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B50D 6 X 6 ARTICULATED DUMP TRUCK OPERATOR’S MANUAL Document Part Number 872101

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TO THE OPERATOR n

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.

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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.

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B50D 6X6 ARTICULATED DUMP TRUCK OPERATOR’S MANUAL THIS MANUAL IS APPLICABLE TO

B50D 6X6 ADT

Document Part Number 872101

Issue:0 (Revised:)

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.

Amendment Record Sheet Authorisation for Amendment

Page No’s. Replaced

Date

Page Amended/ Pages Inserted By

Referance to oil specification corrected

49

3/09/2004

J.P. Mienie

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Amendment Record Sheet

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INTRODUCTION Read this manual carefully for it has been produced to assist you in the correct operation, maintenance and care of your BELL EQUIPMENT machine. Failure to do so could result in personnel injury or equipment damage. This manual should be considered a permanent part of your machine and should remain with the machine when you sell it. Right and left hand sides are determined by facing in the direction of forward travel. Write product identification numbers (P.I.N.), Vehicle Identification Number (V.I.N.) and serial Number in Chapter 9. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the machine. Warranty is provided as part of BELL EQUIPMENT’S support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. 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

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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: [email protected]

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: [email protected]

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: [email protected] (General) Burton-on-Trent................................... e-mail: [email protected] (Sales) DE13 8EN ........................................... e-mail: [email protected] (Customer Support) UNITED KINGDOM............................. e-mail: [email protected] (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: [email protected] 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: [email protected].......................... 7475 7525

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EAST LONDON Bell Equipment Co SA (Pty.) Ltd. 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: [email protected] ........................PORT ELIZABETH EAST LONDON .................................. ..................................................................6001 5200

GEORGE Bell Equipment Co SA (Pty.) Ltd. Pioneer Road ...................................... Tel: 044 878 0930/1 ..................................P.O. Box 1697 Pacaltsdorp ......................................... Fax: 044 878 0932....................................GEORGE GEORGE ............................................ e-mail: [email protected] .........................6530 6534

PORT ELIZABETH Bell Equipment Co SA (Pty.) Ltd. 349 Kempston Road ........................... Tel: 041 451 3202 .....................................P.O. Box 3443 Korste, Port Elizabeth ......................... Fax: 041 451 3208....................................NORTH END 6056 .................................................... e-mail: [email protected]

SPRINGBOK Bell Equipment Co SA (Pty.) Ltd. Drive Inn Road .................................... Tel: 027 712 1124/30 ................................P.O. Box 618 Industrial Park ..................................... Fax: 027 718 1314....................................SPRINGBOK SPRINGBOK....................................... e-mail: [email protected] ..........8240 8240

WINDHOEK Bell Equipment Co SA (Pty.) Ltd. 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 Bell Equipment Co SA (Pty.) Ltd. 109 Fritz Stockenstrom Street ............ Tel: 051 432 7855 .....................................P.O. Box 1878 Ooseinde............................................. Fax: 051 432 3740....................................BLOEMFONTEIN BLOEMFONTEIN................................ e-mail: [email protected] .......................9300 9300

GAUTENG Bell Equipment Co SA (Pty.) Ltd. 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: [email protected] ..................1462 1459 .................................................... e-mail: [email protected]

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KIMBERLEY Bell Equipment Co SA (Pty.) Ltd. 26 South Circular ................................ Tel: 053 832 1078/9 ................................. P.O. Box 2927 KIMBERLEY........................................ Fax: 053 832 1135 ................................... KIMBERLEY 8300 .................................................... e-mail: [email protected]........................ 8300

KURUMAN Bell Equipment Co SA (Pty.) Ltd. 8 Acacia Street.................................... Tel: 053 712 0698 .................................... P.O. Box 1396 KURUMAN .......................................... Fax: 053 712 0697 ................................... KURUMAN 8460 .................................................... e-mail: [email protected] ........................ 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

MIDDELBURG Bell Equipment Co SA (Pty.) Ltd. 9 Celcius Street................................... Tel: 013 246 1169 .................................... P.O. Box 2821 Building B ............................................ Fax: 013 246 1229 ................................... MIDDELBURG Industrial Area ..................................... e-mail: [email protected] ................ 1050 MIDDELBURG 1050

NELSPRUIT Bell Equipment Co SA (Pty.) Ltd. 3 Christie Crescent.............................. Tel: 013 755 2110/6 ................................. P.O. Box 1672 Vintonia 2 ............................................ Fax: 013 755 2117 ................................... NELSPRUIT NELSPRUIT ........................................ e-mail: [email protected] ...................... 1200 1200

RUSTENBURG Bell Equipment Co SA (Pty.) Ltd. 16 Vanadium Street ............................ Tel: 014 538 1003/4 ................................. P.O. Box 3701 Border Industrial.................................. Fax: 014 538 1005 ................................... RUSTENBURG RUSTENBURG ................................... e-mail: [email protected]................ 0300 0300

TZANEEN Bell Equipment Co SA (Pty.) Ltd. 8 Impala Street.................................... Tel: 015 307 4812 .................................... P.O. Box 2102 Industrial Sites..................................... Fax: 015 307 3095 ................................... TZANEEN TZANEEN ........................................... e-mail: [email protected]........................... 0850 0850

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WOLMARANSSTAD Bell Equipment Co SA (Pty.) Ltd. 80 Kruger Street.................................. Tel: 018 596 2319 .....................................P.O. Box 587 WOLMARANSSTAD ........................... Fax: 018 596 2855....................................WOLMARANSSTAD 2630 .................................................... ..................................................................2630

COASTAL REGION EMPANGENI Bell Equipment Co SA (Pty.) Ltd. No.1 Irvine Bell Drive .......................... Tel: 035 792 6517 .....................................Private Bag X20046 Old Mill Industrial ................................ Fax: 035 792 6516....................................EMPANGENI RAIL EMPANGENI ...................................... e-mail: [email protected] ......................3910 3880

PIET RETIEF Bell Equipment Co SA (Pty.) Ltd. 14 Smith Street ................................... Tel: 01782 61523......................................c/o P.O.Box 1221 PIET RETIEF ...................................... Fax: 01782 61580 .....................................VRYHEID 2380 .................................................... ..................................................................3100

PIETERMARITZBURG Bell Equipment Co SA (Pty.) Ltd. 7 Van Eck Place.................................. Tel: 033 386 9319 .....................................P.O. Box 100436 MKONDENI......................................... Fax: 033 386 1837....................................SCOTTSVILLE 3201 .................................................... e-mail: [email protected] ..........................3209

PONGOLA Bell Equipment Co SA (Pty.) Ltd. Akasia Street....................................... Tel: 034 413 1720 .....................................P.O. Box 681 PONGOLA .......................................... Fax: 034 413 1735....................................PONGOLA 3170 .................................................... ..................................................................3170

PORT SHEPSTONE Bell Equipment Co SA (Pty.) Ltd. Shop 5 Industrial Park......................... Cnr. Main Harding and Izotsha Road.. PORT SHEPSTONE ........................... 4240

Tel: 039 685 4124 ..................................P.O. Box 560 Fax: 039 685 5155.................................PORT SHEPSTONE ...............................................................4240

RICHARDS BAY (Training Centre) Carbonate Cell .................................... Tel: (035) 907 9111 ..................................P.O. Box X20046 Alton.................................................... Fax: (035) 797 3196 .................................EMPANGENI RICHARDS BAY ................................. e-mail: [email protected] 3900

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UMHLALI Bell Equipment Co SA (Pty.) Ltd. 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 Bell Equipment Co SA (Pty.) Ltd. 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

MOZAMBIQUE Bell Equipment (Mozambique) LTD Avenida da Oau 121 ........................... Tel: +258 - 1 - 403 137/403 706 .............. Maputo ................................................ Fax: +258 - 1 - 401 949 ........................... MOZAMBIQUE.................................... e-mail: [email protected] . Contact: Eddy Fischer......................... Cel: +258-1-(0)82301894

Caixa Postal 2510 Maputo MOZAMBIQUE

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: [email protected] .......................... 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:[email protected] ........ ZIMBABWE

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DEALER Please supply your dealer details here:

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TABLE OF CONTENTS

SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Safety Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Material Safety Data Sheets (MSDS) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 Unauthorised Modifications of the Roll Over Protective Structure (ROPS) and the Falling Objects Protective Structure (FOPS) - - - - - - - - - - - - - - - - - - - - - - - - - - 26 Noise Emission Levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 General Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 SAFETY DECALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 USER’S INFORMATINON FEEDBACK FORM - - - - - - - - - - - - - - - - - - - - - - - - - - - 43 CHAPTER 1. SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45 MACHINE SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - RECOMMENDED LUBRICANTS AND COOLANT ADDITIVES - - - - - - - - - - - RECOMMENDED TORQUE SETTINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - SERIAL NUMBER PLATES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

45 49 50 52

CHAPTER 2. OPERATOR CONTROL AND INSTRUMENTS- - - - - - - - - - - - - - - - - 53 SECTION 1. OPERATOR CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ACCELERATOR AND BRAKE PEDALS- - - - - - - - - - - - - - - - - - - - - - - - - - - - STEERING WHEEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - OPERATOR’S SEAT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - TRAINER SEAT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - RIGHT HAND CONTROL PANEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 2. INSTRUMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ENGINE OIL PRESSURE GAUGE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - COOLANT TEMPERATURE GAUGE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - AIR PRESSURE GAUGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - TRANSMISSION OIL TEMP. GAUGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - FUEL GAUGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SPEEDOMETER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ALPHA NUMERICAL DISPLAY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MENU DISPLAY SCREEN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INDICATORS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 3. SWITCHES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SWITCHES LEFT HAND SIDE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IGNITION SWITCH- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BATTERY DISCONNECT SWITCH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BATTERY CIRCUIT BREAKER BOX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

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53 53 54 54 55 57 58 61 62 62 62 62 63 63 63 64 65 66 69 69 71 73 74

TABLE OF CONTENTS

STEERING COLUMN SWITCH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CLIMATE CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - AIR CONDITIONER.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LIGHTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - HATCH IN ROOF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CIRCUIT BREAKER PANEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - FUSES AND DIODES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - RELAYS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MISCELLANEOUS EQUIPMENT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - WHEEL SPANNER AND BRACE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - WINDSCREEN WASHER WATER RESERVOIR - - - - - - - - - - - - - - - - - - - - - WINDSCREEN WIPER AND WASHER NOZZLE - - - - - - - - - - - - - - - - - - - - - HORNS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - FIRE EXTINGUISHER (OPTIONAL) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - EMERGENCY EXIT HAMMER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ELECTRICAL MIRROR BRACKETS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12-VOLT ACCESSORY SOCKET - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

74 75 75 76 77 77 78 79 79 80 80 80 80 81 82 82 82

CHAPTER 3. PROCEDURES BEFORE STARTING - - - - - - - - - - - - - - - - - - - - - - - 83 SECTION 1. SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SAFETY INSTRUCTIONS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - NORMAL EXIT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - EMERGENCY EXIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 2. BEFORE STARTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SAFETY RULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

83 83 83 83 85 85

CHAPTER 4. OPERATING INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87 SECTION 1. SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SAFETY RULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 2. STARTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BEFORE STARTING THE ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SHUTTING DOWN THE ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - USING BOOSTER BATTERIES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 3. RUNNING-IN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - RUNNING-IN INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - DOWN SHIFTING OR REVERSE INHIBITOR - - - - - - - - - - - - - - - - - - - - - - - DECELARATION AND STOPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BRAKING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operating with Inter-axle Differential Lock- - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 4. OPERATING THE MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - LOADING THE MACHINE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

87 87 89 89 90 90 93 93 94 94 95 96 99 99

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TABLE OF CONTENTS

STEERING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99 OPERATING INDOORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 100 CHAPTER 5. OPERATING TECHNIQUES - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101 SAFETY RULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Gear Selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - GEAR PRE-SELECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - GEAR HOLD FUNCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - TRANSPORT OPERATION- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

101 101 102 102 103

CHAPTER 6. RECOVERY AND TRANSPORTATION - - - - - - - - - - - - - - - - - - - - - 107 SECTION 1. TOWING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SAFETY RULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 2. LIFTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MACHINE LIFTING POINTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MACHINE TIE-DOWN POINTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - TRANSPORTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

107 107 111 111 113 113

CHAPTER 7. PRE-SERVICE INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - 115 SECTION 1.SERVICE POSITION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INSTALL THE BIN PROP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INSTALL THE ARTICULATION SAFETY BAR - - - - - - - - - - - - - - - - - - - - - - LOWER AND RAISE THE BELLY PLATE- - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 2. RULES WHEN SERVICING - - - - - - - - - - - - - - - - - - - - - - - - - - - GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - DIESEL FUEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CONTAMINATED OILS AND FLUIDS - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

115 116 116 117 121 121 121 122

CHAPTER 8. MENU DISPLAY UNIT AND ALPHA NUMERICAL DISPLAY - - - - - 125 START-UP DISPLAY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 125 DEFAULT SCREEN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126 TO SELECT BETWEEN MENUS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126 CHAPTER 9. SERIAL NUMBERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131 NUMBERS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131 CRIME PREVENTION TIPS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 133 CHAPTER 10. MAINTENANCE SCHEDULES - - - - - - - - - - - - - - - - - - - - - - - - - - 137 CHAPTER 11. AS REQUIRED SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141 SECTION 1. ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SERVICE INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 2. HYDRAULICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

19

141 141 141 149

TABLE OF CONTENTS

CHECK THE BREATHER, HOSES AND CONNECTIONS - - - - - - - - - - - - - - - 149 CHAPTER 12. DAILY OR 10 HOURLY SERVICE CHECKS - - - - - - - - - - - - - - - - 151 SECTION 1. ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 2. TRANSMISSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - TRANSMISSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 3. TRANSFER CASE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHECK THE TRANSFER CASE FLUID LEVEL - - - - - - - - - - - - - - - - - - - - - SECTION 4. HYDRAULICS, CAB AND ELECTRICAL - - - - - - - - - - - - - - - - - - HYDRAULICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION 5. LUBRICATION- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - AUTO GREASING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

151 151 153 153 157 157 159 159 161 161

20

PART 1 OPERATOR’S INSTRUCTIONS AND MACHINE INFORMATION

LEFT BLANK INTENTIONALLY

B50 6X6 ADT

872101

ABBREVIATION LIST The table below lists the abbreviations used in this manual: Abbreviation

Meaning

Abbreviation

Meaning

ºC

degrees Celsius

lb

pound

ºF

degrees Fahrenheit

LCD

Liquid Crystal Display

A

ampere

LED

Light Emitting Diode

ADT

Articulated Dump Truck

m

metre

Ah

ampere hours

m3

cubic metre

CB

circuit breaker

MDV

Monitor Display Unit

CCV

Chassis Control Unit

MM

Memory Module

d

diagnostic

N

Neutral

D

drive

m.p.h.

miles per hour

DNS

Do Not Shift

MSDS

Material Safety Data Sheet

ECU

Electronic Control Unit

Nm

Newton metre

FDC

Fan Drive Controller

OBW

On Board Weighing

FOPS

Falling Objects Protective Structure

psi

pounds per square inch

ft

foot (feet)

PTO

Power Take-Off

ft lb

foot pound

R

Reverse

HP

Horsepower

r.p.m.

revolutions per minute

IDL

Interaxle Differential Lock

ROPS

Roll Over Protective Structure

ISO

International Standards Organisation

SCR

Suspension Control Unit

kg

kilogram

SMR

Service Meter Reading

km

kilometre

TCU

Transmission Control Unit

km/hr

kilometres per hour

USGAL

United States Gallon

kPa

kilo pascal

V

Volt

kW

kilowatt

yd 3

cubic yard

ISSUE 0

23

872101

Abbreviation psi

24

B50 6X6 ADT

Meaning pounds per square inch

ISSUE 0

B50D 6X6 ADT

OMM

872101

SAFETY Specification This machine complies to the CE Specification.

Safety Features 3

15

14

2

1

16

12

11

4

5 50D0004CFM

6 7

1. ROPS/FOPS Cab Protection. The Roll Over Protective Structure has been certified to meet specified test requirements according to SAE J1040 and ISO 3471. The Falling Objects Structure has been certified to meet specified test requirements according to SAE J/ISO 3449 and ISO 3449. 2. Cab with Heater/Defroster. Positive pressure ventilation system circulates both outside and inside air through filters for a clean working environment. Built in defroster vents direct air flow for effective window de-fogging/de-icing. 3.

Dump Body Service Lock.

4.

Stop/Back lights. Highly visible LED lights.

5.

Backup Alarm.

6.

Independent Parking Brake.

ISSUE 0

7.

8

9

13

10

Articulation locking Bar.

8. Secondary Steering. Ground driven, continuously in operation. Secondary steering indicator light will light when activated. 9.

Horn.

10. Halogen Lights and Turn Signals. 11. Engine Fan Guard. 12. Bypass Start Protection. 13. Exhaust Retarder.

Brake

and

Transmission

14. Safety Belt Retractors. 15. Mirrors. 16. Large Windshield Wiper With Washer.

25

872101

OMM

B50D 6X6 ADT

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.

Unauthorised Modifications of the Roll Over Protective Structure (ROPS) and the Falling Objects Protective Structure (FOPS) Do not make unauthorised modifications or alterations to the ROPS and FOPS such as: welding on extinguisher brackets, CB aerial brackets, fire suppression systems etc. Unauthorised modifications will affect the structural limits of the ROPS and FOPS and will void the certification (and increase the risk of an adverse safety incident.) The Roll Over Protective Structure has been certified to meet specified test requirements according to SAE J1040 and ISO 3471. The Falling Objects Protective Structure has been certified to meet specified test requirements according to SAE J/ISO 3449 and ISO 3449, Level II. Any planned modification or change must be reviewed in advance by the BELL EQUIPMENT Engineering Department to determine if the modification or change can be made within the limits of the certifying tests. It is important that each person in your organisation, including management, be made fully aware of these rules involving ROPS and FOPS. Whenever anyone sees unauthorised modifications or changes to a machine’s ROPS or FOPS both the customer and manufacturer must be notified in writing. The protection offered by ROPS or FOPS will be impaired if they are subjected to structural damage, is involved in an overturn incident, or is altered in any way and as such ROPS or FOPS must be replaced, not reused.

Loosening or removal of the Roll Over Protective Structure (ROPS) and the Falling Objects Protective Structure (FOPS) Make sure that all parts are installed correctly if the ROPS or FOPS is loosened or removed for any reason. Once the mounting bolt and nut assembly has been removed or loosened it must be replaced with new parts as specified in the parts manual. Tighten the mounting bolts to the correct torque specification as specified in the parts manual. Failure to comply could compromise product safety and increase the risk to safety. A damaged ROPS or FOPS must be replaced, not reused.

Noise Emission Levels The sound pressure was tested according to ISO 6394 (SAE J/ISO 6394) and the sound power was tested according to ISO 6393 (SAE J 2102).\plain \par

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.

26

ISSUE 0

B50D 6X6 ADT

OMM

Mounting and Dismounting the Machine

872101

Keep Riders Off 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.

GD0015CFM

Do not allow unauthorised personnel on the machine.

Avoid Work Site Hazards Prepare for Emergencies

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 Operate only on solid footing with strength sufficient to support machine. Be alert working near embankments, excavations and with bin raised. Avoid working on surfaces that could collapse under machine. Use caution when backing up to berms before dumping load.

GD0016CFM

Make sure all persons are clear of machine path before moving the machine. Where conditions permit, raise bin for better visibility to the rear. Use mirrors to assist in checking all round machine. Keep windows, mirrors and backup alarm clean and in good condition.

ISSUE 0

27

872101

OMM

Use a signal person when backing if view is obstructed and/or in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.

Handle Chemical Products And Flammable Fluids Safety Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous. If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS).

B50D 6X6 ADT

Do not weld or flame cut pipes or tubes that have contained flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting them. Starting fluid is highly flammable. Keep all sparks and flames away when using it. To prevent accidental discharge when storing the pressurised can, keep the cap on the can and store it in a cool protected place. Do not burn or puncture a starting fluid container.

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

Prevent Battery Explosions and Acid Burns

GD0019CFM

GD0018CFM

Handle fuel with care, as it is highly flammable. Do not smoke or go near an open flame or sparks while refuelling. Always stop the engine before refuelling the machine and fill the fuel tank outdoors. Keep all fuels and lubricants in properly marked containers and away from all unauthorised persons. Do not smoke in the storage areas. Store oily rags and other flammable material in a protective container, in a safe place.

28

The standard battery supplied with the machine is a sealed type that does not need maintenance. keep sparks and flames away from the batteries. If a non-sealed battery is subsequently installed, keep sparks and flames away from the batteries. Use a flashlight to check the battery electrolyte level. Use a voltmeter or hydrometer to check battery charge. Never place a metal object across the posts. Always remove the grounded (Negative -) battery clamp first and replace it last. Do not smoke in areas where batteries are being charged.

ISSUE 0

B50D 6X6 ADT

OMM

872101

Sulphuric acid in battery electrolyte is poisonous and is strong enough to burn skin, eat holes in clothing and cause blindness if splashed into the eyes.

Use the Seat Belt

Avoid the hazard by:

The seat belt must not be altered or modified in any way. Such changes can render the belt ineffective and unsafe.

• • • •

Filling the batteries in a well ventilated area. Wearing eye protection and rubber gloves. Avoid breathing fumes when electrolyte is added. Avoid spilling or dripping electrolyte.

If you spill acid on yourself: • • •

Flush your skin with water. Apply baking soda or lime to help neutralise the acid. Flush your eyes with water for 10 - 15 minutes and get medical attention immediately.

If acid is swallowed: • • •

Drink large amounts of water or milk. Then drink milk of magnesia, beaten eggs, or vegetable oil. Get medical attention immediately.

Wear Protective Equipment

Use a seat belt at all times to minimise the chance of injury in an accident.

The seat belt is designed and intended for the seat’s occupant to be of adult build and for one occupant of the seat only.

Avoid High Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve the pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor who is familiar with this type of injury or gangrene may result.

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.

GD0013CFM

Wear a hard hat, protective glasses and other protective equipment as required by the job conditions. Do not wear loose clothing or jewellery that can catch on controls or other parts of the machine.

Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.

Beware of Toxic Fumes

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.

GD0020CFM

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

ISSUE 0

29

872101

OMM

B50D 6X6 ADT

Operate only in well ventilated indoor areas. Avoid hazardous fumes by first removing paint on painted surfaces before welding.

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

Wear an approved respirator when sanding or grinding painted surfaces.

Lower bin during work interruptions, apply park brake and be careful not to accidentally actuate controls when co-workers are present.

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.

Dispose of Waste Properly Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly. Never pour waste onto the ground, down a drain or into any water source. Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service centre to recover and recycle used refrigerants.

Operating The Machine Avoid Tip Over Use safety belt at all times. Do not jump from machine if it tips. Use extra care when bin is raised. Machine stability is greatly reduced when bin is raised. Drive slowly, avoid sharp turns and uneven ground. Do not over load the machine. Before operating machine after it has tipped, carefully inspect all hydraulic and electrical lines.

Operating on Slopes

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 service brakes frequently when operating on slopes The maximum slope will be limited by the ground conditions.

Welding Repairs

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.

30

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.

ISSUE 0

B50D 6X6 ADT

OMM

872101

GD0021CFM

Avoid welding near fluid lines. Do not let heat go beyond work area near fluid lines. Remove paint properly. Wear eye protection and protective equipment when welding. Do not inhale dust or fumes.

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

500 m (1 640 ft)

Do not stand over the tyre, use a clip-on chuck and extension hose GC0002FM

NOTE: It is recommended that only trained personnel service and change tyres and rims.

ISSUE 0

31

872101

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B50D 6X6 ADT

Inspect and Maintain ROPS A damages roll-over protective structure (ROPS) should be replaced, not reused. If the ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.

To Maintain the ROPS: • • • •

Replace missing hardware using correct grade hardware. Check hardware torque. Check isolation mounts for damage, looseness or wear; Replace if necessary. Check ROPS 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.

32

ISSUE 0

B50D 6X6 ADT

OMM

872101

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

CAUTION BEFORE WEL DING ON THIS UNIT: To avoid control circuit damage: 1. Turn the electrical disconnect switch to “OFF”. 2. Make sure the vehicle ground straps are properly installed. 3. The welding ground clamp must have a good connection to the machine structure and close to the point of weld. 4. Attach welding ground clamp directly to structure before welding.

This instructional seat has been provided only for training operators or to diagnose machine problems. Keep all other riders off this machine. Always wear your seat belt. 207339-aFM

Located inside the cab on the rear panel

Located on the silencer heat shield

CAUTION

WARNING

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.

Torque all wheel nuts to 650 N.m [480 LB.FT.] after the first 5 hours and then again after 50 hours. Repeat this procedure if wheels are changed.

207307FM

207295FM

Located inside the cab on the roof panel

Located on the silencer heat shield

WARNING SPRING UNDER PRESSURE

Located inside the cab next to the park brake

Read the manual before carrying out maintenance in this 207350FM area

WARNING COMPRESSED AIR RESERVOIR Avoid injury, drain completely before carrying out maintenance. Typical working pressure: 800 kPa (116 PSI).

Located on the inside of the rear chassis

WARNING Ensure that the cab support is properly engaged before carrying out any maintenance in this area. 207383FM

207349-AFM

Located on the air reservoir

WARNING HIGH PRESSURE HYDRAULICS See manual for correct maintenance procedure. Typical working pressure: 8000 kPa 207329FM (1160 PSI).

WARNING

Located on the chassis underneeth the cab

AVOID INJURY Ensure propshaft guards are in place at all times 207330FM

Located inside the battery box

ISSUE 0

Located on the inside of the front chassis

GD0024CFM

33

872101

OMM

Located inside the cab on the rear pillar

WARNING Any alteration, modification, repair, structural damage or an overturn reduces this structure’s protective capabilities and invalidates this certification. Consult the manufacturer to determine this structure’s limitations.

IMPORTANT

WARNING

Avoid crushing Do not jump if machine tips

EMERGENCY EXIT Use tool to break window

B50D 6X6 ADT

DANGER Located inside Serious injury or death can result from contact with electric lines. Never move any part of unit or load closer than: 3m[10FT] plus twice the line insulator length to an electric line.

STAY CLEAR

USE SEAT BELT

ROLLOVER (ROPS) AND FALLING OBJECT (FOPS) PROTECTIVE STRUCTURE CERTIFICATION

OPERATOR MAY REVERSE MACHINE.

2071 92FM

Performance certified at date of manufacture to:

WARNING

the cab on the rear pillar

20 73 37 FM

207411FM 2 07 19 1FM

ROPS: SAE J 1040: 1994 ISO 3471: 2000

Located inside the cab on the right hand side window

FOPS: SAE J/ISO 3449: 1998 ISO 3449: 1992

Located on the rear of the machine & on the sides of the machine

PROTECTIVE STRUCTURE PART NUMBERS: 262796

DANGER

CERTIFIED PRIME MOVER MASS: 15750 Kg (34722 Lbs.)

To avoid injury or death, install bin support pole before carrying out any maintenance in this area 207351FM

CERTIFIED ARTICULATED DUMP TRUCK MODELS: B50D

BELL EQUIPMENT C0. S.A. (PTY) LTD RICHARDS BAY SOUTH AFRICA

Located on both sides of the rear chassis

208 645FM

WARNING

Located inside the cab

Crushing injury may result in hing e area if machine is turned . Make sure peo ple are clear of machine b efore starting engine or movin g steering wh eel. Attach lo cking bar before performin g service near center of mach in e or transporting o n a truck. 207336FM

Located on both sides of the articulation joint

WARNING

IMPORTANT

AVOID INJURY Keep clear of rotating fan blades 207331FM

Located in the engine compartment on the fan cowling

Located inside the cab next to the gear shift control

207385-AFM

DANGER Start only from seat in park or neutral. Starting in gear kills. 207408FM

WARNING PRESSURISED GAS Avoid injury from escaping fluid. Refer to manual for correct removal, installation and maintenance procedure. Typical working pressure: 4800 kPa (700 PSI).

IMPORTANT CAB TILT PROCEDURE

Located in the engine compartment on the cab tilt pump

Located on the starter

207340FM

Located on the suspension cylinders 207382-BFM

50D0008CFM

207321FM

Located on the left and right side on the bin top channel of the B50 6X6 TEST ADT.

34

ISSUE 0

B50D 6X6 ADT

OMM

872101

HYDRAULIC OIL LEVEL 207348FM

THIS TAG MUST ONLY BE

207348FM

REMOVED BY THE PERSON

Located on the hydraulic tank next to level sight glass.

SERVICING THE MACHINE.

. .

PART No. 870050

Located inside the PM pack wallet. 207310FM

Located at the rear lifting points.

INFORMATION 50 TON ARTICULATED DUMP TRUCK MAKE

MODEL

SIZE

FRONT MIDDLE REAR kPa PSI kPa PSI kPa PSI

GOOD YEAR

GP-4D 203B

875/65R29

300

44

400

58

400

58

MICHELIN

XAD65-1 203B

875/65R29

275

40

350

51

350

51

208643FM

Located on the left hand side of the machine on the silencer heat shield.

ISSUE 0

207290FM

Located on the front chassis front plate.

35

872101

OMM

B50D 6X6 ADT

208756FM

207409-AFM

Located on the left side of the bonnet of the B50D 6X6 ADT.

Located in the cab, at the tip lever

WARNING

.

HIGH

50 Ton ADT

This decal applies to 50 ton ADT's with a fully laden gross vehicle mass of 81553kg (179794lb), with the exhaust brake and EVB fully functional, the transmission retarder lever in maximum position, and with the transmission locked in the specified gear.

MAXIMUM SPEED

29%

1-H

7.8km/h

17%

2-H

15.7km/h

9.8Mph

13%

3-H

23.5km/h

14.7Mph

9%

4-H

35.3km/h

22.1Mph

8%

5-H

47.1km/h

29.4Mph

6-H

51.0km/h

31.9Mph

LOW

4.9Mph

MAXIMUM SPEED

40%

1-L

5.8km/h

22%

2-L

11.5km/h

3.6Mph 7.2Mph

17%

3-L

17.3km/h

10.8Mph

12%

4-L

25.9km/h

16.2Mph

10%

5-L

34.6km/h

21.6Mph

9%

6-L

37.4km/h

23.4Mph 208644B-FM

Located on the windscreen B50D 6X6 ADT.

0 12% 1 12% 2 24% 3 38% 4 55% 5 75% 6 100% 207416-AFM

Located inside the cab next to the retarder lever.

208755FM

Located on the right side of the bonnet of the B50D 6X6 ADT.

36

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872101

RAISE

LOWER 207897-AFM

Located on the cab lift pump.

218622-AFM

Located on the battery disconnect switch inside the battery box.

207304FM

Located on the front plate of the rear chassis.

P P 207412 207412-AFM

207311FM

Located inside the cab next to the park brake.

Bell Logo located on the left- and right hand side of the cab.

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B50D 6X6 ADT

IMPORTANT 20 Amp *Purging Units *Fuel Filter *Coolant Level Switch

Always engage Park Brake before leaving operator’s seat.

20 Amp *12V

60 Amp *Ignition

Spare Solenoid

207277-AFM

Located inside the cab above the park brake lever.

IMPORTANT AUTOMATIC GREASING When the pump has switched off due to Low grease in the reservoir*:

Ignition Solenoid

1. Fill pump through grease nipple / quick coupler 2. Switch ignition "On" 3. Reset pump by depressing TEST button for 2 seconds (max) *Auto greaser cab feedback unit indicates status of system. Refer to Operator's Manual. 218688FM

Located on mud guard next to the automatic greasing pump. 218649FM

Located inside the battery box.

38

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AUTOMATIC GREASER DISPLAY SIGNALS

872101

R134a Refrigerant PAG Lubricant

Low level Reservoir needs to be filled.

Error System out of operation, caused by empty reservoir or system failure. System can be reset with the testbutton on the pump, after refill or repair.

Light duty greasing mode Long interval.

Normal duty greasing mode Standard interval.

Heavy duty greasing mode Short interval.

207381FM

Located inside the evaporator compartment on the right hand side of the cab. 218873FM

Located inside the cab on the windscreen right hand bottom corner near the autogreasing control.

CIRCUIT BREAKERS

RELAYS

F6

F7

F8

F9

F10

15A

25A

25A

15A

15A 20A

SATMM

K1 CCU

F1

F2

F3

F4

F5

15A

30A

20A

30A

25A

ZFP

F1 - Park Lights. - Interior Lights. - Stop Lights. - Hazards / Indicators. - Wake-Up Module. F2 - Battery Supply to Fuses (F12, F13, F18, F19, F20, F21, F24). F3 - Ignition Supply to Fuses (F11, F14, F15, F16, F23). F4 - Reverse Lights. - Head Lights. - Work Lights. - Rotating Beacon. F5 - Aircon / Headlight Relays. (Crank Cut Relay) F6 - Bin Down Latch Solenoid. 1 - Park Brake Solenoid. - CTD Solenoid. - Automatic Greaser.

SCU

FDC

F7 - Bin Up Limit.1 - Seat Pump. - Wiper Motor. - Mirror Defrost. - Electrical Mirrors. - Washer Motor. - Horn Solenoid. - Electrical Horn. - Automatic Greaser Indicator. F8 - Cold Start. - Suspension Controller. 2 - Artic Spare Power. 1 - Relay Spare Power. F9 - Bin Float Solenoid.1 - Neutral Relay. - Start Relay. - MDU / CCU Power Relay. - CCU Ignition Status. F10 - (15A) Rear Wiper Motor. - Rear Wiper Switch. - Iqan Cut Switch. - CTD Switch. - Iqan Spare Power. - (20A) Bonnet Fans.

K2 K3

MMP

MDU

K4

MMD

K1 - Neutral. K2 - Start (KL50). K3 - Aircon / Lights Cut Out. K4 - Reverse.

Supers cript K ey 1

Not use d on 42 06D

2

Us ed on B5 0D only

3

Not use d on Small Truc ks

FUSES F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22

10A 10A

DIODES / RESISTORS RELAYS / VOLTAGE REGULATOR V1 SPARE

3A 3A

10A 10A

V3 V4 V5 V6 V7

10A 5A 10A

F25 F24 F23

10A 10A

R2 R1

10k

5A 5A 10A

10A 15A

3A

K5

K9

K13

K17 K23

K6

K10

K14

K18 K22

K7

K11 K15

K19 K21

K8

K12

N1

3A 3A 3A 3A

10A

K16

K20

820

F11 - Transmission. (KL15) V1 - Gear Hold Control. - Engine brake request. V3 - Alternator D+ F12 - Transmission. (KL30) V4 - CCU Control - Voltage Regulator. Intermittent Wiper. F13 - MDU / CCU. (KL15) V5 - Washer Control - Hazard input to CCU. Intermittent. F14 - Alternator D+ V6 - Hazard Control F15 - CCU Program. (KL15) MDU / CCU ignition. - MDU Program. (KL15) V7 - Ignition Control - Diagnostic. (KL15) MDU / CCU Ignition. F16 - Engine. (KL15) F17 - Reverse Camera. (12V) R2 - External pull up - FM Radio. (12V) Fuel Throttle. F18 - Engine. (KL30) R1 - External pull up F19 - MDU. (KL30) Air pressure sender. F20 - Diagnostic. (KL30) F21 - Battery Balancer. (KL30) - Accessory. F22 - 2 Way Radio. (12V) F23 - Onboard Weighing. (KL15) 1 - Fan Drive Controller. (KL15) 1 3 - Memory Module. (KL15) - Satellite Communication. (KL15) F24 - Memory Module (KL30), MT2000. (KL30) F25 - Iqan System.

K5 - Stop Light. K6 - 0% Throttle. K7 - Park Brake. K8 - Bin Up Limit/Gear Hold. K9 - Left Indicator. K10 - Right Indicator.

K11 - Dip. K12 - Bright. K13 - Bin Float/Worklights. K14 - Intermittent. K15 - 12V Supply. K16 - ADM / MR Ignition Supply. K17 - MDU / CCU Ignition Supply. K18 - Control Traction Diff. K19 - Laden / Unladen. N1 - Voltage Regulator. K20 - Retarder Enable. K21 - High Range. K22 - Auto Neutral. K23 - Fan Control.

218756-1-FM

Located inside the cab inside the cab roof panel.

207312FM

Located on the front of the bonnet.

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B50D 6X6 ADT

WARNING Torque all wheel nuts to 650 N.m [480 LB.FT.] after the first 5 hours and then again after 50 hours. Repeat this procedure if wheels are changed.

CAUTION BEFORE WELDING ON THIS UNIT: To avoid control circuit damage: 1. Turn the electrical disconnect switch to “OFF”. 2. Make sure the vehicle ground straps are properly installed. 3. The welding ground clamp must have a good connection to the machine structure and close to the point of weld. 4. Attach welding ground clamp directly to structure before welding.

B50D PERIODIC MAINTENANCE

RE F ER TO T HE S E RV I CE MANUAL FO R DETAI L E D I NF ORMAT I ON I N TE RV AL I TE M ITE M H OU R S NO 3 4 4 AS R E Q U IR E D

10 H OU R S OR D A I LY

500 H OU R S

8 10 11 36 37

APPRO VED M AT E R I A L

2 C H E C K A N D CL E A N B OW LS B ELL F ILTER S 1 R EPL A C E A S R EQ ’D A C C OR D IN G T O IN D I C A T O R - M I N IM U M : O N C E A Y E A R A I R C L E A N E R S E C O N D A RY FI LT E R 1 R E P L A C E E V E RY TH I R D P R I M A RY B ELL F ILTER S F IL T E R C H A N G E - M I N I M U M : O N C E A Y E A R P R I M A R Y F U E L F I LT E R / W A T E R S E P E R A T O R 2 C H E C K C O L D . D R A I N W A T E R B E F O R E S T A R T I N G C H A R G E A IR C O O L E R 1 C H E C K , C L E A N A S R E Q U IR E D T R AN S M I S S I ON C O OL E R 1 C H E C K , C L E A N A S R E Q U IR E D R A D IA T O R , G R I L L , A I R C O N C O N D E N S E R C H E C K , C L E A N A S R E Q U IR E D T IR E S 6 C H E C K CO L D T I R E P R E S S U R E H IN GES G RE A S E SEE L UB R IC AN TS

1 4 5 12 15 17 17 27 27 28 29 30 31 32 33 34 35 43

R A D IA T O R C O O L A N T L E V E L 1 A I R C L E A N E R P R I M A R Y F IL T E R 1 E N G IN E O I L L E V E L 1 1 T R A N S M IS S I O N O I L L E V E L T R A N S F E R C A S E O IL L E V E L 1 H YD R A U LIC OIL L EVE L 1 B R A K E A C C U M U LAT OR S 1 O P E R ATO R CO N TR O LS A N D I N S T R U M E N T S W A R NI N G L I G H T S , WA R N I N G B U Z Z E R EXT ER N A L L IGH T S, R E VER SE B U Z ZER A U TO G R EA SIN G SY ST EM GR EA S E LEV EL S T E E R I N G C Y L I N DE R S 4 O S C IL L A T I O N J O I N T 1 A R T I C U L A T I O N J O IN T S 2 4 B OD Y L I FT CY LI N D E R S D U MP B OD Y PIVO T PIN S 2 O S C IL L A T I O N T H R U D R I V E B E A R I N G S 2 E N G IN E F A N B E L T S 2

6 13 22 23

E N G IN E O I L A N D O I L F I LT E R T R A N S M IS S I O N O I L L E V E L PA R K B R A K E SU SP EN SION ST R U TS

C H E C K CO L D C H E C K IN D I C A T O R CHECK C H E C K CO L D O R W A R M W H I L E E N GI N E I D LE S C H E C K T H E O IL L E V E L C H E C K CO L D T E S T T H E B R A K E A C C U M U LAT OR F UN C T I ON CHECK C H E C K E V E R Y S TAR T- U P CHECK CHECK C H E C K FO R F R E S H G RE A S E AT S E A L C H E C K FO R F R E S H G RE A S E AT S E A L C H E C K FO R F R E S H G RE A S E AT S E A L C H E C K FO R F R E S H G RE A S E AT S E A L C H E C K FO R F R E S H G RE A S E AT S E A L C H E C K FO R F R E S H G RE A S E AT S E A L C H E C K CO N D I TI ON

42 43 7 8 9 13 14

16 E N G IN E V A LV E C L E A R A N C E P R I M A R Y F U E L F I LT E R / W A T E R S E P E R A T O R 2 2 S E C O N D A R Y F U E L F IL T E R S 1 T R A N S M I S S I O N O IL 2 T R A N S M I S S I O N F IL T E R S

18 21

H Y D R A U LI C TAN K B R E AT H E R FI LTE R A X L E A N D F I N A L D R I V E O IL

41

F U E L TA N K B R E AT H E R

24 26 29 38 39

ADJUST R EPL A C E FILT ER E LE M EN T REPLACE C H A N GE T H E OIL R E P L A C E E V E RY 1 0 0 0 H R S O R W I TH A B N OR MA L O IL SA MPL E 1 REPLACE 9 R E P L A C E O R E X T E N D T O 2 0 0 0H R S S UB J E CT TO OIL SA M P LIN G 1 REPLACE

R A D IA T O R E X T E N D E D L IF E C O O L A N T T R A N S F E R C A S E O IL T R A N S F E R C A S E O IL F I L T E R A XL E A N D FIN A L D R IVE OIL

2000 H OU R S

P N E U M AT I C S Y S T E M AI R D RY E R F I LTE R

1 C H E C K CO OL A N T C O N DI T I ON E R 1 D R A IN A N D R E F I L L ( A ) ( B ) 1 REPLACE 9 D R A IN A N D R E F I L L ( A S P E R 1 0 0 0 H R S O I L SA M P LIN G) 1 REPLACE

26

5

6

9

10

36

43

7

4

39

6

2

3

8 25

42

SEE SEE SEE SEE SEE SEE

L UB R IC AN TS L UB R IC AN TS L UB R IC AN TS L UB R IC AN TS L UB R IC AN TS L UB R IC AN TS

20

41

19

14

17

27

1 12

13

40

24

39

29

23 30

B ELL F ILTER S

39

32

15

11

16

35 31

B ELL F ILTER S B ELL F ILTER S SEE L UB R IC AN TS B ELL F ILTER S

33 22 39

B ELL F ILTER S SEE L UB R IC AN TS SEE L UB R IC AN TS

37

21

4000 H OU R S

19 20

H YD R A U LIC SYST EM R ET U R N F ILTER H Y D R A U L I C TA N K

1 REPLACE 1 D R A IN A N D R E F I L L ( A )

B ELL F ILTER S SEE L UB R IC AN TS

8000 H OU R S

2

R A D IA T O R E X T E N D E D L IF E C O O L A N T

1

SEE F LU ID S

C H A N GE T H E CO O LA N T - M I N I M U M : E V E RY 4 Y E A R S

ALL S YSTEM CHECKS ARE TO BE MADE WITH: - MA C HINE ON LEVEL SU RFAC E - BOD Y L OW ER ED - TR AN SM ISSION IN N EU TR AL W IT H PA RK B RA K E EN GA GED - REM OVE KEY FRO M IGNITION SW ITC H A ND ATTAC H “D O N OT OPER ATE” WA R NING SIGN TO STEER IN G W HEEL - TU RN B ATTERY DISCO NN ECT SW ITC H TO “OFF ” POSITION - IN STA LL A RT IC U LATIO N LOC K B AR

18

2 1 1 2

D R A IN W A R M A N D R E P L A C E CHECK C H E C K BR A K E P AD W E A R C H E C K CO M M O N R I D E H E I GH T, B O D Y R O LL C ON T R OL , L E A K S , H OS E S , A C C U M U LAT OR S , VA L V E M A N I F O L D , E L E C T R IC A L H A R N E S S 1 C H E C K A N D CL E A N OR R E P L A C E (C ) A I R CO N A I R FI LTE R 2/4 C LE A N A N D T IGH T EN TER M IN A L S B AT TE R I E S 1 REPLACE A U TO -G R E A S I N G FI L LE R F I LTE R C H E C K CO N D I TI ON O F H A R N E S S E S , L OO M S E L E C T RI C A L C O NN E CT I ON S , H A R N E S S E S 5 C H E C K A N D CL E A N A XL E, TR A N SM ISSIO N A N D T R A N SF ER C A S E B R E AT H E R 1 G RE A S E FR O N T U -J O I N T AN D I N S P E C T P T O P R O P S H A FT FR O N T U -J O I N T C O N D I T IO N 1 R EPL A C E FILT ER E LE M EN TS F UE L D E P T H FI LTE R 2 R E P L A C E B O T H B E LT S E N G IN E F A N B E L T S

40

1000 H OU R S

M A I N TE NA N C E D ESC R IPT ION P O I NT S

A I R C L E A N E R P R E - C LE AN E RS A I R C L E A N E R P R I M A R Y F I LT E R

28

33 34

I M P O R TA N T N O T E S : - R E F E R T O O P E R A T O R S M A N U A L F O R C O R R E C T M A IN T E N A N C E P R O C E D U R E S - F O R B R E A K IN O R R E B U I L D , S E E O P E R A T O R S M A N U A L - F O R S E V E R E W O R K IN G C O N D I T I O N S , R E D U C E S E R V I C E I N T E R V A L S A. B. C.

C H AN G E I N TE R V AL S M AY B E E X T E N D E D B Y O I L S A M P LI N G D E P E N D A N T O N S I TE A P P L I CAT I ON I N S E V E R E A P P L I C A T I O N S C H E C K W E E K LY O R D A I LY

LUBRICANTS AND FLUIDS RECOMMENDED LUBRICANTS AND FLUIDS

F C

- 40

- 22

-4

- 40

- 30

-20

A M B I E N T T E M P E R ATU R E R A N GE D U R I N G FI L L P E R I O D 14 32 50 68 -10

0

10

20

86

10 4

12 2

30

40

50

ENGINE OIL - M-BENZ

- OILS TO MEET M -BEN Z 2 2 8.5 SPEC IF IC ATIO N

S AE 1 5W- 4 0 SAE 10 W-4 0

PR EFER RED : - C A STRO L D YN A M AX 1 0 W -40 - CA LT EX XLD 10 W -4 0

ENGINE COOLANT - M-BENZ

CA LTEX EXTEN DED LIFE COOLANT PRE-M IX 50 /50

- EXTEN DED LIFE C OOL AN T TO M EET M -B EN Z 3 2 5 .3 - PR EFERR ED : CA LT EX EXTEN DED LIFE C OOL AN T PR E-M IX 50 /5 0

TRANSMISSION OIL - ALLISON HD4560R AND TRANSFER CASE

CA STR OL TRAN SYND (ATF)

- U SE ONLY CA STR OL TR A NSYN D

HYDRAULIC OIL - OILS TO MEET ATF C OM PLYING W IT H VICK ER S M -29 5 0- S SPEC IF IC ATIO N

ATF SAE 10 W SAE 30

PR EFER RED : - C A LTEX T EXAM ATIC T YPE-G

DRIVE AXLES - BELL - OILS TO MEET A PI G L-5 , M IL-L -21 0 5 D SPEC IFIC ATION PR EFF ERED : - C ALTEX G EAR OIL ZF ( 80 W 9 0 )

GREASE - PR EFERR ED : - C ALTEX M ULTIFAK EP NGL I N 0 . 2 (TH R OU GH D R IVE B EAR IN GS, PTO PROPSH A FT) - C A LTEX U LTRA DU TY GR EA SE NGL I N 0.2 (H IN GES, O SCILLATION , AR TICU LATION , C YLIND ERS)

208646-DFM

Located on the silencer heat shield.

40

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BULLETINS Record the relevant information from the Technical Documentation Bulletins, Service Bulletins and Parts Bulletins into this manual as follows: • Ensure the manual number (87--------) reflected in the bulletin is the same as the 87------ number at the top of the main content pages. • Carry out the instructions as detailed in the bulletin. • Record the required information below. • File the bulletins in numerical order in a suitable 3 or 4 ring binder.

TECHNICAL DOCUMENTATION BULLETIN RECORD BULLETIN NO.

ISSUE 0

SUBJECT

INSERTED BY NAME

SIGNATURE

DATE

41

872101

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B50D 6X6 ADT

TECHNICAL DOCUMENTATION BULLETIN RECORD BULLETIN NO.

42

SUBJECT

INSERTED BY NAME

SIGNATURE

DATE

ISSUE 0

B50D 6X6 ADT

872101

USER’S INFORMATINON FEEDBACK FORM Should you, as user of this manual, have any suggestion for improving the manual, or you find any errors or omissions, then we would like to know. Please complete a facsimile of this form and hand it in to your nearest BELL EQUIPMENT Product Support Representative or post it directly to your nearest BELL EQUIPMENT Branch. Addresses are given at the beginning of this manual. Ideas, Comments (Please State Page Number): _____________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ Machine Model: ______________________________________________________________________ Serial Number: _______________________________________________________________________ VIN: _______________________________________________________________________________ Page Number: _______________________________________________________________________ OVERALL, how would you rate the quality of this publication? (Check one) Poor 1

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Company Name: _____________________________________________________________________ Technician Name: ____________________________________________________________________ Address:____________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ Phone Number: ______________________________________________________________________ Fax Number: ________________________________________________________________________ Thank you for your co-operation.

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LEFT BLANK INTENTIONALLY

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CHAPTER 1

872101

CHAPTER 1. SPECIFICATIONS MACHINE SPECIFICATIONS The specifications for the B50 6X6 ADT are as follows:

Engine Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - DC OM502LA Tier II Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90×V8 Aspiration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Turbo Charged Injection type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Direct Gross power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 380 kW (510 HP) @1 800r.p.m. Gross Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 200 Nm (1622 lbf) @ 1 080r.p.m. Idle speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 600 ± 20 r.p.m. Oil Pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0,5 Bar @ Idle Oil Pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2.5 Bar @ High Idle

Transmission Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -T/Mission, HD4560R.

Transfer Case (Drop Box) Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -VGR 17100

Axles Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BELL 25T

Brakes Service Brakes Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Dual Circuit, oil immersed multi disc brakes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - on all axles. Hydraulic actuated.

Park Brake Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -DXP-195 Type - - -Spring applied, air released, self-adjusting, mechanical calliper on drive-line mounted dry disc

Wheels Tyre size B50 TEST ADT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29.5 R 25 Wheel nut torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -650 Nm (480 ft lb.)

Suspension System Front Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Semi- independent axle movement, leading A-frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -supported on oil/nitrogen suspension struts with - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - adaptive level control by electronic SCU.

Rear Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - Pivoting walking beams with laminated suspension blocks

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CHAPTER 1

B50D 6X6 ADT

Hydraulic System Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Load sensing

Pump Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -P3-145

Pump Emergency Steering System Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A10 VO 28

Steering System Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Articulated with two double -acting, hydraulic cylinders Number of turns to lock - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4.2

Pneumatic System Reservoir capacity - - - - - - - - - - - - - - - - - - - - - - - - 40 litres (10.567 USGAL) @ 7.5 bar (108.778 psi)

Electrical System Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 V Battery Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 X 12 V, maintenance-free Battery capacity - - - - - - - - - - - - - -Cold Crank Amps (-18°C (0.4°F): BCI 625 Amps each 2 X 102 Ah Starter motor capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6.2 kW Alternator voltage rating- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28 V Alternator amperage rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -100 A

Power Ratings (bulbs) Headlight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H4 Halogen - 24 V 75/70 W Front park light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 V 1.8 W Front indicator light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 V 21 W Stop/tail light- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 V Diode Light Unit Rear indicator light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 V Diode Light Unit Reverse light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H3 Halogen - 24 V 70 W Interior light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 V 10 W

Frame and Body Cab Type - - - - - - - - - - - - - - - - - - - - - - - - - -FOPS (SAE J231/ISO 3449)/ROPS (SAE J1040/ISO 3471/1)

Bin Type - - - - - - - - - - - - - - - - - - - - Manufactured from high tensile wear and impact resistant alloy steels Rated payload - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45 400 kg (50 sh tn) Capacity Struck- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21.4 m³ (27.99 yd.³) Capacity Heaped (SAE 2:1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28.2 m³ (36.88 yd.³) Tip cylinders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 X Single stage, double acting Tipping angle max (Can be limited to any lower angle, programable on MDU) - - - - - - - - - - - - - - - 70° Bin raise time - - - - - - - - - - - - - - - - - - - - - - - - - 13.5 (70° tip angle) and 11.25 (60° tip angle) seconds Bin lower time - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9.5 (70° tip angle) and 7.9 (60° tip angle) seconds

Mass Total mass, empty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -36 153 kg (79 703.63 lb.) Total mass, fully laden - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -81 553 kg (179 793.4 lb.)

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Service Capacities Fuel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 640 litres (169.0 USGAL) Engine oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -30 litres (7.9 USGAL) Engine oil (initial fill) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38 litres (10.0 USGAL) Engine coolant (initial and service fills) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33.6 litres (8.9 USGAL) Transmission fluid (initial fill) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40 litres (10.6 USGAL) Transmission fluid (refill) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -34 litres (9.0 USGAL) Transfer Case (initial and service fills) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.5 litres (1.2 USGAL) Hydraulic system (initial fill) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 268.5 litres (70.9 USGAL) Hydraulic reservoir (service fill) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 256 litres (67.63 USGAL) Axle oil (initial fill) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50 litres (13.2 USGAL) Axle oil (service fill)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48 litres (12.7 USGAL) Final drive oil (per final drive initial and service fills) - - - - - - - - - - - - - - - - - - - - - 6.3 litres (1.7 USGAL) Cab Tilt System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1.85 litres (0.5 USGAL) Windscreen Washer Bottle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 litres (1.6 USGAL)

Travel Speeds B50D TEST ADT - LOW RANGE 1st Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5.5 km/h (3.4 m.p.h.) 2nd Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11.7 km/h (7.3 m.p.h.) 3rd Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16.9 km/h (10.5 m.p.h.) 4th Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25.8 km/h (16.0 m.p.h.) 5th Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -33.8 km/h (21 m.p.h.) 6th Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38.4 km/h (23.9 m.p.h.) 1st Reverse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4.7 km/h (2.9 m.p.h.)

B50D TEST ADT - HIGH RANGE 1st Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7.5 km/h (4.7 m.p.h.) 2nd Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15.9 km/h (9.9 m.p.h.) 3rd Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23.0 km/h (14.3 m.p.h.) 4th Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35.2 km/h (21.9 m.p.h.) 5th Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46.0 km/h (28.6 m.p.h.) 6th Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52.3 km/h (32.5 m.p.h.)

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Machine Dimensions The following figure details the dimensions of the B50D 6X6 ADT 6373

4089

3861

3895

3391

27° 632

800

1445

2398

3978 (WITH ROCK GUARD DOWN)

7356 AT 70° TIP

4290 (WITH ROCK GUARD IN POSITION)

70°

1560

4471

1950

2768

10749 OVERALL LENGTH

531

3811 BIN WIDTH

2120 3010 TREAD WIDTH 3900 WHEEL WIDTH

42°

IN S

T IDE

R IN G U RN 1 2 R 47

A DIU

S S ID E OUT

S 1 R 47 2 G R AD IU N IN TU R

500002CFM

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RECOMMENDED LUBRICANTS AND COOLANT ADDITIVES The following chart details the recommended lubricants and coolant additives:

BELL EQUIPMENT RECOMMENDED LUBRICANT AND FLUIDS CHART B50D ARTICULATED DUMP TRUCK

Recommended Lubricant Viscosities and Fluids suitable for use at Ambient Temperatures from -10O C (14O F) to 50 O C (122O F) Ambient Temperature

O O

F -40 C -40

-22 -30

-4 -20

14 -10

32 0

50 10

68 20

86 30

104 40

122 50

ENGINE - M-BENZ OILS TO MEET M-BENZ 228.5 SPECIFICATIONS PREFERRED: - CALTEX DELO XLD SAE 10W-40

SAE 15W - 40 SAE 10W - 40

COOLANT - M-BENZ EXTENDED LIFE COOLANT TO MEET M-BENZ 325.3

CALTEX EXTENDED LIFE COOLANT PRE-MIX 50/50

PREFERRED: - CALTEX EXTENDED LIFE COOLANT PRE-MIX 50/50

TRANSMISSION - HD 4560R AND TRANSFER CASE (DROP BOX) USE ONLY CASTROL TRANSMAX Z or TRANSYND

CASTROL TRANSMAX Z or S (SAE 70W-80W)

DRIVE AXLES - BELL

SAE 80W - 90

OILS TO MEET API GL-5, MT - 1, MIL-L-2105-D SPECIFICATIONS PREFERRED: - CALTEX GEAR OIL ZF SAE 80W-90

SAE 85W - 90 SAE 85W - 140 ATF SAE 10W SAE 30

PREFERRED: - CALTEX TEXAMATIC TYPE - G

RECOMMENDED SERVICE FILLS COMPONENT ENGINE

TRANSMISSION TRANSFER CASE

OIL DESCRIPTION

BELL EQUIPMENT PART No.

CALTEX DELO XLD (SAE 10W - 40) EXTENDED LIFE PRE-MIX 50/50

910276 910245

CASTROL TRANSYND

910302

CASTROL TRANSMAX Z

910208

DRIVE AXLES

CALTEX GEAR OIL ZF (80W-90)

910284

HYDRAULICS

ATF : CALTEX TEXAMATIC TYPE-G

910083 910336

GREASE

GENERAL (PINS, BUSHES, ETC) : CALTEX ULTRA DUTY GREASE 2 DRIVE TRAIN (BEARINGS, ETC) CALTEX MULTIFAK EP NGLI number 2

910026

50D0001CFM

n

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-Z or Transynd in the transmission may render warranty claims invalid.

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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

8.8

8x100=800 Mpa (Ultimate Tensile Stress)

10.9

8x8x10=640 Mpa (Yield Stress or Stress at 0.2% permanent set)

10x100=1000 Mpa (Ultimate Tensile Stress)

METRIC NUT GRADE INTERPRETATION CURRENT STANDARD : Nuts which are 0.8xD high.

|8|

8x100=800 Mpa Proof Stress

8

8x100=800 Mpa Proof Stress

(Subject to international agreement)

ISO Grade 4.6 400 MPa (25.90 tsi)

4.6

ISO Grade 6.9 600 MPa (38.85 tsi)

6.9

12x9x10=1080 Mpa (Yield Stress or Stress at 0.2% permanent set)

1 lb ft = 1.35582 Nm 1 lb in = 0.112985 Nm

FUTURE STANDARD : Nuts which are 1.0xD high.

12.9

10x9x10=900 Mpa (Yield Stress or Stress at 0.2% permanent set)

12x100=1200 Mpa (Ultimate Tensile Stress)

1 Nm = 0.737561lb ft 1 Nm = 8.85073 lb in

ISO Grade 8.8 800 MPa (51.80 tsi)

8.8

Manufacturer's Mark Grade

Manufacturer's Mark Grade (Optional)

ISO Grade 10.9 1000 MPa (64.75 tsi)

10.9

Manufacturer's Mark Grade

Manufacturer's Mark Grade (Optional)

ISO Grade 12.9 1200 MPa (77.70 tsi)

12.9

Manufacturer's Mark Grade

ISO Metric Coarse -Torques [Nm] Size

M5

M6

M8

M10

M12

M14

M16

M18

M20

M22

M24

Pitch (mm)

0.8

1

1.25

1.5

1.75

2

2

2.5

2.5

2.5

3

3

20.1

36.6

58

84.3

115

157

193

245

303

353

459

561

817

10

19

34

58

85

115

165

220

285

420

560

980

2

T/Stress area (mm ) 14.2

ISO Gr. 4.6

M27 M30 M36 3.5

4

2

4

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

120

190

295

400

580

780

1000 1500 2000 3430

10

17

35 41

69

ISO Gr. 12.9

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

1

1.25

1.25

1.5

1.5

1.5

1.5

1.5

1.5

2

2

2

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

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

Pitch (mm) 2

T/Stress area (mm )

RESEARCH AND DEVELOPMENT

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1150 1600

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Imperial Sizes - BS Grades IMPERIAL SIZES - BS GRADES BS Grade A 28 tsi (432 Mpa)

Coarse or Fine

CA

Manufacturer's Mark Grade

BS Grade T 55 tsi (849 Mpa)

Coarse or Fine

CT

Manufacturer's Mark Grade

BS Grade S 50 tsi (772 Mpa)

Coarse or Fine

FA

Manufacturer's Mark Grade

BS Grade V 65 tsi (1004 Mpa)

Coarse or Fine

FV

Manufacturer's Mark Grade

Unified Coarse (UNC) - Torques in Nm. Size Threads/inch

1/4" 20

T/Stress area (mm2)

20.5 33.8

5/16" 18

3/8" 16

7/16" 14

1/2" 13

50

68.6 91.5

9/16" 5/8" 12 11 117.4 146

3/4" 10

7/8" 9

1" 8

215

298

391

1 1/8" 1 1/4" 1 3/8" 1 1/2" 7 7 6 6 492

625

745

906

467

670

861 1148

BS Grade A

4

9

16

25

38

56

78

138

221

335

BS Grade S BS Grade T

12

24

43

66

108

150

209

371

586

885

1256 1735 2333 3051

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"

Threads/inch

28

5/16" 24

T/Stress area (mm2) 23.5

37.4

3/8" 7/16" 24

20

56.6 76.6

1/2"

9/16"

5/8"

3/4"

7/8"

1"

1 1/8" 1 1/4" 1 3/8" 1 1/2"

20

18

18

16

14

12

8

8

8

8

103

131

165

241

328

428

510

645

795

963

670

933 1196

BS Grade A

5

10

18

29

43

60

90

150

239

359

490

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 Mark

SAE Grade 1 26.8 tsi (414 Mpa)

SAE Grade 5 (1 1/8" - 1 1/2") Manufacturer's 46.9 tsi (724 Mpa) Mark

SAE Grade 5 (1/4" - 1") 53.6 tsi (828 Mpa)

Manufacturer's Mark

SAE Grade 8 67 tsi (1035 Mpa)

Manufacturer's Mark

Unified Coarse (UNC) - Torques in Nm. Size Threads/inch 2

T/Stress area (mm )

1/4"

5/16"

3/8"

7/16"

1/2"

9/16"

5/8"

3/4"

7/8"

1"

20

18

16

14

13

12

11

10

9

8

50

68.6 91.5

4

9

16

25

SAE Grade 5

11

22

40

SAE Grade 8

16

32

57

SAE Grade 1

20.5 33.8

117.4 146

1 1/8" 1 1/4" 1 3/8" 1 1/2" 7

7

6

6 906

215

298

391

492

625

745

38

56

78

138

221

335

467

670

861 1148

62

101

140

196

348

550

830

1347

1860 2501 3270

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"

Threads/inch

28 2

5/16" 3/8" 24

24

7/16"

1/2"

9/16"

5/8"

3/4"

7/8"

1"

20

20

18

18

16

14

12

1 1/8" 1 1/4" 1 3/8" 1 1/2" 8

8

8

8 963

T/Stress area (mm ) 23.5

37.4

56.6 76.6

103

131

165

241

328

428

510

645

795

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

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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 B50D 6X6 ADT.

MANUFACTUREDBY: BELL EQUIPMENT CO.SA. (PTY) LTD. RICHARDS BAY, SOUTHAFRICA

MACHINE

CAB ENGINE

TRANSMISSION TRANSFER CASE FRONT DIFFERENT IAL MID DIFF ERENTIAL REAR DIF FERENT IAL

LADEN

AXLE: EMPTY

kg

FRONT MIDDLE

kg kg

REAR TOTAL

kg PAYLOAD 176 114F M

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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 B50D 6X6 ADT cab:

3

10

8

9

13

15

12

4 2

5 5

4 11

7 1. 2. 3. 4. 5. 6. 7. 8.

14

Accelerator Pedal. Right hand control panel. Steering Wheel. Lighter/12V Accessories Socket. Ashtray. Operator’s Seat. Trainer Seat. Centre Panel (instruments).

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6 9. 10. 11. 12. 13. 14. 15.

Ignition Switch. Left hand switch Panel. Footrest. Stalk switch Right hand switch panel. Brake Pedal. Auto Greasing Display.

53

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B50D 6X6 ADT

The steering wheel can be adjusted to ensure maximum operator comfort.

Adjust the Steering Wheel NOTE:Levers (1) and (2) can be orientated by pulling the lever outwards and rotating it to the desired position and then pushing it back in.

1

2

1

The accelerator pedal (1) and the brake pedal (2) are located on the cab floor.

2

Both pedals are progressive and spring loaded to an up, neutral position.

STEERING WHEEL NOTE:There is no self-centring action on the steering. The machine must be returned to the straight ahead position by turning the steering wheel.

n

CAUTION

If there is an engine or main pump failure, the ground driven emergency steering system will enable the operator to steer the machine to a safe stop. In this event the machine must be stopped as quickly as possible.

54

Telescopic Adjustment • • •

Unlock the steering wheel by pulling the lever (1) counter clockwise. Adjust the steering wheel in/out for operator comfort. Lock the steering wheel into place by rotating the lever clockwise until it is secure.

Tilting Adjustment • • •

Unlock the steering wheel by moving the lever (2) counter clockwise. Adjust the steering wheel forwards/backwards for operator comfort. Lock the steering wheel into place by rotating the lever clockwise until it is secure.

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OPERATOR’S SEAT

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Armrest (3) The armrests can be tilted up if required and the height individually adjusted.

1

3

3

The angular position of the armrests can be adjusted by turning the adjusting knob (7). The armrests can also be tilted vertically to allow easier access to the seat.

7

4

1 5

8 10

2

11

12 9 6 The operator’s seat is fully adjustable to suit the operator. The main components of the operator’s seat are as follows:

Automatic Positioning Lever (6)

Back rest (1)

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CAUTION

Take care with the backrest frame - it may jerk forward and cause injury!

To adjust for the required angle pull the lever (4) up while adjusting the back rest to the required angle.

Seat squab (2) To adjust the seat squab depth for varied thigh support, use the depth adjustment lever (5) to lengthen or shorten the seat squab. To adjust the seat squab angle, use the lever (10). The angle is adjustable in four steps, 3° - 11°.

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To adjust the armrests height, separate the round cap (1) from the cover, loosen the hexagon nut (size 13mm), adjust the armrest to the desired position and tighten the nut again. Press the previously separated cap cover back onto the nut.

The automatic positioning lever is used to adjust the ride height of the seat. While sitting in the seat, ensure that the vertical damper switch is in the rear position (soft). Press lever (6) down until most of the air is released from the seat. Briefly pull the lever (6) upwards. The seat will automatically come to rest in the lowest allowable setting. The height can further be adjusted another 80mm from this position by pulling and holding the automatic positioning lever (6) until the required height is reached. If elevated above the maximum height, the seat will automatically correct itself to this maximum position. Press lever (6) down to lower the seat.

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Fore/Aft adjustment lever (9)

Maintenance

To adjust the seat forward or backwards, pull the lever up and hold. Move the seat forward or backwards to obtain the desired position. Release the lever.

Dirt can impair the function of the seat, so make sure you keep your seat clean! During cleaning the upholstery should not be soaked through.

Fore/Aft Isolator Lever (11) The fore/aft isolator enables the seat to absorb shock loads in the fore/aft direction.

Use a standard commercially available upholstery cleaning agent. Test first for compatibility on a small, concealed area.

Position 1 (To Front) = On.

Seat Belt

Position 2 (To Back) = Off.

A self-adjustable lap seat belt is an integral part of the seat.

Vertical Damper Adjustment Lever (12) The required level of vertical dampening can be reached by turning the vertical damper adjustment lever to the desired position (Positions 1 to 5). Forward position = maximum dampening and rearward position = minimum dampening.

Lumbar Support

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 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

1

Two lumbar support areas are controlled by the adjustment knob (1) at the back of the backrest. Rotate the knob until sufficient support is obtained. 1

2

•

56

Pull the seat belt out and push the buckle (1) into the fixed clasp (2) until it clicks into position.

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• •

CHAPTER 2

Ensure that the connection is secure and that the belt fits tightly across the pelvis. Ensure that the strap of the belt is not twisted.

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TRAINER SEAT

Releasing Press down the red push button on the fixed clasp. The seat belt is spring-loaded to return to its stowage position.

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WARNING

1. Always wear a seat belt when operating the machine. In an accident it may save your life. 2. Always wear a seat belt when travelling as a trainer or trainee in the machine. 3. 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 trainer seat is located on the left side of the operator’s seat. The seat is spring loaded and folds up automatically when it is not in use. The seat is not adjustable and is equipped with a seat belt. The seat belt for the trainer is fastened, released and adjusted in the same way as the operator’s seat belt.

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B50D 6X6 ADT

RIGHT HAND CONTROL PANEL

1

4

3 2

1.) 2.)

Retarder Switch/Lever. Park Brake Control Lever.

3.) 4.)

Retarder Switch/Lever

Bin Tip Lever. Gear Shift Control.

When the lever is operated the retarder light on the instrument panel will illuminate. 1

The retarder is applied automatically when the lever is operated but will only be applied when the accelerator is fully released. NOTE:1. The retarder can only function when the exhaust brake is functioning. 2. Position “0” and position “1” induce the same percentage of retardation.

The retarder lever (1) is located on the right hand control panel and has six available positions. Each position increases the degree of retardation to a maximum of six.

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Park Brake Control Lever

•

• • 1

•

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When neutral is selected and the service brake is not pressed, the park brake will automatically be applied after 4 seconds. When the truck is started the park brake will automatically be applied. When the ignition is turned off the park brake will automatically be applied. When the truck is moving at less than 1Km/h and the engine r.p.m. is less than 50, the park brake will automatically be applied.

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WARNING

When the park brake is “ON” (Light Illuminated) and the transmission is in gear, the engine torque is reduced to prevent driving through the park brake and thus causing damage. Pull the park brake lever (1) upwards to unlock and then pull the lever towards the operator to apply park brake and push forward (away from operator) to release park brake mechanically.

Tip Control Lever

NOTE:The park brake lever is locked in position and to move it from engage to dis-engage or vice versa, pull the lever knob upwards to enable the lever to be moved.

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WARNING

Under normal circumstances the operator must not leave the machine unattended with the engine running. If the circumstances are such that the operator must leave the engine running, the operator must not leave the machine 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.

NOTE:When the park brake valve lever is UP (applied), the park brake warning indicator on the instrument panel illuminates. The force on the valve lever is removed when air supply pressure is below 4.1 bar (410 kPa or 60 psi) or when supply pressure drops below 4.1 bar (410 kPa or 60 psi).

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1

The tip control lever (1) is located on right side of the cab and is used to raise and lower the bin. • •

To tip the bin: pull the control lever towards the operator. To lower the bin: push the tip control lever away from the operator to detent to power the bin down. as soon as the bin is approximately 5% from full down, the lever will be electronically kicked out of detent and return to the central position. the bin will be now in float position.

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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Gear Shift Control

B50D 6X6 ADT

The gear shift control (1) comprises of a digital display screen (2) and selector buttons marked as follow: 1

2

• • • • •

D (Drive), to select a forward gear range. N (Neutral), to select neutral gear. R (Reverse), to select reverse gear. Mode, used in diagnoses code reading. The “UP” and “DOWN” arrows are used to select a specific range of gears in drive.

The machine is equipped with an automatic gearbox with the push button selector located on the right hand side panel on the dash board.

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CHAPTER 2. OPERATOR CONTROL AND INSTRUMENTS SECTION 2. INSTRUMENTS The following figure details the “MDU” Monitor Display Unit on the centre panel on the dashboard: 2

1

COLD START

BATTERY CH ARGE

ENGINE OIL PRESSURE

COOLAN T LEVEL

RETAR DER

3

7

EMERGENCY STEERIN G

ENGINE FA ULT

PARK BR AKE

BR AKE PRESSUR E

BIN UP

TRA NSMISSION FA ULT

40

30

COOLANT TEMP

20

50

km/h 20

60

30 mph

10

40

70

10 0 AIR PRESSURE

8

TRANS OIL TEMP

BR AKE TEMP

INTER-A XLE DIF F LOCK

0

80 FUEL

DIFF LOCK / HIGH RAN GE

MENU

RPM

BACK

50

0

HYDR AULIC TEMP / LEVEL

NEXT

HOURS VOLTS

SELECT volts

50D1001CFM

4

5

6

1.

1. 2. 3. 4.

Engine Oil Pressure Gauge. Coolant Temperature Gauge. Speedometer. (Indicating speed in Km/h and m.p.h.) Air Pressure Gauge.

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5. 6. 7. 8.

Transmission Oil Temperature Gauge. Fuel Gauge. Alpha numerical display screen. Menu Display Screen.

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ENGINE OIL PRESSURE GAUGE 1. When the needle is in the red on the following gauges, the buzzer will sound and the main warning light will come on, flashing and a message will appear on the alpha numerical display. 2. For the air pressure, while in the red zone, the buzzer will sound, but no warning light. A message will be displayed on the alpha numerical display.

B50D 6X6 ADT

If the needle is on the green bar, the temperature is acceptable. If the needle is on the red bar, the temperature is out of limits and machine must be stopped and the fault rectified.

AIR PRESSURE GAUGE

AIR PRESSURE ENGINE OIL PRESSURE

GD1017CFM

GD1015CFM

This gauge is located on the centre instrument panel. This gauge indicates if the air pressure is in the specified range.

This gauge is located on the centre instrument panel. This gauge indicates if the engine oil pressure is in the specified range.

If the needle is on the green bar, the pressure is acceptable.

If the needle is on the green bar, the pressure is acceptable.

If the needle is on the red bar, the pressure is out of limits and machine must be stopped and the fault rectified.

If the needle is on the red bar, the pressure is out of limits and machine must be stopped and the fault rectified.

TRANSMISSION OIL TEMP. GAUGE

COOLANT TEMPERATURE GAUGE

TRANS OIL TEMP COOLANT TEMP

GD1018CFM

GD1016CFM

This gauge is located on the centre instrument panel. This gauge indicates if the engine coolant temperature is in the specified range.

62

This gauge is located on the centre instrument panel. This gauge indicates if the transmission oil temperature is in the specified range. If the needle is on the green bar, the temperature is acceptable.

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If the needle is on the red bar, the temperature is out of limits and machine must be stopped and the fault rectified.

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ALPHA NUMERICAL DISPLAY

FUEL GAUGE

The alpha numerical display screen is located on the centre control panel above the speedometer.

FUEL

Alphabetical messages and numerical codes are displayed on this screen.

Immobilizer / Driver ID GD1019CFM

The fuel gauge is located on the centre control panel at the bottom of the speedometer. NOTE:There is no warning light or buzzer for “Low Fuel”, just a message in the alpha numerical display screen.

5

SPEEDOMETER

30 20

40 km/h

50 60

20 30 mph 10

The driver ID key can be used by the customer as an immobilizer. The setup of the driver key is programable by the customer. If set to be an immobilizer, the driver key (green) must be inserted to be able tot start the machine.

40

70

10 0

50

80

0 FUEL

GD1020CFM

The speedometer is located on the centre instrument panel and indicates the travelling speed in Km.p.h. as well as m.p.h.

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MENU DISPLAY SCREEN

B50D 6X6 ADT

Default Display. NOTE:To be able to scroll through the menu, push and hold the “NEXT” button for 3 seconds.

bell b50d 1

7 2 3

0N

4

7 1 2

5 6

2 31 4

2 7 . 7

n/min

volts

50D1002CFM

1

2

3

4

5

The menu display screen (1) is located on the right hand side of the centre control panel. The screen has four display lines. A “Menu” push button (2) to select between menus, a “Back” push button (3) to select “Go Back” to previous setting, a “Next” push button (4) to select the “Next” option and “Select” push button (5) to select the option to be executed. Every option is displayed on the alpha numerical display screen.

1). 2). 3). 4). 5). 7).

Alpha numerical display screen. Gear selection display line. Tachometer display line in r.p.m. Hour meter display line. System voltage F/N/R display.

The default menu is always accessed when the ignition is turned “ON”. The writing on the alpha numerical display will change in accordance with the value displayed on the bottom row when a different function is selected to be displayed as default in this line. The operator can change the bottom default display information to his preference. NOTE:The default screen displays the last values after the machine was switched off. The Display Unit’s selection options and changing of display modes is described in Chapter 8.

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INDICATORS 1

3

2

COLD START

BATTERY CH ARGE

4

COOLAN T LEVEL

RETAR DER

5

ENGINE FA ULT

EMERGENCY STEERIN G

TRAN SM ISSION FA ULT

6

7

8

9

10

PARK BR AKE

BR AKE PRESSURE

BIN UP

12

11

BR AKE TEMP

INTER-AXLE DIFF LOC K

13

HYDRA ULIC TEMP / LEVEL

DIFF LOC K / HIGH RAN GE

19 50D1003CFM

14

1.) 2.) 3.) 4.) 5.) 6.) 7.) 8.) 9.) 10.)

15

16

Cold Start Warning Light. Coolant Level Warning Light. Engine Fault Warning Light. Emergency Steering Warning Light. Left Turn Indicator Light. Main Warning Light. High Beam Indicator Light. Engine Over Speed Warning Light. Right Turn Indicator Light. Park Brake Warning Light.

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17

18

11.) Brake System Pressure Warning Light. 12.) Wet Disc Brake Coolant Temperature Warning Light. 13.) High Hydraulic Fluid Temperature Warning Light. 14.) Battery Charge Warning Light. 15.) Retarder Light. 16.) Transmission Fault Warning Light. 17.) Bin Raised Warning Light. 18.) Inter Axle Differential Lock Light. 19.) High Range Attained Light.

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GENERAL All warning lights are illuminated for about 2 seconds when the ignition is switched on. This is done as a bulb check procedure and the operator should ensure that all lights are illuminated.

Cold Start Warning Light (1)

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B50D 6X6 ADT

Emergency Steering Warning Light (4).

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CAUTION

If the emergency steering warning light flashes, the machine must be steered to safety as soon as possible and then stopped.

WARNING

Do not start the engine until the cold start warning light (1) extinguishes. Damage to the engine could occur if this caution is ignored.

The cold start function is automatic. When the ignition is switched on and the engine o o coolant temperature is below 15 C (59 F ), the warning light illuminates.

The emergency steering warning light flashes if there is an engine or main hydraulic pump failure and the emergency steering is activated. NOTE:The main warning light and the warning buzzer are also activated with the emergency steering warning light.

Left Turn Indicator Light (5).

When it is safe to start the engine, the cold start warning light extinguishes.

The left turn indicator light will flash when the steering column switch is moved to indicate a left turn.

Low Engine Coolant Level Warning Light (2)

If the hazard switch is ON, both direction indicators flash.

n

Main Warning Light (6). CAUTION

If the low engine coolant level warning light flashes, the machine must be stopped and the engine shut down immediately. Engine damage may result if this caution is ignored.

The warning light flashes when the engine coolant requires replenishing immediately. NOTE:The main warning light and the warning buzzer are also activated with the low engine coolant level warning light.

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CAUTION

Continued operation of the machine with the main warning light illuminated will cause serious damage to the engine or transmission.

NOTE:The machine must be stopped as soon as it is safe to do, when this light is on. A warning buzzer also sounds when the main warning light flashes if the engine is running.

Engine Fault Warning Light (3) If a fault on the engine occur the warning light will be illuminated. Stop the machine as soon as it is safe. Check the fault codes and required action to rectify the fault.

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High Beam Indicator Light (7). The indicator illuminates when the high beam mode on the headlights is selected on the steering column switch.

Engine Over Speed Warning light (8).

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CAUTION

If the engine overspeed warning light illuminates, the engine speed must be reduced immediately, using the service brake.

The engine overspeed warning light illuminates and a warning buzzer sounds when the engine speed exceeds 2 500 r.p.m. As soon as the engine speed exceeds 2 500 r.p.m. the following occurs: • •

The engine overspeed warning light illuminates. The exhaust brake is automatically applied.

Right Turn Indicator Light (9). The right turn indicator light will flash when the steering column switch is moved to indicate a right turn.

If the hazard switch is ON, both direction indicators flash.

Park Brake Warning Light (10). The park brake warning light illuminates when the park brake is applied and extinguishes when it is released.

Brake System Pressure Warning Light (11)

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WARNING

If the brake system low pressure warning light flashes, the machine must be stopped immediately. Machine damage and/or personal injury, perhaps fatal, may result if this warning is ignored.

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The light flashes if the brake systems hydraulic pressure drops below 123 bar (1 784 psi). NOTE:The main warning light and the warning buzzer are also activated with the brake system low pressure warning light.

Wet Disc Brake Coolant Temperature Warning Light (12) (Not Used) High Hydraulic Fluid Temperature Warning Light (13)

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CAUTION

If the high hydraulic fluid temperature warning light flashes, the machine must be stopped immediately.

The high hydraulic fluid temperature warning light flashes when the hydraulic fluid temperature o o o o exceeds 90 C /95 C (194 F /203 F ). If overheating occurs stop the machine, engage neutral and allow the engine to run at 1500 r.p.m. until the hydraulic temperature returns to normal temperature and the warning light extinguishes. Check the fluid levels. NOTE:The main warning light and the warning buzzer are also activated with the high hydraulic fluid temperature warning light.

Battery (Charge) Warning Light (14)

n

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. The normal operating voltage is between 25.5V and 29.5V while the engine is running. The balance between the two batteries are also monitored and if a difference of greater than 1.2V occurs, the battery light is illuminated.

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CHAPTER 2

NOTE:This must be rectified immediately, or damage to both batteries will occur.

Retarder Light (15). This light is activated when either the transmission retarder or engine retarder (Exhaust brake and/or Exhaust valve brake (EVB)) is activated.

Transmission Fault Warning Light (16).

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CAUTION

If the transmission fault warning light illuminates, the machine must be stopped immediately using only the service brake and NOT the gear shift control.

The electronic control system is programmed to inform the operator of a problem with the transmission system and automatically take action to protect the operator, machine and transmission. When the Transmission Control Unit (TCU) detects a “Do Not Shift” (DNS) condition, the ECU restricts shifting, turns on the DNS warning light and registers a diagnostic code.

n

CAUTION

For some problems, diagnostic codes may be registered without the ECU activating the DNS warning light. Whenever there is a transmission related concern, consult BELL EQUIPMENT Product Support

B50D 6X6 ADT

Bin Raised Warning Light (17)

n

WARNING

As a safety precaution it is recommended that the operator should not drive the machine when the bin up light is illuminated as this may cause serious damage to the machine and/or injury to personnel. Refer to Tip Control Lever in this Chapter for special instructions regarding driving the machine while the bin is raised.The bin raised warning light will illuminate when the bin is raised.

NOTE:Gear restriction will occur while the bin is up.

Inter-axle Differential Lock Light (18)

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CAUTION

Do not operate the machine on hard surfaces with the inter-axle differential lock engaged. Damage to the drive train may result if this caution is not observed.

The inter-axle differential lock light illuminates when the longitudinal differential lock is engaged. To engage inter-axle differential lock, the dash switch must be activated and the accelerator must be released briefly. The machine can be moving at any speed.

High Range Attained Light (19). This light will illuminate when the high range gear has been successfully selected in the differentials. It is an indication that air is physically been applied to the 2-speed differential actuators.

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CHAPTER 2. OPERATOR CONTROL AND INSTRUMENTS SECTION 3. SWITCHES SWITCHES LEFT HAND SIDE

1

3

2

4

6

5

9

7

8

There are nine positions for switches on the panel. Each switch is manually operated to select a required function. Position 1;2 and 3 are standard. Position 4 - Work lights; Standard. Position 5 - Flashing beacon; Standard. Position 6 - Mirror defrost; Std.

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Position 7 - Not Used. Position 8 - Not Used. Position 9 - Not Used.

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The switches and their functions are as follows:

Switches On Middle Row

Switches On Top Row

NOTE:All optional features not chosen will be covered by a blank piece.

3

1

1

2

3

2

The interior light switch (1). The interior light switch is used to switch the interior light on or off.

The working light switch (1).

The switch has two positions:

The working light switch is used to operate the working lights on the cab roof shining to the front of the truck.

• •

The lights switch has two positions:

OFF: Normal position light off. ON: Interior light on.

The light switch (2). The light switch is used to switch the head lights, rear lights and the dash lights on or off. NOTE:The park and tail will illuminate when the lights switch is in the central position, even if the ignition switch is OFF. However the ignition switch must be ON for the headlights to operate from the ignition switch in the down position. The switch has three positions: • • •

OFF; switch in the normal position. ON Central Position; Park and tail lights ON. ON Third Position: Headlights and Park Lights ON.

The hazard light switch (3). The hazard light switch to switch the hazard lights on or off.

• •

OFF; Normal position light off. ON; Work lights on.

The rotating beacon light switch (2). The rotating beacon light switch is used to switch the flashing beacon on or off. The switch has two positions: • •

OFF; Normal position. ON; Flashing beacon light switched on.

The defrost switch for electric mirrors (3). The defrost switch for electric mirrors is used to defrost the electric mirrors in cold and frosty environments. The switch has two positions: • •

OFF; Normal position. ON; Mirror defrost switched on.

The switch has two positions: • •

70

OFF: Normal position lights off. ON: Hazards on.

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CHAPTER 2

Switches On Bottom Row (Blank)

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When low grease level light (6) illuminates, the reservoir must be refilled or the system will shut down. When warning light (5) is on, the system has shut down due to an empty reservoir or there is an error in the system.

IGNITION SWITCH

Automatic Greasing System

1

6 5 4 The ignition switch (1) is located on the right hand side on the dashboard.

3 2

The ignition switch is key operated and has four positions, OFF, ACCESSORY, ON and IGNITION.

n

1

1. 2. 3. 4. 5. 6.

Switch Selecting Greasing Cycle. Light, Heavy Duty Cycle. Light, Normal Duty Cycle. Light, Low Duty Cycle. Warning Light, System “SHUT DOWN” Light, Low Grease Level In Reservoir.

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 allows for proper lubrication and for all temperatures to stabilise.

NOTE:The ignition switch will only operate if the battery disconnect switch is ON.

The switch (1) is used to select between low, normal and heavy duty cycles on the auto greasing system. To select another cycle, just press and release the switch until the light next to the required cycle illuminates. When the ignition key is turned to the “ON” position the light next to the selected duty cycle will elluminates.

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Switches right hand side.

B50D 6X6 ADT

The inter-axle differential lock is not available when the vehicle is in HIGH range. When the interaxle differential lock has been activated, the vehicle will not be allowed to change to HIGH range. 5

High/Low Range Switch (2). The switch has two positions: • •

1

6

2 3

4

NOTE:When the Inter Axle Lock Switch has been de-activated, selection of high range will not be allowed for a period of 30 seconds after de-activation to ensure that the IDL has properly disengaged before upshift to a higher range will be allowed.

Inter Axle Differential Lock (IDL) Switch (1). This switch is used to activate the inter-axle differential lock. When switched “ON” the interaxle differential lock light will also be illuminated on the dash board. Release the accelerator briefly after this switch has been activated. To ensure IDL is activated, check IDL light “ON” on monitor display unit.

OFF; LOW range hold activated (only LOW range allowed). ON; LOW and HIGH range allowed.

When the switch is “OFF”, the vehicle will not be allowed to change to HIGH range. This is provided to give the operator control over allowing the vehicle to go into HIGH range. In certain applications the operator may want to restrict the vehicle to LOW range only - keep this switch in the “OFF” position to achieve this. When the switch is “ON”, the vehicle will be allowed to change to HIGH range. HIGH range is only achieved if the transmission is in 6th gear, the machine travels faster than 34 km/h (21.1 mph), the engine torque >40%, the accelerator pushed down >95% and the inter-axle differential lock switch has been OFF for 30 seconds. Once these requirements are met, the vehicle will automatically shift the 2-speed differentials into HIGH range - no intervention or precautions are necessary from the operator. The HIGH Range Attained light on the MDU will be illuminated if the shift has occurred successfully. Once the vehicle is in HIGH range, it will only shift back into LOW range if the transmission is in 1st gear, the vehicle travels less than 2 km/h (1.2 mph) and the operator’s foot is completely off the accelerator. If all these requirements are met, the vehicle will automatically shift the 2-speed differentials into LOW range - no intervention or precautions are necessary from the operator. The HIGH Range Attained light on the MDU will be extinguished once the shift to LOW range is completed.

Mirror Adjustment Switches (3) and (4). Use the mirror selector switch (3) to select the mirror you would like to adjust (either left or right). Use the directional switch (4) to adjust the selected mirror in the direction desired.

The switch has two positions: • •

72

OFF; Normal position. ON; Inter-axle differential lock switched on, if conditions are met.

Move the mirror selector switch (3) to the centre position when done to prevent accidental mirror movement if switch (4) is bumped.

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Gear Hold Switch (5). The switch has two positions: • •

OFF; Normal position. ON; Gear hold switched on.

When the switch is “OFF”, the transmission is in the normal automatic operating mode. When the switch is “ON”, the transmission will hold the gear that it is in at the time of the switch being activated. Normal down shifting will occur, but the transmission will not upshifts to a higher gear until the switch is switched “OFF” (except in overspeed conditions).

1

When the switch is activated, the gear shift display screen on the gear shift control will display the gear number that the transmission will be ‘held’ in.

Blank (6).

BATTERY DISCONNECT SWITCH

n

CAUTION

1. Always switch OFF the battery disconnect switch when the engine is shut down and the machine is left unattended. If the switch is left ON for long periods while the engine is shut down, the batteries may become discharged. 2. Always switch OFF the battery disconnect switch before any maintenance or repair is performed on the machine’s electrical system or any welding work is performed. 3. Only in an emergency use the battery disconnect switch to switch off the machine.

ISSUE 0

The battery disconnect switch (1) is located inside the battery box. The battery disconnect switch is used to isolate the electrical power from the batteries to the machine. The battery disconnect switch has two positions, “OFF” and “ON”, the switch position is clearly marked on the switch’s face plate.

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CHAPTER 2

BATTERY CIRCUIT BREAKER BOX

B50D 6X6 ADT

STEERING COLUMN SWITCH

The battery circuit breaker box is located inside the battery box.

3 2 1

1 The steering column switch is a stalk switch (1) located on the steering column. The operation of the switch is as follows:

There are three circuit breakers located in the battery box. One circuit breaker rated 60A and two rated 20A. 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. (Battery Balancer Marked 12V). The 20A circuit breaker (3) protects the machine’s fuel heater system (optional equipment) and the purging unit and coolant level switch.

• • • • •

To indicate a right turn, move the switch upwards (1). To indicate a left turn move, the switch downwards (2) from the operator. For high beam headlights move the switch towards the dash (3). To dip the headlights move the switch away from the dash (4). To operate the horn push the end (5) of the switch.

NOTE:Intermittent wiper time cycle can be set via the Menu Display Unit. •

• •

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Turn handle of switch anti-clockwise to switch wiper intermittent on (6) (Timing is set on the MDU). Position (0) is “OFF”. Turn handle clockwise to position (7) for slow wiper speed.

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CHAPTER 2

Turn handle clockwise to position (8) for fast wiper speed. To flash for passing: push switch forward to position (9) and release.

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AIR CONDITIONER.

2

CLIMATE CONTROL 1

Vents 3

2 The air conditioner and the filter housing (1) are located inside the right side panel (2) on the cab. 1

The air conditioner radiator is located in front of the engine cooling package. 2

There are six climate control vents (1) installed in the cab. The vents are opened and closed manually. The vents can be turned to direct the flow of the air by turning the serated outer ring. To open the vents, push on the serated area of the large fin (2) and to close, push on the opposite side of the large fin (3).

Sun Visor

3

4

1

5

The air conditioner’s control panel is located on the left hand side of the cab roof and enables the following functions: Switch (1) controls the fresh air vent. When the switch is pressed the air vent is closed to allow re circulation. When the fan speed knob (4) is turned in a clockwise direction, the fan speed is increased progressively. Air conditioner switch (3) switches the air conditioner on or off in conjunction with the blower fan being on.

The sun visor is located in the roof and folds down when pulled. The operator can adjust it to the best position to block out sun light to his face.

When the air conditioner and fan switches are both ON, conditioned air is circulated through the air vents. When the temperature control knob (2) is turned in a clockwise direction, the air circulated through the air vents is progressively warmed. When the temperature control knob is turned in a counter clockwise direction, the air circulated through the air vents is progressively cooled.

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Control knob (5) controls the position where the air is directed to in the cab.

B50D 6X6 ADT

Reverse Lights

LIGHTS Front Lights (Grill Optional) 2

1

1

The machine is equipped with two white halogen work lights (1) as reverse lights. The reverse lights illuminate and a warning buzzer sounds when the reverse gear is selected. The front of the machine is equipped with two front light units, one on each side of the machine: headlight (1), and indicator (2). The headlights are operated from the lights switch on the dashboard and the stalk switch on the steering column.

Interior Light

1

NOTE:The grill in front of the lights is optional.

Rear Lights 1

2 There are two interior lights in the cab and both operated from a switch on the dashboard.

3

One is in the inside of the roof hatch to illuminate the circuit breaker area. The other light is shown above (1).

The rear of the machine is equipped with stop/tail lights (1) and indicator light (2) and a reflector (3). The stop light illuminates when the brake pedal is depressed or when the engine retarder or transmission retarder is activated. The park lights operates from the lights switch on the dashboard. The indicator light operates from the stalk switch on the steering column.

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Front , Rear Work Lights and Rotating Beacon Light 3

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HATCH IN ROOF

2 1

1

The truck is equipped with three working lights fitted and a rotating beacon light (3) on the roof of the cab. One facing rearwards (1) and two facing forward (2).

The hatch in the roof provides access to the circuit breakers and relays.

The working lights are switched ON with a switch on the dash.

To open hatch; push knob (1) on locking mechanism.

The rotating beacon light is switched ON with a switch on the dash.

The hatch has a gas operated shock to assist with the lowering of the hatch.

Manuals Compartment

CIRCUIT BREAKER PANEL The following figure details the circuit breaker box located above the hatch inside the roof: 6

7

8

10

9

1

The Operator’s manual and parts cataloque compartment (1) is in the roof panel above the emergency exit.

1

2

3

4

5

Refer to decal for description of circuit breaker functions on page 39 of this manual. Push in a circuit breaker to reset a circuit that has tripped.

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FUSES AND DIODES 2

1

14

15

4

16

5

17

6

18

7

20

WARNING

1. Do not touch the front of the lighter when removing if from the housing. This will cause a serious burn. 2. Smoking while operating the machine is not recommended. Driver distraction due to hot cigarette dropping onto driver’s lap could result in an accident which could lead to injury or death.

13

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19 The cigarette lighter socket can be used as a 12 V power supply point.

21

8 22

9

The following procedure must be used to utilise the socket as a power point:

23 24

10

•

Remove the cigarette lighter from the socket and store in a safe place. do not place lighter on surfaces that could get damaged if lightef is hot.

The relays are located above the hatch inside the roof.

•

For functions of the relays and fuses, refer to the decal on page 39 of this manual.

•

Place the 12 V accessory plug into the socket. The accessory will have electrical power when the ignition switch is ON. When the accessory is no longer required replace the cigarette lighter into the socket.

Ash Tray, Cigarette Lighter/ 12 V Accessories Socket and Drinks Holder

A drinks holder (3) is also installed to hold a cup or glass and is located next to the ash tray.

11

12

2

1

3

The cigarette lighter (1) is located in the 12 V accessories socket on the right hand side of the cab next to the ash tray (2). To operate the cigarette lighter: • • • •

78

Ensure that the ignition switch is ON or in the accessory position. Press the lighter push button in. Wait until a click is heard and lighter pops to normal position. Remove the lighter from the housing.

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RELAYS

1

13

17

5

23 14

18

15

6

22

2

9

3

21

10

7

20 11 8 16

12

19

N1

4

For functions of the relays, refer to page 39 of thiss manual.

MISCELLANEOUS EQUIPMENT Bonnet Catch Release Handle

1

When the bonnet is raised ensure that it is fully open, the lifting strut (1) will be fully extended.

When the handle is pulled the bonnet catch is released and the bonnet can be raised.

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WHEEL SPANNER AND BRACE

B50D 6X6 ADT

WINDSCREEN WIPER AND WASHER NOZZLE

1

A wheel spanner and brace are located on the floor of the cab, next to the left hand side of the operator’s seat and are secured in position by two plates.

WINDSCREEN WASHER WATER RESERVOIR

The machine is fitted with a single windscreen wiper which is equipped with a washer nozzle (1). 2

The wiper/washer switch (part of the stalk switch) activates the windscreen wiper motor and/or washer.

HORNS

1

1

The windscreen washer water reservoir (1) is located at the left hand side of the cab under the bonnet. To refill the water bottle: • • • •

Tilt Bonnet. Remove the filler cap (2) and fill the bottle with a window cleaning solution. Ensure that the cap is replaced securely. Check electrical connection and fluid delivery hose for wear/damage and operation. The horns (1) is located on the right of the machine, mounted on a bracket next to the air cleaner and is operated from the steering column stalk switch.

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Electrical Horn (Optional)

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FIRE EXTINGUISHER (OPTIONAL)

1

An electrical horn (1) can be fitted as optional equipment and will be activated along with the normal horns from the steering column stalk switch.

Reverse Warning Buzzer 1

1

The fire extinguisher is mounted between the operator and trainer seat. When reverse gear is selected, the reverse lights illuminate and a warning buzzer (1) sounds at the rear of the machine.

To use the fire extinguisher:

Removing The Fire Extinguisher Remove the pin securing the clip, loosen the clip (1) securing the fire extinguisher and remove the fire extinguisher from the mounting bracket.

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Activate The Fire Extinguisher

B50D 6X6 ADT

ELECTRICAL MIRROR BRACKETS

2 1

3

Pull out the safety pin (1), point the nozzle (2), at the base of the fire and pull the lever (3) towards the handle. NOTE:1. Replace the fire extinguisher immediately after use with a charged fire extinguisher. 2. The fire Extinguisher must be serviced at regular intervals to ensure optimal serviceability of the fire extinguisher.

The electrical mirrors are mounted on a bracket. The bracket can be swivelled out to the front or rear of the cab to make access to the bonnet easier. Swing the bracket back after work has been done.

12-VOLT ACCESSORY SOCKET

EMERGENCY EXIT HAMMER

1

A 12-Volt accessory socket used to power operator accessories.

The hammer is located on the cab frame on the rear right hand pillar and is used in emergencies to break a window to exit the cab.

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CHAPTER 3. PROCEDURES BEFORE STARTING SECTION 1. SAFETY SAFETY INSTRUCTIONS EMERGENCY EXIT 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.

The cab has 2 exit points, which are as follows:

NORMAL EXIT •

Emergency exit (right side window).

To remove the window: • • • • •

1

•

Remove the emergency exit tool from the holder. Move as far away from the window that’s going to be broken. Strike the window as hard as possible. Keep on till the window is shattered. Remove the window, and get out.

NOTE:1. Be careful not to cut yourself with broken glass. 2. Protect face and body from flying glass slivers.

The cab access door (1) for normal access and exiting of the cab.

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CHAPTER 3. PROCEDURES BEFORE STARTING SECTION 2. BEFORE STARTING SAFETY RULES Operator Duties

1. Raise the bonnet and check the condition of the lifting strut, pivots and restraining straps.

The operator must know the rules and safety aspects of the site. The operator must study the following rules and become aware of how to avoid serious injury and/or machine damage.

2. Check the machine for oil leaks especially in the region of the transmission.

•

• •

•

•

It is the operator’s duty to report all damage and wear which may endanger the operator or cause damage to the machine. Only trained personnel may operate the machine. Check that a “DO NOT OPERATE” tag is not attached to the steering wheel. If the tag is attached, do not operate the machine. Complete the Walk Round Check (refer to next instruction). If any defects are found, do not operate the machine. Attach the “DO NOT OPERATE” tag to the steering wheel and remove the machine key. Report all defects and problems encountered during the Walk Round Check to the service personnel.

Daily Walk Round Check The Daily Walk Round Check must always be carried out before operating the machine at the beginning of a work shift or after a change of operator during a shift. The operator starts his check at the left of the machine and walks around the machine in a clockwise direction. NOTE:The machine must be parked in the straight ahead position on firm, level ground with the bin down and the park brake applied. It is recommended that the machine is thoroughly 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 12. The service decal located on the side of the cab lists the scheduled service needs (maintenance schedule) and is useful for locating the items.

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3. Check the condition and tension of the engine fan belt. 4. Check for loose, frayed or corroded connections in the wiring harness. 5. Check the engine mountings and cab mountings are secure and the rubber elements are not damaged. 6. Ensure that all the hose connections are tight and inspect for leaks, cracks or chafing damage. 7. Check that the exhaust connections, exhaust brake valve and actuator are secure. 8. Check that the batteries are secure and the connections are tight. 9. Check that the hydraulic motor driven fan and cooler fins of the hydraulic oil cooler are not damaged. 10. Check that the hydraulic oil cooler fins are not restricted. 11. Check the cooling pack (engine and air conditioner) for cleanliness and ensure there are no restrictions to the cooling function. 12. Check the security of the cooling pack assembly and inspect for leaks. 13. Inspect the air cleaner assembly for damage and security. 14. Clean the pre-cleaner bowls if required. 15. Check the service indicator and service the filter elements if required. 16. Reset the service indicator. Check that the vacuator valve is not restricted and is undamaged

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17. Check the engine oil level 18. Check the engine coolant level.

30. Ensure that the drive shaft assemblies are secure.

19. Drain the fuel/water separator filter.

31. Check the wheels, wheel nuts and components for damage and security.

20. Inspect the suspension.

32. Check the tyres for cuts and damage.

21. Check that the steering cylinders are secure. 22. Check the transfer case oil level. 23. Ensure that the transfer case mountings are secure and undamaged. 24. Check the hydraulic fluid level. 25. Lubricate as required. 26. Check auto greaser reservoir level. 27. Check all lubrication points for proper lubrication. 28. Inspect the park brake disc pads linings. 29. Check the axles and components (trailing arms, stabiliser links and sandwich blocks) for leaks, damage and security.

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33. Check the tyre pressures (refer to the decal for pressures). 34. Check the fuel level. 35. Ensure that the wind shield, side and rear windows and the rear view mirrors are clean. 36. Ensure that there are no obstructions around the machine before moving off. 37. Ensure that there are no obstructions in the cab, especially under and around the pedals and controls before moving off. 38. Ensure that the seat belt is in proper working order and fasten the seat belt before start-up.

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CHAPTER 4

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CHAPTER 4. OPERATING INSTRUCTIONS SECTION 1. SAFETY

n

CAUTION

Read and understand all of the operator related chapters in this manual before performing any of the following procedures and obey all Warnings and Cautions contained in the sections. Refer to the detailed procedures in the relevant chapter.

SAFETY RULES Trainers are only allowed on machines provided with a trainer seat and with approval by site management. Always wear the seat belt when operating the machine. Check that the mirrors are correctly positioned for the best visibility. Check that no personnel are near the machine. Adapt the machine speed to road conditions, load and visibility.

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CHAPTER 4. OPERATING INSTRUCTIONS SECTION 2. STARTING BEFORE STARTING THE ENGINE

•

Ensure that the Daily or 10 Hourly Service Checks have been completed.

Turn the key one step further to start engine.

n

Adjust the operator’s seat for the best operator comfort and easy access to the machine controls.

CAUTION

1. Do not run the engine at high speed (r.p.m.) or heavy loading until the engine oil, transmission fluid and hydraulic fluid have warmed up to normal operating temperatures. 2. Do not hold the key in the start position for more than seventeen seconds. If the engine does not start, wait one minute before attempting to restart the engine to allow the battery to stabilise and starter motor to cool down. If the engine does not start after two attempts investigate the cause.

Fasten the seat belt and adjust the seat belt to fit firmly across the front of the pelvis.

n

Apply the horn for two seconds, wait for five seconds.

WARNING

Do not start the machine by shorting across starter terminals. Never start machine while standing on the ground. Always start machine from operator’s seat with park brake applied.

Starting the Engine in Warm Weather Starting the engine in warm weather does not require any special procedures. The following procedure must be used to start the engine in warm weather:

Starting the Engine in Cold Weather The following procedure must be used to start the engine in cold weather: •

• • •

Ensure the battery disconnect switch is turned ON. Ensure the park brake is applied. Ensure the gear shift is in the neutral position.

NOTE:The engine cannot be started when any gear is selected.

• •

Ensure the batteries disconnect switch is turned ON. Ensure the park brake is applied. Ensure the gear shift is in the neutral position.

n

WARNING

Do not use starting fluid in machine. Damage to the engine may result.

NOTE:The engine cannot be started when any gear is selected.

1 • •

Insert the ignition key into the ignition switch (1). Turn the ignition switch clockwise to the ON position.

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B50D 6X6 ADT

SHUTTING DOWN THE ENGINE •

The following procedure must be used to shut down the engine:

n

1. Never stop the engine from high idle. This will cause damage to the turbocharger and the engine. 2. Do not shut the engine down with the ignition still “ON” using the battery disconnect switch. This could cause error codes to be logged from electrical modules that need ignition sequence shut down before battery power is disconnected. Allow 10 seconds delay from ignition OFF to battery disconnect switch OFF.

1

•

Insert the ignition key into the ignition switch (1). Turn the ignition switch clockwise to the ON position.

•

CAUTION

NOTE:The cold start function of the machine is automatic. The cold start function will only operate when the outside temperature drops below o o 15 C (59 F ).

i.

Stop the machine in the straight ahead position.

ii .

Apply the park brake.

iii . Select neutral (N). •

Wait until the cold start indicator light extinguishes (approx. 20 seconds). Apply the horn for two seconds, wait five seconds. Turn the ignition key to the start position to start the engine.

• •

n

iv . Allow the engine to idle for 2 minutes to allow the engine temperature to stabilise. v . Turn the ignition switch counterclockwise to the OFF position. vi . If the machine is stopped overnight ensure the battery disconnect switch is turned to the OFF position and that the park brake is ON.

CAUTION

1. Do not run the engine at high speed (r.p.m.) or heavy loading until the engine oil, transmission fluid and hydraulic fluid have warmed up to normal operating temperatures. 2. Do not hold the key in the start position for more than 17 seconds. If the engine does not start, wait 1 minute before attempting to restart the engine to allow the battery to stabilise. If the engine does not start after two attempts investigate the cause. 3. Engine will not start by towing or pushing. Permanent damage to the transmission will result.

USING BOOSTER BATTERIES Before boost starting, machine must be properly shut down and secured to prevent unexpected machine movement when engine starts. • •

Check battery connections to ensure they are good. Check battery condition at battery indicator eye - If green, look for other problems before jump starting.

n

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.

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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.

Rules For Jump Starting

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• • •

• • •

GD1025CFM

•

•

•

• •

•

Switch battery disconnect switch to “OFF” Connect one end of the positive cable to the positive terminal of the machine batteries (A) and the other end to the positive terminal of the booster batteries (B). Ensure a good solid connection. Connect one end of the negative cable to the negative terminal of the booster batteries (B) and the other end to the machine as far away from the batteries as possible, preferably to a machine earth point and not onto a painted section. Verify that the booster batteries are connected in the correct order to prevent reverse battery polarity connection. switch battery disconnect switch to “ON” and all other electrical loads such as lights, air conditioner, etc. “OFF” before starting the engine. Start the engine (See Starting Engine in this section). Remove the cables. (Disconnect negative cable first from the machine and then from the negative terminal on the booster batteries. Only disconnect with engine idling). Disconnect positive cable.

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WARNING

Jump starting could damage or destroy electronic control units. Jump starting procedure is carried out at your own risk.

Procedure

• •

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•

• •

•

Maintain batteries & connections in good condition to avoid jump starting. Do not smoke while jump starting or per forming maintenance checks on batteries. If using another vehicle to jump start ensure the system voltage are the same: 12 volt cannot be used to crank a 24 volt engine. Do not allow vehicles to touch one another. Never use a rapid battery charger to boost from. Electrolye can freeze at -10°C (14°F). Never jump start a frozen battery as it can axplode. Always thaw out frozen batteries completely before jump starting. Always disconnect the negative booster lead at the chassis connection point first when disconnecting booster batteries. Never disconnect booster batteries at high r.p.m. Never remove/disconnect the machine batteries while the engine is running (i.e. no batteries connected on the truck - only alternator supply electrical requirements). This can damage alternator regulator and electronic control units. Never connect batteries or booster batteries the wrong way around. Reverse polarity connection will destroy theengine control unit and alternator rectifier.

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CHAPTER 4. OPERATING INSTRUCTIONS SECTION 3. RUNNING-IN RUNNING-IN INSTRUCTIONS 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 life. The 100 SMR service MUST ONLY be done by BELL EQUIPMENT Service Personnel.

Gear Shifting Safety Functions The transmission control unit does not allow shifting from neutral to a gear when the engine r.p.m. is above 900 r.p.m. If “D” is selected while the engine r.p.m. is above 900 r.p.m. the shifter display will blink. Select “N” again, let engine return to idle and re-select “D”.

Gear Shifting

Driving Safety Rules Check that all the gauges and indicators are operational. Ensure the readings are correct. Refer to Chapter 2, Operator’s, Controls and Instruments for the correct readings. Wait until there is sufficient air pressure {750kPa (109psi)} before driving the machine. Check that there are no personnel on or around the machine before driving the machine. Check the steering and brake functions and confirm that the reverse alarm sounds when reverse is selected. Sound the horn before moving off.

Gear Shifting

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CAUTION

1. Do not allow the machine to free wheel (coast in neutral) as this will cause damage to the transmission. 2. Do not continually select from 1st forward to 1st reverse as this will cause damage to the transmission.

The truck is equiped with two speed differentials; High Range and Low Range. For more information See “Operating The High Range Switch” on page 96.

NOTE:If you want to select a forward gear while in reverse or vice versa, select neutral first and then the required gear. Gear shifting in automatic is dependent upon engine speed (r.p.m.) and operating conditions (on site conditions) The following procedure must be used in gear shifting: • • •

Start the engine. Ensure that the park brake is applied. Apply the service brake.

Forward Selection (Automatic) • • •

Select D on the gear selector. Release the park brake. Release the service brake and increase the engine speed (r.p.m.).

As the machine speed increases, the transmission will select (sequentially) the next gear. With drive D selected, the attainable gears will be displayed. Reverse Selection • • •

Select Reverse (R) on the gear selector. Release the park brake. Release the service brake and increase the engine speed (r.p.m.).

The transmission has 6 forward gears and 1 reverse gear with automatic lock-up in all gears. The transmission can be operated as a fully automatic transmission. All automatic gear shifting will be controlled by the machine’s electronic control unit.

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Controlled Gear Range For certain conditions only a limited range of gears may be required. To select the range of gears required, proceed as follows: • • • • •

Start the engine. Ensure that the park brake is applied. Apply the service brake. Select D on the gear selector. Press the down shift button to the required number of gears. Example: if 3 is pre-selected, gears 4, 5, and 6 will not be attained unless an overspeed condition occurs.

To select normal driving gear range the drive button D must be pressed.

DOWN SHIFTING OR REVERSE INHIBITOR NOTE:Shifting from neutral (N) to drive (D) or reverse (R) is inhibited when engine speed is above 900r.p.m. Although there is no speed limitation on upshifting, there is on down shifting and shifts from neutral to drive or reverse. If a down shift or N - to - D or R is selected when engine speed is too high, the TCU will prevent he shift until neutral is selected or engine speed is reduced.

Accelerator Control

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CAUTION

To avoid injury or property damage caused by sudden movement of the machine, do not make shift from neutral (N) to drive (D) or reverse (R) while pressing accelerator.

B50D 6X6 ADT

DECELARATION AND STOPPING NOTE:If the transmission is in neutral and the service brake is not applied, the park brake will automatically be applied after 4 seconds. During normal operation, machine must be stopped using the service brakes. If a machine is stopped for more than a few seconds, the parkbrake must be applied.

Retarders Engine Retarder The engine retarder system (Exhaust Brake) is fully automatic and will be activated when the accelerator pedal is fully released. On down hill operation, if engine governed speed is exceeded, the transmission may upshift to the next higher gear. This will reduce braking. Apply service brakes to prevent exceeding engine governed speed. NOTE:Down shifting to a lower gear increases the effectiveness of the engine braking. When machine is fully loaded or slope is steep, it may be desirable to pre-select a lower gear before reaching the slope. When exhaust brake is engaged, the transmission automatically starts to down shift to a lower gear. The digital display will indicate “2” while this happens. When second gear is attained and machine has slowed, the exhaust brake will be disengaged and the digital display will return to the previous value shown.

NOTE:Shifting from neutral to drive or reverse is inhibited when engine speed is above 900r.p.m. “R” or “6” will flash in the display window if a shift is attempted above 900r.p.m.

Transmission Retarder

The position of the accelerator pedal influences the timing at which automatic shifting will occur at fast engine speeds.

The retarder light on the dash will light whenever the transmission retarder is activated.

A partially depressed accelerator pedal position will cause upshifts at low engine speeds.

The transmission retarder is applied when a retarder position is selected at the retarder lever and the accelerator pedal is fully released.

94

The transmission retarder is automatically engaged when the accelerator pedal is released.

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Retardation can be selected between a choice of 6 different retardation percentages.

• •

Position “0” and “1” induces the same amount of retardation. 15% retardation is applied whenever the service brake pedal is pressed, even if the lever is in the “0” position. To resume driving, release service brake pedal. The transmission will automatically select the lowest gear.

BRAKING The general rule for braking is that the retarder should be used before the service brakes in order to reduce the brake disc wear.

Service Brakes and Park Brake During normal operation the machine must be stopped using the service brakes. When the machine is stopped for more than a few seconds the park brake must be applied. Service Brakes

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WARNING

Avoid using the service brake over extended periods. Excessive use of the service brakes will result in the brake assembly overheating which in extreme circumstances could result in a brake assembly failure.

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While driving the machine normally the brake pedal must be pressed. When extra brake force is required or continuous retardation, use the retarder switch to activate the retarder.

NOTE:The transmission will automatically select the lowest pull-off gear. Park Brake (Normal Operation) NOTE:1. The park brake will be applied when the key is turned to OFF position. If machine was stopped and the park brake was not applied, the park brake lever must be moved to the engaged position before park brake can be released. 2. The park brake must only be applied when the machine is completely stationary. When the machine is to be stopped for more than a few seconds the following must be done: • • • •

Stop the machine using the service brake. Apply the park brake. Select Neutral (N). Release the service brake.

Park Brake (Truck Moving) When the transmission is in neutral for more than 4 seconds and the vehicle speed is below 5km/hr the park brake will be applied automatically.

Stopping the machine with the service brakes is done as follows:

NOTE:Before park brake can be released, the park brake lever must be moved to the applied position, a gear must be selected or the brake pedal pressed.

•

Park Brake Protection

Release the accelerator.

NOTE:1. When the accelerator is released the engine retarder as well as transmission retarder will be activated. 2. It is recommended that the retarder brake function is used to slow the machine down and the service brakes used to stop the machine.

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NOTE:This feature is to assist in pulling-off on an incline. When the Brake Pedal is not pressed and the truck is standing still(< 1km/h) and the Park Brake is on while the transmission is in gear then the engine torque is limited to 55%. This limit is set at 55 % so that the parkbrake can be tested to function correctly without being able to drive through it. As soon as the park brake lever is released, 100% torque is available for pull away on steep inclines.

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If the Park Brake is applied while driving(>1km/h) then the engine torque is limited to 0% until the vehicle speed is below 1 km/h at which time 55% torque is allowed. NOTE:1. The park brake will be applied when the key is turned to OFF position. If machine was stopped and the park brake was not applied, the park brake lever must be moved to the engaged position before park brake can be released. 2. The park brake must only be applied when the machine is completely stationary. When the machine is to be stopped for more than a few seconds the following must be done: • • • •

Stop the machine using the service brake. Apply the park brake. Select Neutral (N). Release the service brake.

Emergency Braking The park brake can be used (if possible in conjunction with the retarder) as an emergency brake if service and secondary brakes fail. If the service brakes fail after the machine has been slowed down with the retarder, the machine can be stopped using the park brake. The following must be done: • • •

Apply the park brake. When the machine has come to full stop turn the ignition switch to the OFF (O) position. Contact your BELL Product Support Representative

NOTE:The service brake system is designed such that the front and rear chassis brakes are applied via two separate brake control systems. If brake system failure occurs in one of the systems, the other system will still have sufficient retardation force to stop the machine. If both brake systems are defective use the park brake to stop the truck, as described above.

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Operating with Inter-axle Differential Lock NOTE:It is recommended that the inter-axle differential lock is only engaged when the machine is operating on very poor ground conditions.

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CAUTION

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 transfer case.

Inter-axle Differential Lock Control Engaging the Inter-axle Differential Lock The following procedure must be used to engage the inter-axle differential lock: • • •

Switch the inter-axle differential lock switch ON (can be done at any speed). Release the accelerator pedal briefly. IDL light will illuminate to confirm successful engagement.

The inter-axle differential lock is not available when the vehicle is in HIGH range. Once the interaxle differential lock has been activated, the vehicle will not be allowed to change to HIGH range. Disengaging the Inter-axle Differential Lock The following procedure must be used to disengage the inter-axle differential lock: • •

Switch the inter-axle differential lock switch OFF (at any speed). The inter-axle differential lock indicator will extinguish.

Operating The High Range Switch The B50D 6X6 ADT is equipped with 2-speed differentials. These differentials are spring loaded into LOW range, and is pneumatically shifted into HIGH range only when certain conditions are met.

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This allows the vehicle to always start off in LOW range, rapidly climb arduous inclines and then change into HIGH range (faster vehicle speeds) once conditions allow. The switching to HIGH range and back into LOW range is controlled by the chassis computer, and no additional inputs, precautions or intervention is necessary from the operator.

Switching Into HIGH Range

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Switching Into LOW Range Switching into LOW range is allowed only when the following conditions are met: • • •

The transmission is in 1st gear. The vehicle travels slower than 2 km/h (1.2 mph) The operator’s foot is completely off the accelerator.

NOTE:All six Transmission forward gears are available in High Range as well.

In certain applications the operator may want to restrict the vehicle to LOW range only. Switch the Range hold switch to the “OFF” position, and the vehicle will not shift into HIGH range.

Switching into HIGH range is allowed only when the following conditions are met:

Gear Hold Switch

•

• • • •

The High/Low Range Switch is in the “ON” position (See “High/Low Range Switch (2).” on page 72). The transmission is in 6th gear. The vehicle travels faster than 34 km/h (21.1 mph). The inter-axle differential lock switch is on the “OFF” position. Accellerator is pushed in >95% and the engine torque is >40%.

The gear hold switch allows the operator to lock the transmission so that it will not be able to atain a higher gear than the one when the gear hold switch was activated. See “Gear Hold Switch (5).” on page 73

Once these requirements are met, the vehicle will automatically shift the 2-speed differentials into HIGH range - no intervention or precautions are necessary from the operator. The HIGH Range Attained light on the MDU will be illuminated if the shift has occurred successfully. The operator can keep his foot on the accelerator during this shifting progress, and continue driving as normal. The transmission will take care of shifting to the appropriate transmission gear for the conditions.

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CHAPTER 4. OPERATING INSTRUCTIONS SECTION 4. OPERATING THE MACHINE LOADING THE MACHINE The following procedure must be used to load the machine: • • •

Position the machine in a straight ahead position. Apply the park brake. Select Neutral (N).

When the loading operator signals that the bin is fully loaded the following must be done: Select Drive (D). Release the park brake and drive off slowly.

WARNING

Do not operate the bin tip lever unless the transmission is in neutral (or dumping in 1st or reverse). This practice can over-ride the safety functions and could cause damage to the machine and/or personal injury. • • • • • • •

• •

Select Drive (D). Release the park brake and drive off slowly.

NOTE:The tip control lever is spring-loaded to the central position (holding position).

STEERING

Raising the Bin

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NOTE:If the bin is not fully lowered (the bin raised warning indicator is illuminated), the transmission will only select 1st gear, neutral and reverse. As soon as the bin raised warning indicator is extinguished, normal transmission gear selection will resume.

Position the machine in a straight ahead position. Apply the park brake. Select Neutral (N). Increase the engine speed to approximately 1 500 r.p.m. Move the tip control lever towards the operator. Reduce engine speed as the bin reaches maximum travel. Release the tip control lever.

NOTE:The tip control lever is spring-loaded to the central position (holding position).

Normal Steering The machine’s normal steering system operational when the engine is operating.

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is

WARNING

There is no self-centring function on the machine steering. After turning the steering, the machine must be straightened by turning the steering wheel to the straight ahead position.

Emergency Steering

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WARNING

If there is an engine or main pump failure, the ground driven emergency steering system will enable the operator to steer the machine to a safe stop. In this event the machine must be stopped as quickly as possible.

Lowering the Bin •

Move the tip control lever away from the operator. It will be kept automatically in this position until the bin is fully lowered and then automatically return to the central position.

When the engine or main pump fails the emergency steering indicator will flash.

NOTE:The lever is hold automatically till the bin is fully lowered. •

Ensure that the bin raised warning indicator is extinguished.

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The machine’s emergency steering system is ground driven and will be operational until the machine is stationary. When the emergency steering system is activated the emergency steering indicator on the centre instrument panel will illuminate. NOTE:There is no self centring function with the machine steering. The machine must be straightened by turning the steering wheel to the straight ahead position.

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CAUTION

If the engine fails the machine must be steered to safety as soon as possible.

B50D 6X6 ADT

Overnight Parking When the machine is to be parked overnight the following must be done: • • • • • • • • • • •

Ensure the machine is unloaded. Park the machine on firm level ground. Move all the switches to the OFF position. Ensure the transmission is in Neutral (N). Ensure the park brake is applied. Switch the ignition OFF and remove the key. Lock the cab door. Open the battery box lid and move the battery disconnect switch to the OFF position. Ensure the battery box lid is closed properly. Secure with padlocks if required. Ensure that the fuel cap and the bonnet release levers are locked. Ensure that nothing is left under the machine, as the front suspension might lower over night.

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. When raising the bin indoors, ensure that there is enough free space above the bin when it is fully raised.

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CHAPTER 5. OPERATING TECHNIQUES The following information details suggested techniques to obtain the safest and most efficient use of your machine.

SAFETY RULES Ensure there is sufficient space for the machine before entering confined areas. Accidents and injuries must be reported immediately. Site management must also be informed of any "narrow escapes" and areas and situations which could present an accident risk. If possible, after an accident, the machine must be left in its position. Do not do anything to the machine that may hamper an investigation into the accident. Follow the instructions management.

given

by

the

site

Gear Selection The transmission makes it unnecessary to select the right moment to up shift or down shift during changing travelling conditions. However knowledge of the ranges and when to select them will make machine control and the operator’s job easier. The following table is a brief summary of the range selections covered in this manual. R

Completely stop the machine before shifting from a forward gear to R or from R to a forward gear.

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WARNING

Do not allow the machine to coast in N, there is no engine breaking and the operator may lose control. Coasting in neutral will also cause transmission damage.

N

Use N to start the machine and for periods of engine idle operation. N is selected by the ECU at start-up. Always select N before turning off the engine.

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The shift from N to D or R is inhibited when the engine speed is above idle. N must be reselected and the idle speed reduced before the shift will occur. When shifts to D or R are inhibited, the digit on the shift selector will flash.

D

The transmission will initially attain 1st gear when D 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 D is selected, it may not be attained due to active inhibit functions such as high throttle or engine idle speeds. Check for active diagnostic codes if D is not attained.

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WARNING

If the operator just downshifts or just uses the service brakes while going downhill, he may lose full control of the vehicle.

To help in keeping full control on down-hills, use a combination of downshifting and braking. Downshifting to a lower gear increases engine braking and helps the operator maintain full control. The transmission has a feature which prevents automatic upshifting above the lower gear selected. However during downhill operation, if engine governed speed is exceeded in the lower gear, the transmission may shift to the next higher gear. This will reduce braking and may cause loss of control. Apply service brakes to prevent exceeding engine governed speed in the lower gear selected.

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Occasionally road conditions, load or traffic conditions will make it desirable to restrict automatic shifting to a lower gear. Lower gears provide greater engine breaking for going down grades (the lower the gear; the greater the braking effect).






The shift control utilises the (Up) and (Down) arrow buttons to select individual forward gears. The shift control will display the operator’s choice.

- 2nd gear is attained and the machine has slowed down almost to a stop

Use this gear when pulling through mud and deep snow, when manoeuvring in tight spaces or while driving up/down grades.

The engine exhaust brake is automatically applied and the exhaust brake warning indicator is illuminated during the above retardation period.



When selecting D from N and the bin is raised (bin raised warning indicator is illuminated), the transmission will limit gear selection to 1st gear. The display on the shift selector will show “1”. As soon as the bin is fully lowered (bin raised warning indicator is extiguished), the transmission will automatically revert to normal gear selection and the gear shift screen will revert to the original display.

102

The gear shift display will show “2” as long as retardation is in progress and will revert back to the original displayed value when:

- or when the operator applies the accelerator to cancel retardation.

Push the (Down) arrow button on the shift selector until first gear appears on the display screen.

R

When retarding, (i.e. The operator takes his foot off the accelerator) the transmission will start downshifting from the current gear, down to 2nd gear to maximise engine braking.

Even though a lower gear was selected, the transmission may not downshift until machine speed is reduced.

1st gear provides the machine with maximum driving torque and maximum engine braking effect.

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B50D 6X6 ADT

Reverse operation of the machine is not affected by the bin raised condition (as described above).

GEAR PRE-SELECTION Gear pre-selection means selecting a lower gear to match driving conditions which the operator encounters or expects to encounter. Learning to take advantage of pre-selected shifts will give the operator better control on slick or icy surfaces and on downgrades. Downshifting to a lower gear increases engine braking. The selection of a lower gear often prevents cycling between that gear and the next higher gear on a series of up-and-down gradients. (See Chapter 4 Controlled Gear Range).

GEAR HOLD FUNCTION See “Gear Hold Switch (5).” on page 73 for more information on this function.

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TRANSPORT OPERATION

Downhill Operation

When operating the machine in ideal conditions (e.g. level graded surfaces) normal driving and gear selection must be used.

When driving downhill the exhaust brake and retarder must be utilised to assist the service brakes and to reduce brake pad wear.

The machine may be operated at maximum speed in accordance with the site and road regulations.

If necessary, slow down before the downhill slope begins so that the transmission automatically selects a low gear.

Always adapt the machine speed to the road and traffic conditions. When driving through a bend do not drive too fast. The machine’s centre of gravity is changed which may cause the machine to tip or roll if the road is slippery or cambered the wrong way. The machine load must not be allowed to fall off the machine at any time. Do not use the inter-axle differential lock when operating on smooth graded surfaces. Due to the mass of the machine allow for long braking distances, especially on slippery roads.

Uphill Operation If the machine is operating in full automatic mode, transmission will select the correct gear for travelling uphill.

During icy or other slippery conditions, utilise the inter-differential lock to improve traction and braking effect. Using the Engine to Slow the Machine

n

WARNING

If the operator just down shifts or just uses the service brakes while going downhill, he may lose full control of the machine.

To help in keeping full control on down hills, use a combination of down shifting, braking and the retarder. Downshifting to a lower gear increases engine braking and helps the operator maintain full control.

When operating on slippery roads the inter-axle differential lock must be applied to allow for even traction on all the driving wheels. The engine speed must be kept constant at all times when driving uphill.

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The transmission has a feature which prevents automatic up shifting above the lower gear selected. However during downhill operation, if engine governed speed is exceeded in the lower gear, the transmission may up shift to the next higher gear. This will reduce braking and may cause a loss of control. Apply the service brakes and/or retarder to prevent exceeding engine governed speed in the lower gear selected. To use the engine as a braking force, the operator must: • •

Take his foot off the accelerator. The transmission will start to down shift and the exhaust brake will be applied.

If the machine is exceeding the maximum speed for this gear, use the service brakes and/or retarder to slow the machine. When a lower speed is reached, the TCU will automatically down shift the transmission. Engine braking provides good speed control for travelling downhill. When the machine is fully loaded, or the gradient is steep, it may be desirable to pre-select a lower gear before reaching the gradient. Use the hydraulic retarder on severe gradients. If engine-governed speed is exceeded, the transmission will up shift automatically to the next gear.

Off-road Operation Do not operate too close to quarry edges, ramp edges, quay edges and soft edges that may collapse under the machine weight. Always use the inter-axle differential lock and sixwheel drive during off-road operation when there is a risk of wheels slipping.

B50D 6X6 ADT

GD0003CFM

To cover difficult areas (e.g. soft mud) use the articulation steering combined with the inter-axle differential lock to move through the area in the so called “duck waddle”. Where the ground is particularly soft and there is no space restriction, choose a new track for each approach to avoid making deep tracks.

Loading NOTE:For more information, See Chapter 8 on “Payload and On Board Weighing”. Ensure there is sufficient space for the machine before entering confined areas. Ensure that no personnel are near the machine or loading area. Do not operate too close to quarry edges, ramp edges, quay edges and soft edges that may collapse under the machine’s weight. Be aware of other machines and personnel when entering or leaving the loading area. If a spotter is present follow only his instructions. Reverse up to a loading machine in a single, straight manoeuvre so that you can maintain eye contact at all times with the operator of the loader. Steer the machine so that it is straight. The operator must have clear and unobstructed vision through his rear view mirrors. If the machine is articulated and not in the straight ahead position the operator may find it difficult to observe the spotter and the loading machines. Stop the machine on a firm level surface.

Always engage the inter-axle differential lock before any of the wheels begin to slip.

Ensure that the bin is fully lowered so that the load is not dumped into a bin which is supported on the tip cylinders. Do not overload by exceeding the rated capacity of the machine. The operator of the dump truck is responsible for the size and mass of the load.

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Ensure the machine is loaded evenly. An uneven load will cause tyre and axle damage. 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.

When raising the bin ensure that when the bin is fully raised it is no less than 4 metres (13’) away from any power lines. Ensure that no personnel are near the machine or dumping area. NOTE:Ensure that there are no debris or obstructions between the bin and chassis before lowering the bin.

Unloading

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WARNING

1. Be careful when tipping the bin. It is possible that the material may stuck to the bin and when the bin reach a certain point, the front chassis may lift from the ground and the cab to roll over and end up upside down. Also see Chapter “SAFETY Avoid Tipping Over” 2. Do not operate the bin tip lever unless the transmission is in Neutral (or dumping in 1st or Reverse). This practice can over-ride the safety functions and could cause damage to the machine and/or personal injury.

Be aware of other machines and personnel when entering or leaving the dumping area.

Stuck Machine NOTE:If the ground is soft with deep wheel tracks constant attention must be given to the rear chassis angle. If the rear chassis starts to lean sideways excessively, stop the machine immediately and try another route. If the machine becomes stuck the following must be done:

NOTE:If the bin position is greater than 70% and the transmission is in reverse, the engine torque will be limited to 20% to avoid that the operator use the bin as a scraper when fully tipped or drives into a pile.

• • • •

Ensure there is sufficient space for the machine before entering confined areas.

•

Do not operate or stop too close to quarry edges, ramp edges, quay edges and soft edges that may collapse under the machine mass. The use of stopping chocks or other safety devices is recommended. Reverse up to the unloading site in a single, straight manoeuvre so that you can maintain eye contact at all times with the spotter and have allround vision from the machine.

•

•

Select Neutral (N). Engage the inter-axle differential lock. Select Forward (D). Check that the inter-axle differential lock indicator illuminates. Drive off slowly keeping the engine speed (r.p.m.) constant and not too high. To assist with traction, turn the steering wheel one way and then the other alternately causing the machine to adopt a “duck waddle”. Continue with this movement until the machine is free and can be operated normally.

NOTE:If the machine does not move, get a towing vehicle to move the machine from the soft soil.

If a spotter is present follow only his instructions. Steer the machine so that it is straight and on level ground. The operator must have clear and unobstructed vision through his rear view mirrors. If the machine is articulated and not in the straight ahead position the operator may find it difficult to observe the spotter and the dumping action.

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Rocking Out

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WARNING

To help in avoiding injury or property damage caused by sudden movement of the machine, do not make shifts from N to D 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 D or R only when the throttle is closed.

n

CAUTION

Do not make N to D 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 D or R.

Full power for more than 30 seconds under the above conditions will cause the transmission to overheat. If the transmission overheats, shift to N and operate the engine at 1 500 r.p.m. until it cools (23 minutes). If the machine is stuck in deep sand, snow or mud, it may be possible to rock it out as follows: • • • • •

• •

Shift to D and apply steady, light throttle (never full throttle). When the vehicle has rocked forward as far as it will go, apply the service brakes. Allow the engine to return to idle. Select R. Release the service brakes and apply a steady, light throttle and allow the machine to rock in R as far as it will go. Again apply and hold the service brake and allow the engine to return to idle. This procedure may be repeated in D and R if each directional shift continues to move the machine progressively further.

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CHAPTER 6. RECOVERY AND TRANSPORTATION SECTION 1. TOWING SAFETY RULES Always consult your BELL EQUIPMENT Product Support Representative before towing a disabled machine. Always chock the machine before releasing the brakes and/or disconnecting the driveshafts. Only use a rigid A-frame when towing a machine The A-frame must be securely fastened to both towing eyes and must distribute the towing force evenly on both towing eyes when towing or turning the machine. Ensure the A-frame is strong enough to tow a machine at least 1.5 times the gross weight of the towed machine, when towing from mud or on a gradient. Never exceed 2 km/h (1.2 m.p.h.) when towing a disabled machine for short distances. Load a disabled machine onto a suitable breakdown vehicle or remove the driveshafts between the transmission and transfer case when moving it long distances. Shielding must be provided on the towing machine 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 disabled machine. Gradual smooth movement is necessary for safe towing. Quick movements will overload the A-frame and cause it to break. The towing machine must be the same size or larger than the disabled machine. Ensure the 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. A larger machine and a solid tow bar is required when towing a disabled machine downhill. An additional machine connected to the rear may also be required to prevent the disabled machine from rolling away.

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If the disabled machine is to be articulated (manoeuvred) a towing machine with an A-frame must be attached to the front of the machine for manoeuvring and a machine attached to the rear for controlling. Minimum towing capacity is required for towing on smooth level surfaces and maximum towing capacity is required for towing on gradients and poor ground conditions.

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CAUTION

Failure to lift the wheels off the road or disconnect the drivetrain can cause damage to the transmission.

The engine can not be started by pushing or towing.

Towing a Machine with Inoperable Engine

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WARNING

1. Before releasing the brakes, always chock the wheels to prevent the machine from rolling. 2. Ensure the brake system of the towing machine is sufficient to hold the combined mass of the towing machine and the disabled machine. 3. Removing the drive shafts on either side of the park brake renders the park brake inoperative.

With the engine stopped the machine hydraulic and pneumatic systems are not operative. This means there is no powered steering or braking system. NOTE:The park brake may be released mechanically but the steering system will remain inoperative. Articulation can only be obtained by disconnecting the steering cylinders hydraulic supply hoses.

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Road speed must not exceed 2 km/hr. (1.2 m.p.h.). Before towing disconnect the driveshaft between the transmission and the transfer case. With the brakes released and the drive shafts disconnected, the towing machine must be capable of steering and stopping the complete mass of the disabled machine. NOTE:Given the danger in towing a vehicle without an effective braking system it is recommended that the machine is transported on a suitable breakdown vehicle.

Towing a Machine with Operable Engine If the steering system has no fault and the engine can be run, an operator must steer the machine.

B50D 6X6 ADT

NOTE:Some oil spillage will unavoidable. Clean up any spillage as soon as possible. •

Loop the two steering cylinder T-pieces together using a suitable hose.

Releasing Park Brake for Towing Disconnecting Drive Shafts

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CAUTION

1. Machine will roll freely when drive shafts are disconnected. To prevent injury or damage, chock wheels and connect machine to towing vehicle before disconnecting drive shafts. 2. To prevent damage to transmission, disconnect front axle and middle axle drive shafts when towing a machine with an inoperable engine.

If the failure is in the transmission do not run the engine, as the engine is directly coupled to the transmission. Refer to Towing A Machine With Inoperable Engine (previous instruction). If the failure is in the transfer case, engage neutral and disconnect the driveshaft connecting the transfer case to the front differential and the driveshaft connecting the transfer case to the through drive.

be oil

2

1

If the fault does not affect the braking system the brakes can be released using the park brake hand control AFTER the wheels have been chocked.

Towing a Machine with Inoperable Steering System Use these procedure in conjunction with relevant Engine Operative or Engine Inoperative Towing Procedures detailed previously.

Remove U-joint cap screws (1) and disconnect front axle drive shaft (2) at rear of front axle. Move drive shaft aside and support to allow front axle drive shaft yoke to turn freely.

If the machine must articulate while being towed and the steering system is inoperable disconnect as follows: • •

Remove the supply hoses from the T-pieces on the left hand steering cylinder. Block off the two supply hoses using suitable plugs.

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1

2

Remove U-joint cap screws (1) and disconnect middle axle drive shaft (2) at rear of middle axle. Move drive shaft aside and support to allow middle axle drive shaft yoke to turn freely.

Mechanically Release Park Brake

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CAUTION

Machine will roll freely when park brake is released. To prevent injury or damage, chock wheels and connect machine to towing vehicle before releasing park brake.

1

4

2 3

Remove release stud (1), nut (2) and washer (3) from storage position (4). Install release stud in hole at rear of park brake actuator housing and rotate clockwise a 1/4 turn to lock into place. Install washer and nut unto release stud and tighten until park brake releases.

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CHAPTER 6. RECOVERY AND TRANSPORTATION SECTION 2. LIFTING MACHINE LIFTING POINTS The following figure details the machine lifting points: 10420 MM ONLY USE NYLON SLINGS IN FRONT TO PREVENT DAMAGE TO BONNET

4000mm Minimum

CRANE

CRANE

50D0005CFM

NOTE:Ensure that the articulation bar is installed.

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Lifting the Machine NOTE:1. The machine lifting points are indicated in red on the machine. 2. Use nylon slings in front to prevent damage to the machine.

NOTE:The crane must be moved slowly to prevent excessive swinging of the lifted machine. • •

• •

When lifting the machine the following must be done: Park the transporting vehicle next to the machine being lifted.

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WARNING

Install the articulation safety lock bar to prevent the machine from turning. •

Attach the chains to the machine lifting points and the lifting beam.

B50D 6X6 ADT

• • • •

Move the machine over the transporting vehicles trailer slowly. When the machine is directly over the transporting vehicle’s trailer lower the machine onto the trailer slowly, following the instructions of the spotters. Lower the lifting beam until the chain can be removed from the machine. Lift the lifting beam and move it away from the machine. Chock all the machine’s wheels. Secure the machine to the transporting vehicle’s trailer with chains. (See Machine tie Down points in this section).

NOTE:The lifting beam must be longer than the machine length to avoid damaging the machine and must be able to carry the total machine weight. {36 100 kg (79 586lb).} •

Attach the lifting beam to the crane.

NOTE:The crane must be able to carry total machine weight. • •

Lift the lifting beam until all the play in the chain is removed. Lift the machine until it is clear of the transporting vehicle’s trailer.

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MACHINE TIE-DOWN POINTS The following figure indicates the machine tie-down points:

50D0006CFM

NOTE:Ensure that the articulation bar is installed.

TRANSPORTING

When driving the machine onto other transportation vehicles do not install the articulation safety bar until the machine is secured.

Transporting the Machine on Other Vehicles

When the machine is lifted onto the transportation vehicle the articulation safety bar must be installed.

The machine can be loaded onto the transporting vehicle by two methods: •

•

Lifting the machine (refer to Lifting the Machine and Machine Lifting Points; previous procedure). Driving the machine.

Always chock the machine when securing it to the transportation vehicle.

Driving the Machine onto a Transporting Vehicle To drive the machine onto the transporting vehicle the following must be done:

Safety Rules 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.

• • • • • •

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Position the transporting vehicle’s trailer against the loading ramp. Drive the machine onto the trailer very slowly following the instruction of the spotter. Install the articulation safety bar. Chock all the machine wheels. Secure the machine to the transporting vehicle’s trailer with chains. Drive the transporting machine away slowly.

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CHAPTER 7

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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 6

1 WARNING DO NOT OPERATE THIS TAG MUST O NLY BE REMOVED BY TH E PERSON SERVICI NG THE MAC HINE

HOT COLD

5 4

3 50D0007CFM

Park the machine in the straight ahead position and prepare for servicing as detailed below:

n

Relieve pneumatic pressure.

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WARNING

When servicing the machine and one of the axles of the machine is raised off the ground using jacks, the wheels on at least one of the other axles must be chocked. This is because there is a risk that the machine may roll off the jacks, even if the park brake is applied.

If the following steps are not observed it could result in injury or death. • •

• • •

Shut down the engine and apply the park brake. Remove the keys from the ignition switch and attach the “DO NOT OPERATE” warning sign to the steering wheel. Install the articulation safety bar. Relieve hydraulic pressure by turning the steering back and forth 3 times. If bin is fully lowered, hydraulic pressure is automatically relieved. When raised and bin prop is installed, move bin tip lever forward and rearward 3 times to ensure that the weight of the bin is securely settled onto the bin prop.

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WARNING

•

Install wheel chocks to ensure that the machine cannot move backwards or forwards during the service.

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WARNING

1. Beware of hot fluids and components. Do not work on a hot machine. 2. Do not work on syspension hydraulic circuit unless the pressure in the system has been released by lowering the truck onto the front axle stops. • •

1

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: 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.

WARNING

Check to ensure that the bin prop is located safely inside the holder.

INSTALL THE ARTICULATION SAFETY BAR

INSTALL THE BIN PROP

n

Lower the bin until the bin prop is located safely in the holder (1).

n

iii . The hydraulic, fuel and air conditioner system pressures should only be relieved by qualified personnel.

WARNING

When the bin is raised to perform maintenance tasks, the bin prop must be installed.

The following procedures must be used to install the bin prop: •

B50D 6X6 ADT

The operator, in the cab, must control the bin operation.

1

The following procedures must be used to install the articulation safety bar: NOTE:Two people are needed to install the safety lock bar. One to turn the steering to get the two holes to align, while the other one is installing the lock bar. •

Park the machine in the straight ahead position.

2

1

2

•

•

Raise the bin high enough to allow the bin prop (1) to be hinged up to the vertical position. Use the handle (2) to raise the bin prop.

116

• •

Hinge up the retaining lug (1). Remove the pin (2) from the articulation safety bar mounting.

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4 2

2

1 1

3 • •

• •

•

Swing the articulation safety bar out and locate it in the lug (1). Fit the pin (2) through the holes to secure in position. The steering wheel must be turned so that the articulation allows the holes to align. Shut down the engine and apply the park brake Remove the keys from the ignition switch and attach the “DO NOT OPERATE” warning sign to the steering wheel. Secure the articulation safety bar back in the travelling position after the service.

LOWER AND RAISE THE BELLY PLATE To perform some maintenance tasks it is necessary to lower the belly plate for access.

Lower the Belly Plate

n

WARNING

The suspension should not be lowered with the belly plate open

NOTE:1. Clear the debris from the bottom of the machine before lowering the belly plate. 2. Use a trolley jack to lower the belly plate. The following procedures must be used to lower the belly plate:

• •

Remove the two Belly Plate securing bolts (1). Loosen the catch bolt (2) but do not remove it.

n

CAUTION

The Belly Plate is now only resting on the catch. If the catch is moved the Belly Plate will fall to the ground. • •

One person should support the belly plate. A second person should then remove the catch (3) and then assist the first person with lowering the Belly Plate (4) to the ground.

n

WARNING

The Belly Plate is very heavy. Be careful when lowering the belly plate as it can cause injury or even death.

Relieve Pneumatic Pressure Lower belly plate as described in previous procedure.

1

2

Push and hold stem of drain valve (2) on pneumatic reservoir (1). Air will discharge through drain valve under pressure. Hold stem until “hiss” stops completely. Repeat for other reservoir.

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Raise the Belly Plate The following procedures must be used to raise the belly plate:

n

1

WARNING

Be careful when raising the belly plate as it can cause injury or even death if it slips off the trolley jack. • •

Manoeuvre a trolley jack under the belly plate so that the belly plate can be safely raised. Install the bolts and remove the trolley jack.

Tilt and lower the cab

n

Fully Raised (1) - for full access to the area underneath the cab.

WARNING

Never re-use loosened cab mounting bolts. Always replace bolts after loosening.

Tilt The Cab

The machine’s cab is hinged so that it may be tilted for access to the hydraulics and transmission systems below. The cab can be raised to two different heights: .

1

NOTE:The cab tilt pump is located on the left hand side under the bonnet on the bonnet catch cross bar. • • •

Close the cab and right hand side external compartment door and open the bonnet. Mirrors to be in normal operating position. Move the directional valve handle (1) to the “Cab Raise” position.

1

Half raised (1) - for quick access to Main Hydraulic Pump, etc.

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Lower The Cab 1

• • •

• • 2

• • • •

Ensure that the area is free of obstructions. Ensure all doors are closed and mirrors are in operating position. Turn the directional valve to the “Cab Raise” position and operate the pump to lift the cab until peg has disengage from cab prop. Pull the cab prop away from engine compartment. Turn the directional valve handle to the “lowering” position. Lowering cab until properly seated. Install and torque new locking bolts. (See Chapter 1 for correct torque specifications). Ensure directional valve handle is in “Cab Lower” position. Stow the wheel nut spanner.

n

WARNING

Ensure both mountings are locked into position with new mounting bolts and nuts. Never re-use loosened mounting bolts and nuts. • • • •

•

Unscrew the mounting bolts (1) on the left hand side front and rear of cab. Insert the wheel spanner into the cab tilt pump and start pumping. Install the cab prop (2). Change the directional valve handle to the lowering position and lower the cab till cab is secure. Place directional valve lever in “Cab Raise” position.

n

WARNING

Do not work under the raised cab unless the cab prop is fitted.

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CHAPTER 7. PRE-SERVICE INSTRUCTIONS SECTION 2. RULES WHEN SERVICING GENERAL

•

Do not carry out any work on the machine unless you are trained and have the knowledge to carry out the work.

•

Service which is not carried out in the correct way may be dangerous. Make sure that you have sufficient knowledge, the correct information, the correct tools and the right equipment in order to carry out the service in the correct way. Repair or change broken tools and faulty equipment. Read all plates and decals on the machine and in the manual before you start servicing the machine. Each of the instructions contains important information about handling and servicing. Do not wear loose fitting clothing or jewellery when working on the machine. Always wear a hard hat, safety glasses, gloves, shoes and other protective articles as the job requires. When carrying out service work in the articulation area, ensure that the articulation safety bar has been installed. Always stop the engine to service the machine, unless otherwise instructed in this manual. When changing oil in the engine, fluid in the hydraulic system or transmission, remember that the oil and fluid may be hot and can cause burns. When lifting or supporting components, use equipment with a lifting capacity which is at least as great as the components. All lifting devices, for example slings and ratchet blocks, must comply with national regulations for lifting devices. BELL EQUIPMENT COMPANY will not accept any responsibility if any lifting devices, tools or working methods are used other than those described in this manual. • •

• • •

•

•

Switch OFF the batteries disconnect switch or disconnect the battery before performing maintenance on the machine. Relieve the pressure in the relevant system gradually before starting to work on a system component or assembly. All pressurised vessels must be opened very carefully. When checking for leaks, use a piece of paper or wood, do not use your hands. Never set a pressure limiting valve to a higher pressure than that recommended by the manufacturer. Only qualified personnel must adjust any valve settings. Before starting the engine indoors, make sure that the ventilation is sufficient to cope with the exhaust gases. Do not stand behind the machine while the engine is running.

DIESEL FUEL Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuel are blended to satisfy the temperature requirements of the geographical area in which they are marketed. In all cases, the fuel shall meet the following properties:

Cetane Number of 40 Minimum Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500m (5000ft). Cold Filter Plugging Point Cold filter plugging point below the expected lowest temperature or Cloud point at least 5°C (9°F) below the expected lowest temperature. Fuel Lubricity Fuel lubricity should pass a minimum of 3100 gram load level as measured by theSLBocle scuffing test.

Stop the engine before removing engine covers or similar. Make sure that no tools or other objects which can cause damage are left in or on the machine.

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Sulphur Content • •

•

Sulphur content should not exceed 0.5%. Sulphur content less than 0.05% is preferred. If diesel fuel with sulphur content greater than 0.5% sulphur content is used, reduce the service interval for engine oil and filter by 50%. Do Not use diesel fuel with Sulphur content greater than 1%.

Bio-diesel fuels may be used ONLY if the fuel properties meet DIN E51606 or equivalent specification. DO NOT mix used engine oil or any other type of lubricant with diesel fuel. Low Sulphur Diesel Fuel Conditioner When possible, use existing fuel formulations for engines used off-highway. This fuel will not require any additives to provide good performance and engine reliability. However, many local fuel distributors will not carry both low and regular sulphur diesel fuels.

Handling and Storing Diesel Fuel

n

CAUTION

1. Handle diesel fuel carefully. Do not fill the tank when engine is running. 2. DO NOT smoke while you fill the tank or service the fuel system. 3. The fuel tank is vented through the filler cap. Always replace the cap with an original filler cap.

Fill the tank at the end of each day’s operation to prevent condensation and freezing during cold weather. When fuel is stored for an extended period or if there is a slow turn over of fuel, add a fuel conditioner to stabilize the fuel and prevent water condensation.

B50D 6X6 ADT

Mark all containers properly. Dispose of all old containers and any residual lubricants they may contain.

CONTAMINATED OILS AND FLUIDS Whenever the engine oil or transmission or hydraulic fluid is changed always inspect the old oil and fluid for any signs of contamination (water and foreign matter etc.) The presence of contamination could indicate a fault in the system. The old oil and hydraulic fluid filters must also be checked for the presence of foreign matter. Always use new, clean oil, fluids and filters when replenishing the systems.

Measures to Prevent Fires There is always a risk of fire. Find out which type of fire extinguisher to use, where it is kept and how to use it. Any fire fighting equipment stored on the machine must be maintained in working order. At the slightest sign of fire, and if the situation allows, take the following steps: • • • •

Move the machine away from the danger area. Stop the engine and turn the ignition to the OFF position. Leave the cab. Start putting out the fire and notify the fire brigade if required.

Do not smoke or have a naked flame near a machine when filling with fuel or when the fuel system has been opened. Diesel fuel oil is flammable and should not be used for cleaning, use an approved solvent. Remember that certain solvents can cause skin rashes and are usually flammable. Do not inhale solvent vapour.

Contact your fuel supplier for recommendations.

Lubrication Storage Use clean containers to handle all lubricants. Whenever possible, store lubricants and containers in an area protected from dust, moisture and other contamination. Store containers on their side to avoid water and dirt accumulation.

122

Store flammable starting aids in a cool, well ventilated location. Remember that such aids (starting gas) must not be used in connection with preheating of the induction manifold. Keep the work place clean. Oil and/or water on the floor makes it slippery.

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Oil and/or water in close proximity to electrical equipment or electrically powered tools are dangerous and any spills should be cleaned up immediately. Oily clothes are a serious fire hazard. Check daily that the machine and equipment are free from dirt and oil. In this way the risk of fire is reduced and it is easier to detect faulty or loose components.

n

CAUTION

If a high pressure jet is used for cleaning, take great care as the insulation of electrical leads can become damaged even at a moderately high pressure and temperature.

n

WARNING

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Refrigerant R134a The air conditioning system contains refrigerant R134a. Servicing, refilling or emptying of the refrigerant R134a must only be done by trained and qualified service personnel.

n

WARNING

1. Refrigerant R134a can cause frostbite, if it comes into contact with bare skin. 2. The air conditioning system is pressurised. Never loosen the filling plug on the compressor or any hose and pipe unions, as an unintentional leak could result. If a leak is suspected, do not try to refill the system. Contact your BELL EQUIPMENT Representative.

Do not point the high pressure jet at personnel.

Avoid breathing in the air conditioner refrigerant and lubricant vapour or mist. Exposure may irritate the eyes, nose and throat.

Check if the electric leads have been damaged by chafing which could lead to a short circuit and fire.

The refrigerant is under high pressure and the system must be serviced by qualified personnel only. Improper service methods may cause injury.

Check that there is no damage to hydraulic and brake hoses caused by chafing.

If accidental system discharge occurs, ventilate the work area before resuming work.

n

CAUTION

Switch OFF the battery disconnect switch or disconnect the batteries, when welding on the machine.

Welding and grinding may only be done on the machine when it is placed in a clean area where there are no fuel tanks, hydraulic pipes or similar lying around. Take extra care when welding and grinding near flammable objects. A fire extinguisher should be kept handy.

Additional health and safety information may be obtained from your refrigerant and lubricant manufacturers.

Working on Painted Surfaces When welding and cutting, the paint must first be removed up to a distance of 100 mm (4") from the welding or cutting point. Paint which is heated gives off unhealthy gases. Ideally paint should be removed using sand blasting. If the paint cannot be removed using sand blasting, it must be removed in some other way for example using paint stripper or a high speed grinder. NOTE:When using paint stripper or a high speed grinder, you must use a portable air extractor, safety glasses and protective gloves.

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Working with Polymer Material Polymer materials, such as rubber and certain 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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CHAPTER 8. MENU DISPLAY UNIT AND ALPHA NUMERICAL DISPLAY The “MDU” (Menu Display Unit) and the Alpha Numerical Screen work together to make the interface of operator and machine more effective. The MDU displays the selected menu and it’s different values, while the Alpha Numerical Display gives the operator a more detailed message of what the MDU is displaying. NOTE:In the Default Menu the bottom value on the MDU (10) can be altered by the operator to display the information that the operator would prefer.

START-UP DISPLAY

1

7

2

8

COLD START

COOLAN T LEVEL

EMERGENCY STEERIN G

ENGINE FA ULT

PARK BR AKE

BR AKE PRESSUR E

BR AKE TEMP

HYDR AULIC TEMP / LEVEL

3 BATTERY CH ARGE

RETAR DER

BIN UP

TRA NSMISSION FA ULT

INTER-A XLE DIF F LOCK

DIFF LOCK / HIGH RAN GE

4 ENGINE OIL PRESSURE

30

COOLANT TEMP

20

40

50

km/h 20

60

30 mph

10

40

70

10 0 AIR PRESSURE

TRANS OIL TEMP

0

MENU

RPM

50

80

0 FUEL

NEXT

HOURS VOLTS

5

BACK

6 SELECT volts

50D1001CFM

10

1). 2). 3). 4). 5).

Alpha Numerical Display Screen. Menu Display Screen. Menu Push Button. Back Push Button. Next Push Button.

9

6). 7). 8). 9).

Select Push Button. First Line of Display; Gear Attained. Second Line of Display; Engine R.P.M. Third Line of Display; Total Machine Operating Hours. 10). Fourth Line of Display; Configurable. 24V Battery only with Machine Model Name in the Alpha Numerical Display.

NOTE:1. There are six main menus (0-E), including the default menu, each with their own submenus. 2. Software MDU 4.0 at time of writing.

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• • •

DEFAULT SCREEN

bell b50d 1

7 2 3 4 5 6

0N 7 1 2

n/min

2 31 4

2 7 . 7

volts

50D1002CFM

To change the bottom line display information in the default menu: •

Press “NEXT” button for 3 beeps until the alpha numerical display screen shows the next option.

NOTE:“Bin Tip Counter” is the first option on the options list after the 28V battery display value. •

The amount of bin tip cycles will now be displayed on the bottom line.

NOTE:The value displayed on the default menu when the machine is switched off, will be displayed as the default menu when switched on again. The following list are the options in sequence: • • • • • • • • • • • • • • • • • • • • • •

BINTIP COUNT TRIP KM TRIPTIME MIN TRIPFUEL L/H TRIPLOAD ODO KM LCKUP CLUTCH CURRENT GEAR TRANS TEMP C RET TEMP C RETADER TORQ ENG TEMP C ENG PRES BAR BOOST PRESS KPA ENG OIL LVL FUEL CON L/H ACTUAL TORQ ENG RET TORQ FUEL L AIR PRES BAR HYD TEMP C BRAKE TEMP C

126

B50D 6X6 SDT

PAYLOAD XXHXXMXXS XX-XX-XXXX

NOTE:1). To scroll from one option in the default menu to the next option, just press “Next”. 2). It is only necessary to press and hold the “Next” button for 3 beeps after the machine was shut down and restarted and the operator wants to change the setting of the last line on the display screen. 3). A corresponding message will be displayed on the Alpha Numerical Display Screen for the option selected.

TO SELECT BETWEEN MENUS Press the “MENU” button to select the next menu.

Menu Option “A” To get to menu “A0” from the default menu, press “MENU” button. The following screen display will appear:

COUNTERS

a 0

REV4D1001CFM

In menu “A0” there are 4 sub menus and 5 subsub menus in sub-menu “A1” and 1 sub-sub menu in menu “A2”. To go to sub-menu “A101”: Press “Select”. To scroll between sub-menus “A101 to A105”, press “NEXT” press button or “BACK” to get to the previous menu. To get back to menu “A0”, press and hold “BACK” for 3 beeps or more.

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The following values are in the sub-menus: Menu “A1” : TRIP INFO, Menu “A2” : BINTIP COUNT, Menu “A3” : ODO KM, Menu “A4” : MACHINE HRS.

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To keep the value, press “BACK” to go to the previous menu. Sub-menu “A1” has 5 sub-sub menus. Menu “A101” Menu “A102” Menu “A103” Menu “A104” Menu “A105”

TRIP INFO

: TRIP KM RESET?, : TRIPTIME MIN RESET?, : TRIPFUEL L/H RESET?, : TRIPLOAD RESET?, : RESET ALL?.

When in menu “A0” and you want to go to menu “A2”, Press “SELECT” and then “NEXT”.

a

Sub menu “A2” has one sub-sub menu: “A201” : RESET?

1

To keep the value and not change it, Press “BACK” push button for 3 beeps or more.

000000 Km

REV4D1002CFM

NOTE:When in a sub-menu and the “BACK” press button is pressed for 3 beeps or more, the system will go back to menu “A0”. To reset a value in this sub-menu: Press “SELECT” push button to go to the sub-sub menu.

To reset the value in menu “A2”, Press “SELECT” to go to sub-sub menu “A201” and press “SELECT” again. The system will go back to the sub-menu and the value will be reset to “ZERO”. NOTE:Menus “A3” and “A4” cannot be reset.

Menu “B” Actual Values The same procedure is followed to go into Submenus as for Menu “A”. Menu “B” has three sub menus.

The Sub-sub menu will now appear.

“B1” : ENG VALUES, “B2” : TRANS VALUES, “B3” : VEHICLE VAL

TRIP KM RESET?

Sub-menu “B1” has eleven Sub-Sub-menus.

a 101

000000

“B101” : ENG. PRES. BAR “B102” : BOOST PRESS KPA “B103” : ENG. TEMP. C “B104” : THROTTLE POS “B105” : ACTUAL TORQ “B106” : ENG RET TORQ “B107” : ENG OIL LVL “B108” : FUEL CON (L/H) “B109” : ENG OIL TEMP C “B1010”: FUEL TEMP C “B1011”: INTAKE MANIFOLD TEMP C

REV4D1003CFM

When in a sub-sub menu and “SELECT” is pressed and hold for fifteen beeps, the system will select or reset that value in the sub menu.

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Sub-menu “B2” has five Sub-Sub-menus. “B201” “B202” “B203” “B204” “B205”

: TRANS TEMP C : LCKUP CLUTCH : CURRENT GEAR : RETADER TORQ : RET TEMP C

Sub-menu “B3” has five Sub-Sub-menus. “B301” “B302” “B303” “B304” “B305”

: AIR PRES BAR : FUEL L : BIN POS : HYD TEMP C : BRAKE TEMP C

The only other two menus that realy concerns the perator is MENU D2, INTERMITTENT WIPER TIMING and MENU D607, HOPPER SITE.

B50D 6X6 SDT

If set to “ON”, the truck can be driven up to 5 km/ h. If the travel speed exceeds 5 km/h and the truck is stopped the auto zero routine will be executed. If the truck has been driven for more than one minute at a speed of higher than five Km/h, the load will be frozen and any load added to the bin after weight has been frozen will not be added to the pay load. This allows the truck to creep forward and not to go into the auto zero function after coming to a standstill. If set to “OFF”, the moment the truck comes to a standstill, the park brake is applied and the transmission is in neutral, the auto zero routine will be executed.

Menu “D” Machine Conf.

To set Hopper Site “ON” or “OFF”, scroll to Menu D0.

The same procedure is followed to go into Submenus as for Menu “A”.

Press “SELECT” to goto MENU D1. Press next until Menu “D6” appears (OBW).

Menu “D” has eight sub menus;

Press “SELECT” to go to MENU “D601”. Press “NEXT” 6 times to go to MENU “D607”, HOPPER SITE. Press “SELECT” to go to MENU “D6071” “HOPPER SITE” “ON”. Press “SELECT” and hold for 3 beeps to select hoppe site “ON” or press “NEXT” to go to MENU “D6072” (HOPPER SITE OFF). Press “SELECT” and hold for three beeps to turn Hopper Site to OFF.

“D2” : WIPER TIMING Sub-menu “D2” has eighteen Sub-Sub-menus. “D201” through “D218” (From 3 seconds to 20 seconds) Scroll to Menu “D0”: Press Select button to choose MENU D1, then press “NEXT” to go to MENU “D2”, WIPER TIMING, Press SELECT again to go to MENU “D201”. To change this value, Press next for the next longer value or back for the previous lower value. On the desired value, press and hold SELECT button for three beeps. The selected timing will now be displayed in the window.

Scroll back to default menu.

Trip Load This option on the default menu gives the accumulated weight in metric tons since the last reset of the “Trip Load”. (Example: If the trip load was reset in the morning and has done 10 trips for the day; it will display the total amount of tons moved for the ten trips).

Press “BACK” for 3 beeps to go to MENU “D2” and BACK again to got to MENU “D1”. Press “BACK” for 3 beeps to go to MENU “D0”.

MENU D607 (Hopper Site) Use this function when loading at hopper sites. Hopper site “ON” must be selected. Stop the truck and allow system to auto zero before loading. (See “Pay Load” on page 129).

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Pay Load This value is displayed in the “Payload Menu”. It is the actual load on the bin. If the bin is empty, the value displayed will be “0”.

n

CAUTION

For accurate On Board Weighing measurements it is important to allow the Auto Zero function to complete the auto zero routine before loading the truck. The truck must stand still (Speed zero); The Park Brake Applied (On) and the transmission must be in “N”. After the Auto Zero routine is complete, the MDU will beep and the loading of the truck can begin.

The “Pay Load” is measured automatically by the “On Board Weighing System”. When the truck starts moving and has been travelling for more than 1 minute at a speed of more than 5 Km/h, the on board weighing system controller will freeze the weight that it recorded and if any weight is added after “freeze” it will not be recorded and added onto the recorded freeze pay load.

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The “On Board Weighing System” has an “Auto Zero” routine. This routine will record the reading at “Power-up” and when the truck comes to a stand still and wait for a stable reading from the “On Board Weighing System Controller”. When the auto zero mode is activated, “Auto Zero” will be displayed on the Alpha Numerical display Screen of the MDU. The raw weight will be displayed on row 4 of the LCD. After a successful auto zero the MDU will beep once and return to weight measuring. NOTE:If the MDU measures a difference of more than one tonne since starting the Auto Zero Routine, or the truck starts moving, or the bin starts tipping, the auto zero routine will be abandoned and the previous zero measurement is used. To cancel the freeze value and start recording a new pay load measuring, the bin must have been fully tipped. This will reset the payload to zero.

On Board Weighing System (OBW) The OBW weighs the load as it is loaded onto the bin. It automatically add up the weight as it is loaded.

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CHAPTER 9. SERIAL NUMBERS NUMBERS

Engine Serial Number

Product Identification Number (P.I.N.)

1

1

Engine serial Number (1) ________________________ P.I.N. (1)________________________________

Transmission Serial Number Vehicle Identification Number

1 1

V.I.N. (1)________________________________

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Transmission Serial Number (1) ________________________

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Front Axle Serial Number

B50D 6X6 ADT

Rear Axle Serial Number

1 1

Front Axle Serial Number (1) ________________________

Middle Axle Serial Number

Rear Axle Serial Number ___________________________

Front Differential Serial Number

1 1

Middle Axle Serial Number (1) ________________________

132

Front Differential Serial Number (1) ________________________

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Middle Differential Serial Number

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Keep your documented identification numbers, photographs and inventory in a safe and secure location.

Park Indoors And Out Of Sight Make machines hard to move. Park large equipment in front of exits. Remove keys. Remove batteries when in storage.

1

Lock cab doors, windows and latches. Middle Differential Serial Number (1)_________________________

Lock the building.

When Parking Outdoors

Rear Differential Serial Number

Make machines hard to move. park in well-lighted, fenced area. Lower all equipment to the ground.

1

Remove ignition keys. Remove batteries when machines is in storage Lock cab doors, windows and latches.

Rear Differential Serial Number (1)_________________________

CRIME PREVENTION TIPS Keep proof of ownership Mark the machine numbering system.

with

your

own

unique

Take photographs from several angles of your machines. Maintain an machines.

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inventory

of

your

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CHAPTER 10. 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 Details

Daily

Every 500

Every 1000

Every 2000

Every 4000

As Required

ENGINE For further maintenance and service procedures, refer to the Mercedes-Benz OM 502LA Manual. Change the oil and oil filters

X

X

Drain water from the primary fuel filter check cold, drain before starting).

X

X

Change the fuel depth filter.

X

Change the primary fuel filter/water separator.

X

Change secondary fuel filter. (Situated on engine).

X

Clean/replace the primer pump fuel screen.

X

Clean crankcase breather filter.

X

Check the coolant level.

X

Check the coolant mixture.

X (A)

Change the coolant.

X (A)

Adjust the valve clearance. (Every second oil change).

X

Replace fuel tank breather filter.

X (E)

Replace both fan belts.

X (D)

X

Check fan belt condition & replace if necessary.

X

Change the air cleaner primary filter.

X

Change the air cleaner secondary filter.

X

Clean the air intake pre-cleaner assembly.

X

Check the air cleaner service indicator. Check the oil level,.

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X X

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Maintenance Schedule in Running Hours Details

Daily

Every 500

Every 1000

Every 2000

Every 4000

As Required

TRANSMISSION-ALLISON HD Check for oil leaks.

X

X

Check transmission oil level.

X

Change the oil.

X

Change the filters.

X (B) X

Check and clean transmission breather.

X

TRANSFER CASE Change the oil filter.

X

Check the oil level. (Sight Glass).

X

X

Change the oil.

X (B)

Check and clean transfer case breather.

X

HYDRAULICS Check the oil level.

X

X

Change the oil.

X (B)

Change the return filters.

X (E)

Change the breather filter.

X (E)

X (D)

X (D)

Replace the suction screens.

X

Test the brake accumulator function.

X

AXLES AND CHASSIS & SUSPENSION Change the oil in all axles, wet disc brakes and clean debris from all magnets.

X

Replace through drive differential axle oil filter.

X

Clean intermediate diff. oil strainer.

X

Check the park brake pads wear.

X

Check and adjust bin shock pad clearance

X (H)

Check conditions of all drive shafts. Check and clean breathers of all axles.

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X X

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Maintenance Schedule in Running Hours Details

Daily

Every 500

Every 1000

Every 2000

Every 4000

As Required

CAB, PNEUMATICS AND ELECTRICAL Change the air drier filter.

X

Check the operator controls, buzzers and instruments.

X

X

Check the working lights, reverse buzzer and horn.

X

X

Check the electrical connections and wire routings for chaffing.

X

Replace Pneumatic block breather filters (situated on block)

X

Record and clear fault codes found on the MDU

X

Clean or replace air conditioner filters.

X (C)

X

LUBRICATION Grease the hinges

X

Grease all remaining lube points. (If applicable). Check the grease level in the auto greasing system.

X X

X

Change the auto greasing filler filter.

X

Grease PTO propshaft front U-joint.

X (G)

GENERAL WALK ROUND Check and clean coolers.

X

General check of driveline & suspension fasteners. Check for fuel, water and oil leaks. Check tyre pressures

X X X

X

NOTES: A B C D E F G H

Refer to bulletin 2000/033 regarding water & coolant specification Change intervals can be extended by oil sampling. Use kit 261677 for sampling the Allison transmission and axles and final drives. Daily depending on site conditions. To be changed in wet & muddy conditions.(Note service kit applicable for this condition). To be changed in dry & dusty conditions. (Note service kit available for this condition). Refer to SIB 2004/1018. Grease should meet DIN 51825 KP2-R-20, and not contain any solids such as Graphite or Molybdeendisulphide. See SIB 97/105/07 for details of thickness.

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Torque all wheel nuts to 650 Nm. (480 ft lb.) after the first 5 hours of operation and again after 50 hours of operation. Repeat the procedure if the wheels are changed. The air conditioner internal filter should be cleaned every 50 hours (or as required, depending upon conditions) and replaced if damaged. The air conditioner external filter should be cleaned every 250 hours (or as required, depending upon conditions) and replaced if damaged.

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CHAPTER 11. 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 OM 502LA Check the alternator for security.

Check the Components

Engine

Compartment

Perform a general, visual check on the engine and components in the engine compartment as follows: NOTE:Photo taken without mounting for clarity.

Check all electrical connections to alternator for proper tight installation.

engine

1

1

Ensure that the starter motor (1) is mounted securely and not damaged. Ensure all battery cables are tightly fastened on the starter motor, earth bosses and batteries. Ensure that the pipes and hoses and all linkages are secure and not damaged.

Check the air conditioner compressor pump (1) for cracks and security. Inspect the alternator, air conditioner compressor and water pump drive belt for cracks, fraying, wear and tension.

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1

1

2

Check the transmission breather (1) for cleanliness and security. Ensure that the transmission breather pipe is secure.

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

2 1 1

Check the exhaust brake valve (1) and linkage for damage and security.

2

Check the air pipe (2) 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 and not damaged.

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4

1

1

5 3

Check the transmission cooler (1) for damage and security. 2 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. Check the radiator fins for damage and cleanliness. Ensure that there is no restriction to the air flow. Check the fan cowling (4) for damage and cracks.

Check the hoses and clamps for damage and security.

Clean Cooling System Turn battery disconnect switch OFF.

n

CAUTION

Use a pressure washer and a mild detergent that is not caustic to aluminium. Do not spray cooling system fins at an angle. Fins may bend.

Ensure that the mounting bolts and fan guard (5) are secure. Raise hood and wash front cooling system, spraying from the engine side to the front. Remove access covers and wash hydraulic cooling system from the fan side out. Clean cooling systems and grilles and keep them clean.

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.

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Check all Hoses and Clamps Visually inspect all the hoses in the engine compartment for leaks, cracks, deterioration and chafing damage. Ensure that the hoses are routed correctly, all securing straps are functional and undamaged. Check that the hoses are fastened in the correct position and no chafing can occur when the machine is in use. 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. Check that the cables and wires are fastened in the correct position and no chafing can occur when the machine is in use. Check all the electrical connections in the engine compartment to ensure that they are secure.

Check the Wiring 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 exhaust stack, mounting bolts and clamps for security and damage as well as the heat shields.

Check the Engine Components (External) Check the exhaust pipes and mounting bolts and clamps for security and damage.

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Check The Air Cleaner 7

2

1

6

3 1

4

Check the level of the dirt in the bowl, if it reaches the level (1) marked on the bowl, the bowl must be cleaned.

5 Check the air cleaner assembly for damage to the air cleaner (1) and pre-cleaners (2 & 3).

Clean the Air Cleaner Pre-cleaner Bowls

Check the rubber elbow (4) and connecting pipes (5), clamps (6) and mounting bolts for security and damage.

1

Check service indicator (7) for damage.

2

Check that the service indicator is not showing a red flag, re-set if necessary.

3

Remove the wing nut (1) securing the lid (2) to the bowl (3).

1 2 1 Check that the vacuator valves (1 & 2) is undamaged and free from obstruction. 2

3

Remove the lid (1) and bowl (2) from the precleaner body (3). Remove the dirt from the bowl and clean the bowl with a lint-free cloth.

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Install first the bowl then the lid onto the precleaner body and secure them with the wing nut.

1

Check the Air Cleaner Service Indicator

1

Remove the primary filter element (1) from the air cleaner housing. Discard the primary filter element, do not re-use.

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.

Change the Primary Filter Element

Clean the air filter housing inside and the end cover with a damp cloth and inspect for damage. Install the new primary filter element into the air 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. Check the end cover to ensure that it is fitted correctly with the arrows pointing up.

Change the Secondary Filter Element 1

NOTE:At minimum, secondary element must be replaced every third time primary filter is replaced.

1 1 Loosen the clips (1) and remove the end cover from the air cleaner housing.

Remove and inspect secondary element (1). Replace if necessary.

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Wipe housing clean with a lint free cloth. Squeeze unloader valve to empty air cleaner housing of dust and debris. Install secondary filter element, ensure that it is evenly and firmly seated. Install primary filter element, ensure that it is firmly and evenly seated. Install air cleaner cover and fasten clasps. Press top of service indicator to reset flag.

Drain the Racor Fuel Filter

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Inspect Tires and Check Pressure

n

WARNING

Improperly inflated tires can cause excessive heat built-up, excessive or uneven tire wear, rim damage resulting in blowouts.

Ensure that valve caps are installed. Check for wear and cuts to tires. If in doubt, consult your local authorized dealer. (See decal for pressures).

2

1

Connect a pipe to the outlet (1) and hang the other point in a container. Loosen the nut (2) on the Racor fuel filter. Drain the accumulated water. Tighten the wing nut when fuel flows out water free. Remove the pipe.

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CHAPTER 11. AS REQUIRED SERVICE SECTION 2. HYDRAULICS CHECK THE BREATHER, HOSES AND CONNECTIONS

Check the Tip Cylinders, Hoses, Pipes and Connections 3 2

1 4

1 Check the tip cylinders (1) for damage and leaks. Check breather (1) for damage and security. Check that the hoses and connectors are secure and not damaged.

Check the Steering Cylinders, Hoses and Connections

Ensure that the connections (2), pipes (3) and hoses (4) are secure and undamaged.

Check the Main Hydraulic Pump, Hoses and Clamps

3

3

2

1

1

Check both of the steering cylinders for damage and leaks and ensure that the mountings are secure. Ensure that the hydraulic hoses and connections (1) are secure and undamaged.

Check the main hydraulic pump mounting bolts (1), connections (2) and hoses (3) for security. Check the hoses and connections for damage and leaks.

Check that the lubrication hoses are secure and not damaged.

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Check the Emergency Steering Pump, Hoses and Clamps

B50D 6X6 ADT

Axles and Chassis Inspect all pipes, hoses, clamps and connections on the axles and differentials for security.

3 Ensure that the hoses cannot chafe against moving parts.

2

Check all the axles for damage and security. 1

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.

3

Ensure that the walking beam and joints are not damaged and that the securing bolts are secure.

Check the emergency steering pump (1) mounting bolts, connections (2) and hoses (3) for security. Check the hoses and connections for damage and leaks.

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CHAPTER 12. DAILY OR 10 HOURLY SERVICE CHECKS SECTION 1. ENGINE INTRODUCTION 2

The daily or 10 hourly service checks must be performed by qualified service personnel. It is recommended that the daily or 10 hourly service checks are performed in conjunction with the Walk Round Checks so that the operator can assist in the service checks which require two people.

SERVICE INSTRUCTIONS Ensure that the machine is in the service position. Refer to Pre-service Instructions, Chapter 7.

Engine NOTE:For further engine information or details not shown in this manual, refer to the Mercedes-Benz Manual OM 502LA.

1

Remove the dipstick and check that the oil level reaches the upper mark (1) on the dipstick. NOTE:When the oil is hot, the oil level must be on the top mark (1) of the dipstick, but not above it. When the oil is cold, ensure that the level is between marks (1) and (2), but not below mark (2).

Open the bonnet. Check the bonnet catch for damage and ensure that the bolts are secure.

Check the Oil Level

Re-insert the dipstick, ensuring that it is properly seated and fasten the dipstick clip. If necessary, replenish the engine oil.

Check the Coolant Level 1

n

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.

Remove the dipstick (1). 1 Wipe the dipstick clean with a lint free cloth. Re-insert the dipstick, ensuring that it is properly seated.

The coolant must be between the maximum and minimum marks on the sight glass (1).

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n

CAUTION

When coolant is drained from the cooling system, it must be replaced with the recommended coolant specified by the manufacturer.

B50D 6X6 ADT

Check Engine Air Intake System 1

2 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.

1 3 5 6

4

Check air cleaner assembly for damage to the precleaner (1) and air cleaner housing (2). Check the service indicator (3) is not showing a red flag. If red flag is shown; service air cleaner and reset indicator. (See Service Engine Air Intake System in Maintenance - As Required Section). Check rubber elbows (4), clamps (5) and pipes (6) for tightness, cracks or damage.

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CHAPTER 12. DAILY OR 10 HOURLY SERVICE CHECKS SECTION 2. TRANSMISSION TRANSMISSION Check the machine for oil leaks in the region of the transmission.

Push-button Check-(Electronic Transmission Fluid Level Check) The electronic method of checking the transmission fluid level incorporates a fluid level sensor to display the fluid level on the shift selector. The electronic method compensates for transmission temperature between 65°C to 104°C (149°F to 220°F). Any temperature below 65°C (149°F) or above 104°C (220°F) will result in an Invalid for Display condition.

1

The normal operating temperature of the transmission fluid is 71°C to 93°C (160°F to 200°F), measured at the transmission sump. The reading obtained on the digital analogue will show the temperature measured at the transmission convertor out. Note that this temperature is normally higher than the sump temperature. The following procedure must be used to check the transmission fluid level using the push-button shift selector: • •

•

Press the (UP) and (DOWN) arrow buttons (1) simultaneously.

NOTE:The fluid level check may be delayed until the following conditions are met:

Ensure that the machine is parked on a level surface and the park brake is applied. Allow the engine to run at idle in N (Neutral).

• The fluid temperature is above 65°C (149°F) and below 104°C (220°F). • The transmission is in neutral. • The machine has been stationary for approximately two minutes to allow the fluid to settle. • The engine is at idle. • The transmission output shaft is stopped. NOTE:The indication of a delayed fluid level check is a flashing display and a digital countdown from 8 to 1. • •

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Check the characters displayed. The fluid level information is sequentially displayed on the digital analogue as in the following examples.

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Correct Fluid Level “O” then “L” are displayed (“OL” represents Fluid (oil) Level Check Mode), followed by “O” then “K” (“OK” represents Oil Level is “OK”). The sensor display and the transmission dipstick may not agree because the oil level sensor compensates for fluid temperature. NOTE:1 quart is approximately equal to 1 litre. Low Fluid Level “O” then “L” are displayed (“OL” represents ‘Fluid (oil) Level Check Mode’), followed by “L” then “O” (“LO” represents Low Oil Level) and the number of quarts that the transmission fluid is low e.g. “0” then “2” indicates 2 additional quarts/litres of fluid will bring the fluid level within the middle of the “OK” zone.

B50D 6X6 ADT

High Fluid Level “O” then “L” are displayed (“OL” represents Fluid (oil) Level Check Mode), followed by “H” then “I” (“HI” represents High Oil Level) and the number of quarts that the transmission is over filled e.g. “O” then “1” indicates 1 quart/litre of fluid above the full transmission level. Replenish or drain the transmission fluid as required. Refer to Change the Transmission Fluid and Filter (next instruction in this Chapter). NOTE:The maximum Low Oil Level and High Oil Level values are “04”. If the transmission fluid level is lower or higher than 4 quarts/litres, the fluid level will have to be checked twice to obtain the correct reading. If a condition occurs which prevents the display of fluid level information, the Invalid for Display will show the reason as follows: Invalid for Display “O” then “L” is displayed (“OL” represents Fluid (oil) level Check Mode), followed by a numerical display. The numerical display is a fault code and indicates conditions are not correct to receive the fluid level information, or that there is a system malfunction. The numbers are fault codes.

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The fault codes are as follows: Reading

Result

Action

OL OK

Oil Level OK

None: Check complete

OL Lo

Oil Level Low

Add the number of litres of oil indicated by “#”

OL Hi

Oil Level High

Drain the number of litres of oil indicated by “#”

OL 0X

Setting time too short

Allow oil to settle by letting machine idle in neutral for several seconds

OL 50

Engine Speed (r.p.m.)too low

Increase engine speed

OL 59

Engine Speed (r.p.m.)too high

Reduce engine speed

OL 65

Neutral not selected

Select neutral and repeat the check

OL 70

Sump oil temperature too low

Operate machine under light load until temperature is within range. Partially raise bin to disengage side cooling fan while performing check.

OL 79

Sump oil temperature too high

Run engine at slow idle until temperature is within range. Inspect and clean side cooling system. (See Inspect and Clean Cooling System in Maintenance As Required Section

OL 89

Output shaft is rotating

Stop machine and engage park brake. If park brake does not hold machine, Refer to BELL EQUIPMENT Product Support.

OL 95

Sensor failure

Refer to BELL EQUIPMENT Product Support.

Correct the problem as indicated above. When all the conditions have been met, the countdown resumes where it stopped. NOTE:Report sensor failure or any problem you are having difficulty with to your nearest BELL EQUIPMENT representative. •

•

To exit the fluid level display mode, press either the D, N or R button on the shift selector. Perform a general, visual check on the transmission and components.

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CHAPTER 12. DAILY OR 10 HOURLY SERVICE CHECKS SECTION 3. TRANSFER CASE CHECK THE TRANSFER CASE FLUID LEVEL

1

Check the transfer case fluid level at the sight glass (1). Drain or add oil as necessary. (See Change Transfer Case Oil in 2000 hours service).

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CHAPTER 12. DAILY OR 10 HOURLY SERVICE CHECKS SECTION 4. HYDRAULICS, CAB AND ELECTRICAL HYDRAULICS

•

Check the Hydraulic Fluid Level Ensure that the bin is in the lowered position.

• • •

Apply the service brakes repeatedly to make the pump re-charge a few times. Discontinue applying the brakes in a re-charge cycle while the pump is still charging (to ensure the brakes are not consuming oil after the pump stops, wait 4 seconds while listening to the engine. Engine revolutions must go up after pump stops). Switch off the engine. Switch the ignition on an wait until the warning lights extinguishes. Fully apply the service brakes and count the number of applications before the accumulator low pressure light illuminates.

2

NOTE:If less than two full applications, have the system checked by a BELL EQUIPMENT serviceman.

1

Cab and Electrical Check the Instruments

Operator’s

Controls

and

Carry out a functional check on all controls and instruments daily. Refer to Chapter 2 - Operator Control and Instruments.

Check for error codes on the MDU. If necessary, Contact Bell Equipment Service Department. Check all Working Lights, Reverse Buzzer and Horn Check the hydraulic fluid level in the sight glass (1). The fluid level must be on the mark (2) with the engine shut down and the machine parked on level surface. If necessary replenish the fluid in the hydraulic tank. Refer to Specifications, Chapter 1 Recommended Lubricants and Coolants.

Service Brake Accumulator Routine Test •

Two people are needed to perform this check. One person inside the cab to control the switches and the other outside to ensure all the lights are working. Refer to Specifications, Chapter 1 Recommended Lubricants and Coolants. •

•

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

Start engine. Wait until main pump has fully charged the accumulators (Listen to the tone of the engine, while charging the engine revolutions will be lower).

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Check the Head lights - Bright and dip to ensure bulbs are working. 1

Check rear lights - tail, brake and indicators. Check bin switch for damage.

Ensure that the reverse buzzer (1) is securely mounted.

Functionally test the horns and ensure that they are securely mounted.

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CHAPTER 12. DAILY OR 10 HOURLY SERVICE CHECKS SECTION 5. LUBRICATION AUTO GREASING SYSTEM The system can be selected for Standard, Low, Normal and heavy duty cycles via a switch inside the cab. (See Chapter 2, Section 3, Switches). All the grease points are connected to the auto grease pump. NOTE:To ensure trouble free operation, it is advised that a daily inspection (before start-up) is undertaken of the lube points served by the Auto Greasing System. A “Dry” point will indicate damage to the grease lines or specifically of one of the metering units.

1

2

The pump and reservoir is located on the right hand side of the truck between the mudguard and the chassis. The reservoir is refilled via a grease nipple (1) on the side of the unit. The pump Test/Reset button (2) is situated on the pump, next to the filler nipple.

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INDEX

A ABBREVIATION LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23 ACCELERATOR AND BRAKE PEDALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54 AIR CONDITIONER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75 B BRAKING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95 BULLETINS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41 C Cab and Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159 CHAPTER 1. SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45 CHAPTER 2. OPERATOR CONTROL AND INSTRUMENTS - - - - - - - - - - - - - - - - - - 53 CHAPTER 3. PROCEDURES BEFORE STARTING - - - - - - - - - - - - - - - - - - - - - - - - - 83 SAFETY INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83 CHAPTER 4. OPERATING INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87 Safety Rules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87 CHAPTER 5. OPERATING TECHNIQUES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101 SAFETY RULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101 CHAPTER 6. RECOVERY AND TRANSPORTATION - - - - - - - - - - - - - - - - - - - - - - 107 CHAPTER 7. PRE-SERVICE INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - 115 CHAPTER 8. MENU DISPLAY UNIT AND ALPHA NUMERICAL DISPLAY - - - - - - - 125 CHAPTER 9. SERIAL NUMBERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131 CHAPTER 10. MAINTENANCE SCHEDULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - 137 CHAPTER 11. AS REQUIRED SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141 CHAPTER 12. DAILY OR 10 HOURLY SERVICE CHECKS - - - - - - - - - - - - - - - - - - 151 CHECK THE TRANSFER CASE FLUID LEVEL - - - - - - - - - - - - - - - - - - - - - - - - - - - 157 CIRCUIT BREAKER PANEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77 D Daily Walk Round Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85 DECALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 DECELERATION AND STOPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94 DIESEL FUEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 121 Differential Lock - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96 Downhill Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103 Driving - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93

163

INDEX

F FIRE EXTINGUISHER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81 FUSES AND DIODES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78 G Gear Hold Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73 Gear Shift Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60 Gear Shifting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93 H High/Low Range Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72 HORNS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 HYDRAULICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159 I INDICATORS Bin Raised - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68 Inter-axle Differential Lock - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68 Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65 Inspect Tires and Check Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147 INSTALL THE ARTICULATION SAFETY BAR - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116 INSTALL THE BIN PROP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116 INSTRUMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53 L LIGHTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76 LOADING THE MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99 LOWER AND RAISE THE BELLY PLATE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117 Lower The Cab - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119 Lowering the Bin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99 LUBRICANTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 M Machine Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48 MACHINE LIFTING POINTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111 MACHINE TIE-DOWN POINTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 113 Mechanically Release Park Brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 109 MENU DISPLAY SCREEN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64 MISCELLANEOUS EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 79

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INDEX

O Off-road Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 104 OPERATING INDOORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 100 OPERATOR’S SEAT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55 Overnight Parking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 100 P Park Brake Control Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59 R Racor Fuel Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147 Raising the Bin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99 RELAYS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 79 Relieve Pneumatic Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117 Retarder Switch/Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Retarders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94 RULES WHEN SERVICING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 121 S SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 Material Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 Protective Clothing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29 Unauthorised Modifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 SCREEN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126 SERIAL NUMBER PLATES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52 Service Brake Accumulator Routine Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159 Service Capacities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47 SERVICE INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141 SERVICE POSITION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115 Start Button - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 74 Starting the Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89 START-UP DISPLAY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 125 STEERING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99 STEERING WHEEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54 Stuck Machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 105 Rocking Out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 106 Sulfer Content - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 122 SWITCHES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

165

INDEX

T Tilt and lower the cab - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 118 Tip Control Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59 TORQUE SETTINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50 Towing a Machin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 107 TRAINER SEAT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 TRANSPORT OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103 TRANSPORTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 113 Travel Speeds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47 Tyre Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31 U Unloading - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 105 Uphill Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103 USING BOOSTER BATTERIES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 W WINDSCREEN WASHER WATER RESERVOIR - - - - - - - - - - - - - - - - - - - - - - - - - - - 80

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