage to piston. to BELL EQUIPMENT Product Support.
Coolant Insufficient coolant or cooling system not Replenish, vent.

temperature too properly vented.
high.
Belt for driving coolant pump or fan Tension or renew.
insufficiently tensioned or broken.
Radiator fouled or clogged with deposits Clean or flush out deposits.

on inside; radiator fouled on outside.
Automatic fan coupling of viscous fan Block fan temporarily and refer to BELL
faulty. EQUIPMENT Product Support.
Thermostats faulty. Renew.
Engine oil Oil level in sump too low. Replenish oil to correct level.
pressure drops.
Engine oil too thin. Refill with correct grade of oil. Refer to
CAUTION: If Chapter 1, Specifications -
pressure drops Recommended Lubricants and
rapidly, switch Coolant Additives Chart; Check for
off engine presence of water or fuel in oil.
immediately
Pressure relief valve blocked or leaking Refer to BELL EQUIPMENT Product
when open, oil pump faulty, oil pressure Support.
gauge faulty, wear causing excessive
bearing play, damage to bearings.
ISSUE 0 153
Engine
Alternator Bulb faulty or electric lead interrupted. Replace bulb or rectify interruption.
indicator
warning light
does not
illuminate when
engine is not
running.
Alternator Drive belt not tensioned correctly. Check, correct belt tension.
indicator
warning light Drive belt broken. Replace drive belt.
illuminates
when engine is Alternator, rectifier or regulator faulty. Check, renew faulty parts, refer to BELL
running. EQUIPMENT Product Support.
Transmission
Low clutch Low oil level. Refill transmission. Refer to Chapter 1,
pressure. Specifications - Recommended
Lubricants and Coolant Additives
Chart.
Low converter Low oil level. Refill transmission. Refer to Chapter 1,

charging pump Specifications - Recommended
output. Lubricants and Coolant Additives
Chart.
Suction screen blocked. Clean the suction screen.
Overheating. Low oil level. Refill transmission. Refer to Chapter 1,

Specifications - Recommended
Chart.
Axles
Final drive Loose or damaged oil plugs. Tighten or replace the oil plugs.
leaking oil.
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.
154 ISSUE 0
ISSUE
Axles
Noisy final drive. Low oil level in the final drive. Refill the final drive. Refer to Chapter 1,
Chart.
Final drive Oil level too high. Drain oil to the correct level.
overheating.
Oil level too low. Refill the final drive. Refer to Chapter 1,
Lubricants and Coolant Additives Chart.
Differential Bolts loose on main housing. Tighten bolts to the correct torque.
assembly
leaking oil.
Differential Oil level too low. Refill the differential. Refer to Chapter 1,
assembly noisy. Specifications - Recommended
Chart.
Differential Oil level too high. Drain the oil to the correct level.
assembly
overheating. Oil level too low. Refill the differential. Refer to Chapter 1,
Chart.
Axle breather blocked. Clean the axle breather.
Red oil in final SAHR brake seals have failed. Do Not Operate Machine. Contact
drives or axles BELL EQUIPMENT Product Support
Representative.
Wheels
Wheel Wheel bent or damaged. Change the wheel.
misalignment.
Wheel cracked. Impact damage. Change the wheel.
Tyres
Tyres wearing in Tyres over inflated Reduce the tyre pressure to the correct
tread centre level
ISSUE 0 155
Tyres
Tyres wearing Tyres under inflated Increase the tyre pressure to the correct
on both sides of level
the tread
Tyres loosing Tyre punctured Repair the puncture or change the tyre
pressure
Cracks, splits or Impact damage. Change the tyre.

bulges in the
tyre sidewall Defective tyre. Change the tyre.
Tyre over inflated. Change the tyre.
Tyre under inflated. Change the tyre.
Rapid tyre wear Excessive speed. Instruct the operator on proper driving.
Change the tyre.
Poor road surface conditions Recommend road surface maintenance.

Change the tyre.
Tyre component Excessive speed Instruct the operator on proper driving.

heat separation Change the tyre
Cracks in the Incorrect tyre pressure Change the tyre if separation occurs.
tyre tread
grooves
Brakes
Increased Not reading charge pressure. Check sensors and reset charge
stopping pressure.
distances.
Oil bypassing seals to axle. Check axle oil colour: If red refer to axle
faults.
Brake pressure Not reading charge pressure. Check sensors and reset charge
gauge not pressure.
reaching green
zone. Oil bypassing seals to axle. Check axle oil colour: If red refer to axle
faults.
Brakes do not Not reading charge pressure. Check sensors and reset charge
fully release. pressure.
Oil bypassing seals to axle. Check axle oil colour: If red refer to axle
faults.
156 ISSUE 0
ISSUE
Hydraulics
Pump not Hydraulic fluid in hydraulic tank is too Refill the hydraulic tank. Refer to
delivering low. Chapter 1, Specifications -
hydraulic fluid. Recommended Lubricants and
Coolant Additives Chart.
Outlet pipe from the tank to the pump is Check the suction strainer for blockages.
blocked. Clean if necessary.
Hydraulic fluid viscosity and type is Drain and refill the hydraulic system.
incorrect. Refer to Chapter 1, Specifications -
Recommended Lubricants and
Pump making Pump intake is partially blocked. Clean the hydraulic tank strainer. Check
noise. the hydraulic fluid condition, if necessary
drain and flush the system and refill.
Refer to Chapter 1, Specifications -
Recommended Lubricants and
Breather is blocked. Replace the breather filter.
Electrics
Gauge not Circuit breaker tripped. Reset circuit breaker.
working
properly. Loose or broken connections. Tighten or repair the connections.
Gauge defective. Change the gauge.
Switch not Circuit breaker tripped. Reset circuit breaker.

working
properly. Loose or broken connections Tighten or repair the connections.
Switch defective Change the switch.
Warning Warning indicator bulb defective. Change the bulb.

indicator not
working. Circuit breaker tripped Reset circuit breaker.
Loose or broken connections Tighten or repair the connections
Alternator Warning indicator bulb defective. Change the bulb.

charge warning
indicator not
illuminated
when master
switch is in the
ON position.
ISSUE 0 157
Electrics
Alternator Alternator drive belt is loose or broken. Adjust drive belt tension or fit new drive
charge warning belt.
indicator
illuminated Poor battery connections. Clean and check the battery
when engine is connections.
on.
Batteries do not Battery cells dry. Check the battery electrolyte and top up.
hold a charge.
Short running time with lights on. Remove the batteries and charge or fit
new batteries.
Starter motor Batteries are flat. Charge the batteries.

does not turn or
turns very Batteries defective or damaged. Change the batteries.
slowly.
Battery terminals loose or damaged. Tighten or clean the battery terminals.
Start button defective or damaged. Change the start button.
Starter motor Start button defective or damaged. Change the start button.
does not
disengage after
the engine has
started.
Headlights do Circuit breaker tripped. Reset circuit breaker.

not work
Headlight bulb defective. Change the bulb.
Light switch defective. Change the switch.
Loose or broken connections. Tighten or repair the connections.
One headlight Headlight bulb defective. Change the bulb.

does not come
on (high or low Loose or broken connection. Tighten or repair the connections.
beam).
Tail lights do not Tail light bulb defective. Change the bulb.
come on.
Light switch defective. Change the light switch.
Loose or broken connection. Tighten or repair the connections.
Stop lights do Stop light bulb defective. Change the bulb

not come on.
Loose or broken connection. Tighten or repair the connections.
Horn does not Circuit breaker tripped. Reset the circuit breaker.
work.
158 ISSUE 0
ISSUE
Rear Frame and Cab Trouble Shooting

Excessive cab Loose or missing mounting bolt(s) or Tighten or replace the mounting bolts
movement while rubbers. and/or rubbers.
machine is
operating.
Seat is difficult Obstruction in the seat runner. Remove the obstruction.

to adjust.
Lack of lubricant. Lubricate the seat runners.
ISSUE 0 159
160 ISSUE 0
INDEX
A
ABBREVIATION LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
B
BRAKING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
C
CHAPTER 1. SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
CHAPTER 2. OPERATOR CONTROL AND INSTRUMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
CHAPTER 3. PROCEDURES BEFORE STARTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
CHAPTER 4. OPERATING INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51
Safety Rules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51
CHAPTER 5. OPERATING TECHNIQUES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
Safety Rules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
CHAPTER 6. RECOVERY AND TRANSPORTATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71
CHAPTER 7. PRE-SERVICE INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
CHAPTER 8. MAINTENANCE SCHEDULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87
CHAPTER 9. AS REQUIRED SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
CHAPTER 10. DAILY OR 10 HOURLY SERVICE CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
CHAPTER 11. FIRST 100 HOUR SERVICE CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 105
CHAPTER 12. 500 HOURS SERVICE AND CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117
CHAPTER 13. 1 000 HOURS SERVICE AND CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 127
CHAPTER 16. MISCELLANEOUS SERVICE AND CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 139
CHAPTER 17. TROUBLE SHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 151
D
DECALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
DIESEL FUEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81
Differential Lock - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
Downhill Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
Driving - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
E
Error Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
G
Gear Hunting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
Gear Shifting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
I
Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
ISSUE 0 1
INDEX
Bin Raised - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39
Inter-axle Differential Lock - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39
Main - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
Install the Articulation Safety Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
Install the Bin Prop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
L
Lights - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
LOADING THE MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
Lowering the Bin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
Lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
M
Machine Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
Miscellaneous Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
O
Off-road Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68
OPERATING INDOORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
Overnight Parking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
R
Raising the Bin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
Retarder Switch/Pedal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
Retarders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
Rocking Out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
Rules when Servicing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81
S
SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Material Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Protective Clothing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
Serial Number Plates - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
Service Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
Service Position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
SLOWING AND STOPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
Starting the Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
STEERING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
Stuck Machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
Sulfer Content - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81
2 ISSUE 0
INDEX
T
Torque Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
Transport Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
Tyre Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
U
Unloading - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68
Uphill Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
USING BATTERY CHARGER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141
USING BOOSTER BATTERIES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55
ISSUE 0 3

OMM B25L & B30L 4X4 ADT MK II May 2003

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OMM B25L & B30L 4X4 ADT MK II May 2003

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B25L & B30L Mk II 4 X 4

ARTICULATED DUMP TRUCK

WARNING AND CAUTION SYMBOL

 CALIFORNIA PROPOSITION 65 WARNING

THIS MANUAL IS APPLICABLE TO

B25L Mk II 4X4 (411829)

Document Part Number 872120

Amendment Record Sheet

Authorisation for Page/Pages No’s. Amended Page/

LEFT BLANK INTENTIONALLY

The following address list was correct at 2 May 2001.

GROUP OPERATIONS LISTING

RICHARDS BAY (HEAD OFFICE)

SOUTHERN AFRICA REGION

RICHARDS BAY (Training Centre)

Abbreviation Meaning Abbreviation Meaning

ºC degrees Celsius m metre

ADT Articulated Dump Truck m.p.h. miles per hour

Ah ampere hours MSDS Material Safety Data Sheet

CB circuit breaker Nm Newton metre

d diagnostic psi pounds per square inch

D drive PTO Power Take-Off

DNS Do Not Shift R Reverse

ECU Electronic Control Unit rev/min. revolutions per minute

FOPS Falling Objects Protective ROPS Roll Over Protective

ft foot (feet) SMR Service Meter Reading

ft lb foot pound USGAL United States Gallon

ISO International Standards cubic yard

km/hr kilometres per hour

kPa kilo pascal

LCD Liquid Crystal Display

LED Light Emitting Diode

LEFT BLANK INTENSIONALLY

SAFETY DECALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12

CHAPTER 1. SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -19

CHAPTER 2. OPERATOR CONTROL AND INSTRUMENTS - - - - - - - - - - - - - - - - -29

SECTION 1. OPERATOR CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29

SECTION 2. INSTRUMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -33

SECTION 3. SWITCHES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -41

CHAPTER 3. PROCEDURES BEFORE STARTING - - - - - - - - - - - - - - - - - - - - - - - -47

SECTION 1. SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47

SECTION 2. BEFORE STARTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -49

CHAPTER 4. OPERATING INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51

SECTION 1. SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51

SECTION 2. STARTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -53

SECTION 3. RUNNING-IN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -57

SECTION 4. OPERATING THE MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - -63

CHAPTER 5. OPERATING TECHNIQUES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65

CHAPTER 6. RECOVERY AND TRANSPORTATION - - - - - - - - - - - - - - - - - - - - - - 71

CHAPTER 7. PRE-SERVICE INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - 77

SECTION 1. SERVICE POSITION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77

SECTION 2. RULES WHEN SERVICING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81

CHAPTER 8. MAINTENANCE SCHEDULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87

CHAPTER 9 . AS REQUIRED SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89

SECTION 2. HYDRAULICS CAB AND ELECTRICAL - - - - - - - - - - - - - - - - - - - - - 95

CHAPTER 10 . DAILY OR 10 HOURLY SERVICE CHECKS - - - - - - - - - - - - - - - - - 99

SECTION 2. TRANSMISSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101

SECTION 3. HYDRAULICS, CAB AND ELECTRICAL - - - - - - - - - - - - - - - - - - - - 103

CHAPTER 11 . FIRST 100 HOUR SERVICE CHECKS - - - - - - - - - - - - - - - - - - - - - 105

SECTION 1. ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 105

SECTION 2. TRANSMISSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 109

SECTION 3. HYDRAULICS, CAB AND ELECTRICAL - - - - - - - - - - - - - - - - - - - - 113

CALIFORNIA PROPOSITION 65 WARNING