Troubleshooting engine issues

SECTION 7.
TROUBLE SHOOTING
873506 - REV 00 SECTION 7. TROUBLE SHOOTING 7-1

April 19, 2001
7-2 SECTION 7. TROUBLE SHOOTING 873506 - REV 00
April 19, 2001
CHAPTER 32. TROUBLE SHOOTING
1. Introduction
The following chapter lists the possible problems that could occur with the machine, engine, transmission and
components.
Note: These lists are not exhaustive. If in doubt contact your BELL Customer Support Representative.
Engine Difficult to Start
Symptom Possible Cause Remedy

Starter motor turns engine too slowly Battery under charged Check the battery charge. Recharge or re-
place the battery
Loose or dirty battery terminals Tighten or clean the battery terminals
Faulty engine earth connection Repair, clean or secure the connection
Incorrect grade of engine lubrication oil Change the oil. Refer to Section 1. General
Information, Chapter 1. Specifications, 2.
Recommended Fuel, Lubricants and
Coolant Additives
Residual hydraulic load present Check for hydraulic pressure build up at any
hydraulic test point on the machine.
Engine hard starting when cold Engine starter motor turns engine too slowly Check the battery charge. Recharge or re-
place the battery
Engine turns but does not start Insufficient fuel in fuel tank Fill fuel tank and bleed fuel system
Engine difficult to start (hot or cold) Starter motor turns too slowly Check the battery charge. Recharge or re-
place the battery
Air in the fuel system Bleed the fuel system
Restricted air inlet Service air filter system
Restricted exhaust system Locate and repair the restriction
Engine cuts out soon after starting Insufficient fuel in the fuel tank Fill the fuel tank and bleed the fuel system
Air in the fuel system Bleed the fuel system
Blocked fuel tank air vent Clean out the air vent and bleed the fuel sys-
tem
Blocked fuel filters Replace the fuel filters
Air filter restriction Service the air filter system
Exhaust restriction Locate and repair the restriction
Engine Difficult to Start

Loss of power Air filter restriction Service the air filter system
Engine does not attain the required speed Tachometer error Re-calibrate the tachometer. Contact your
during daily brake test BELL Customer Support Representative.

April 19, 2001
Engine Lacks Power

Engine overheating Water level too low Top up the radiator. Check for leaks and re-
pair
Drive belt slipping Inspect, adjust or replace the drive belts
Radiator filler cap not sealing or worn Fit new radiator filler cap
Blocked radiator Clean radiator
Engine running too cold Temperature gauge faulty Check temperature gauge. Contact your
BELL Customer Support Representative.
Incorrect fan fitted Check the manufacturer’s specification. Con-
tact your BELL Customer Support
Representative
Incorrect radiator fitted Check the manufacturer’s specification. Con-
tact your BELL Customer Support
Representative
Engine knocking Incorrect fuel grade Drain and refill if necessary
Excessive Fuel Consumption

Excessive fuel consumption External fuel tank leak Check the fuel tank, fuel lines and filter for
leaks and/or damage
Too low operating temperature Check and repair cooling system
Air filter restriction Service the air filter system
Defective cold start function Contact your BELL Customer Support Rep-
resentative
Low Engine Oil Pressure

Low Engine Oil Pressure Faulty pressure gauge Check gauge. Contact your BELL Customer
Support Representative.
Incorrect grade of oil used Refer to Section 1. General Information,
Chapter 1. Specifications, 2. Recom-
mended Fuel, Lubricants and Coolant
Additives
Abnormal Oil Consumption

Abnormal Oil Consumption Engine overfilled Instruct operator on correct oil level mainte-
nance
Engine oil leaks Locate and repair oil leaks
Incorrect grade of engine oil Refer to Section 1. General Information,
Chapter 1. Specifications, 2. Recom-
mended Fuel, Lubricants and Coolant
Additives
Incorrect operating temperature Check the cooling system and repair

April 19, 2001
Abnormal Oil Consumption

Oil pressure too high Incorrect engine oil used Drain the engine sump. Refer to Section 1.
General Information, Chapter 1. Specifi-
cations, 2. Recommended Fuel,
Lubricants and Coolant Additives
Faulty pressure gauge Check gauge. Contact your BELL Customer
Support Representative
Internal Engine Oil Sludge

Engine oil sludge Incorrect grade of oil used Drain the engine sump. Refer to Section 1.
Engine operating temperature too high or too Check and correct cooling system
low
Oil in service for too long Change the oil and the oil filters Refer to Sec-
tion 1. General Information, Chapter 1.
Specifications, 2. Recommended Fuel,
Engine Vibration

Excessive vibration at any speed Loose components (e.g. alternator etc.) Secure all components including the engine
mountings and exhaust system
Worn or damaged engine mountings Check and replace the engine mountings
Prop shaft out of balance Balance and/or replace the prop shaft
Engine overheating Air intake is blocked. Refer to Engine Trou- Clean as necessary.
ble Shooting if over heating continues
Exhaust Smoke Analysis

Black smoke from the exhaust Inlet system restricted Service and repair the inlet system
Incorrect grade of fuel Drain and refill the fuel tank. Refer to Section
1. General Information, Chapter 1. Speci-
fications, 2. Recommended Fuel,
Blue smoke from the exhaust Engine oil level too high Correct the engine oil level
White smoke from the exhaust Engine running too cold Check the cooling system
Water in the fuel supply Clean out the fuel system

April 19, 2001
Transmission Trouble Shooting

Low clutch pressure Low oil level Refill the transmission. Refer to Section 1.
Low converter charging pump output Low oil level Refill the transmission. Refer to Section 1.
Suction screen blocked Clean the suction screen
Overheating Low oil level Refill the transmission. Refer to Section 1.
Wheel Trouble Shooting

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

Increased stopping distances Worn brake pads Change the brake pads
Oil or grease on the brake pads Change the brake pads
Squealing noise from the brakes when ap- Brake pads glazed Change the brake pads
plied
Brake discs warped or scored Inspect the brake discs for damage
Brakes do not fully release Brake caliper pistons sticking Change the brake caliper
Tyre Trouble Shooting

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

April 19, 2001
Axle Trouble Shooting

Final drive leaking oil Loose or damaged oil plugs Tighten or replace the oil plugs
Oil level too high Drain oil to the correct level
Final drive bolts loose Tighten the final drive bolts to the correct
torque
Axle breather blocked Clean the axle breather
Noisy final drive Low oil level in the final drive Refill the final drive. Refer to Section 1.
Final drive overheating Oil level too high Drain oil to the correct level
Oil level too low Refill the final drive. Refer to Section 1. Gen-
eral Information, Chapter 1.
Specifications, 2. Recommended Fuel,
Differential assembly leaking oil Bolts loose on main housing Tighten bolts to the correct torque
Differential assembly noisy Oil level too low Refill the differential. Refer to Section 1.
Differential assembly overheating Oil level too high Drain the oil to the correct level
Oil level too low Refill the differential. Refer to Section 1.
Axle breather blocked Clean the axle breather
Hydraulic System Trouble Shooting

Pump not delivering hydraulic fluid Hydraulic fluid in hydraulic tank is too low Refill the hydraulic tank. Refer to Section 1.
Outlet pipe from the tank to the pump is Check the suction strainer for blockages.
blocked Clean if necessary
Hydraulic fluid viscosity and type is incorrect Drain and refill the hydraulic system. Refer to
Section 1. General Information, Chapter
1. Specifications, 2. Recommended Fuel,
Pump making noise Pump intake is partially blocked Clean the hydraulic tank strainer. Check the
hydraulic fluid condition, if necessary drain
and flush the system and refill
Pump worn Perform a flow test. Refer to Section 6. Sys-
tem Checks, Chapter 31. Hydraulic
System Checks, 2. Hydraulic System
Checks, Hydraulic System Flow Test

April 19, 2001
Instruments and Controls Trouble Shooting

Gauge not working properly Circuit breaker tripped Investigate the cause and rectify
Loose or broken connections Tighten or repair the connections
Gauge defective Change the gauge
Switch not working properly Circuit breaker tripped Investigate the cause and rectify
Switch defective Change the switch. Contact your BELL Cus-
tomer Support Representative
Warning light not working Warning light bulb defective Change the warning light bulb
Circuit breaker tripped Investigate the cause and rectify
Electrical Supply Trouble Shooting

Alternator charge warning indicator not illu- Indicator light bulb defective Change the light bulb
minated when master switch is in the ON
position
Alternator charge warning indicator illumi- Alternator drive belt is loose or broken Adjust drive belt tension or fit new drive belt.
nated when engine is on Contact your BELL Customer Support Rep-
resentative
Poor battery connections Clean and check the battery connections
Batteries do not hold a charge Battery cells dry Check the battery electrolyte and top up
Short running time with lights on Remove the batteries and recharge or fit new
batteries
Starting System Trouble Shooting

Starter motor does not turn or turns very Batteries are flat Recharge or charge the batteries
slowly
Batteries defective or damaged Change the batteries
Battery terminals loose or damaged Tighten or clean the battery terminals
Start button defective or damaged Change the start button. Contact your BELL
Customer Support Representative
Starter motor does not disengage after the Start button defective or damaged Change the start button. Contact your BELL
engine has started Customer Support Representative

April 19, 2001
Electrical Equipment Trouble Shooting

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

Excessive cab movement while machine is Loose or missing mounting bolt(s) or rubbers Tighten or replace the mounting bolts and/or
operating rubbers. Contact your BELL Customer Sup-
port Representative
A smear remains on the windshield when the Wiper blade damaged Replace the wiper blade
windshield wiper is in operation
Oil or grease on the windshield Clean the windshield
Seat is difficult to adjust Obstruction in the seat runner Remove the obstruction
Lack of lubricant Lubricate the seat runners. Refer to Section
1. General Information, Chapter 1. Speci-
fications, 2. Recommended Fuel,
Excessive movement of the wing mirrors Loose or missing retaining bolts Tighten or replace the retaining bolts
while machine is operating
Wing mirror difficult to view Damaged wing mirror arm Replace wing mirror arm
Incorrect adjustment Adjust as necessary
Wing mirror cracked Replace the wing mirror

April 19, 2001
April 19, 2001

Troubleshooting engine issues

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SECTION 7.

873506 - REV 00 SECTION 7. TROUBLE SHOOTING 7-1

Engine Difficult to Start

Symptom Possible Cause Remedy

Engine Difficult to Start

Symptom Possible Cause Remedy

873506 - REV 00 SECTION 7. TROUBLE SHOOTING 7-3

Symptom Possible Cause Remedy

Excessive Fuel Consumption

Symptom Possible Cause Remedy

Low Engine Oil Pressure

Symptom Possible Cause Remedy

Abnormal Oil Consumption

Symptom Possible Cause Remedy

7-4 SECTION 7. TROUBLE SHOOTING 873506 - REV 00

Symptom Possible Cause Remedy

Internal Engine Oil Sludge

Symptom Possible Cause Remedy

Symptom Possible Cause Remedy

Exhaust Smoke Analysis

Symptom Possible Cause Remedy

873506 - REV 00 SECTION 7. TROUBLE SHOOTING 7-5

Symptom Possible Cause Remedy

Wheel Trouble Shooting

Symptom Possible Cause Remedy

Brakes Trouble Shooting

Symptom Possible Cause Remedy

Tyre Trouble Shooting

Symptom Possible Cause Remedy

7-6 SECTION 7. TROUBLE SHOOTING 873506 - REV 00

Symptom Possible Cause Remedy

Hydraulic System Trouble Shooting

Symptom Possible Cause Remedy

873506 - REV 00 SECTION 7. TROUBLE SHOOTING 7-7

Symptom Possible Cause Remedy

Electrical Supply Trouble Shooting

Symptom Possible Cause Remedy

Starting System Trouble Shooting

Symptom Possible Cause Remedy

7-8 SECTION 7. TROUBLE SHOOTING 873506 - REV 00

Symptom Possible Cause Remedy

Rear Frame and Cab Trouble Shooting

Symptom Possible Cause Remedy

873506 - REV 00 SECTION 7. TROUBLE SHOOTING 7-9

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