Professional Documents
Culture Documents
Bloemfontein:
Cape Town:
Empangeni:
No.1 Irvine Bell Drive (035) 792 6517 P.O. Box 7332
Old Mill Industrial Fax :(035) 792 6516 EMPANGENI
Email : shelleyb@bell.co.za 3880
East London:
Kimberly:
Kuruman:
Middleburg:
Nelspruit:
Pietermaritzburg:
Pongola:
Port Shepstone:
Rustenburg:
Springbok:
Tzaneen:
Umhlali:
Vryheid:
Wolmaransstad:
(018) 596 2319 C/o P.O. Box 587
80 Kruger Str. Fax : (018) 596 2855 WOLMARANSSTAD
9300
U.S.A.
Garden City (BELL Equipment North America Inc.):
(+1 912) 966-2615
2843 Hwy 80 Fax : (+1 912) 964-1594
Garden city Email : billr@bellequipment.com
GEORGIA
AUSTRALIA
Australia (BELL Equipment Asia Pacific Region):
(+61 8) 9350 5346 P.O. Box 34
12 Granite Place Fax : (+61 8) 9350 437 Welshpool
Email : asiapac@bell.net.au WESTERN AUSTRALIA
6986
SOUTH EAST ASIA
South East Asia (BELL Equipment (SEA) PTE Ltd):
(09) 65 769 8394# 04-06
Lam Soon Industrial Fax : (09) 65 769 8029
Building
Hillview Avenue Email :
bellsea@magix.com.sg
EUROPE
France (BELL France SARL):
(09) 33 55 589 23 56
Z.A. Rte d’ Argenton sur Fax : (09) 33 55 589 23 24
Creuse
Le-Palestel Email : bell-france@inext.fr
FRANCE
UNITED KINGDOM
United Kingdom (BELL Equipment U.K.):
Unit 316B industrial Estate (+44) 128 381 2954
Tutbury Fax : (+44) 128 381 5684
Burton on Trent Email : bell@belluk.demon.co.uk
E-mail : techsupport@bell.co.za
INDEX
SECTION 1 PAGE
ELECTRICAL
Specifications 1
Operator controls and instruments 2-8
Switches 18-20
General
Schematics 36
Earth points 36
Starting and charging 37
Warning lights 38
MFA 10 & Over rev 39
Lighting 40
Turn and hazards 41
Brake lights and exhaust brake 42
Aircon 43
Wipers / washer 44
Cold Start 45
Battery Balancer 46
Range Hold 47
Allison / Bell Allison 48
Electric mirrors 49
Transmission cooler 50
Connector 1 51
Connectors 2 & 3 52
Connectors 4,5,6 & 7 53
Connectors 8,9,10 & 11 54
Connectors 12 , 13 & 14 55
Connectors 15,16,17 & 18 56
Connectors 19,20,21 & 22 57
Connectors 23,24,25 & 26 58
Connectors 27,28,29,30 & 31 59
Connectors 32 – 37 60
SECTION 2
TRANSMISSION
General Description 1
Identification 2
Torque Convertor 2-7
Stall Testing 8-11
System function 25
Main pressure 26
Solenoid and Regulator valves 26
Clutch application 27
Latching valves 28
Control main circuit 29
Torque convertor circuit 29-31
Exhaust backfill 31
Main pressure regulator 32
Control main regulator 33
Solenoids
Normally open 34
Normally closed 35-36
ECU 52
Pulse width modulation (PWM) 53-54
Upshift clutch control 55-56
Shift selectors 57-59
Vehicle interface module 59
Throttle position sensor and adjustment 60-78
Speed sensors 79
Wiring Harness 80-82
Upshift tests 82-83
Do not shift light (DNS) 84
Auto detect 85-87
Wire check procedures 88-91
Oil level sensor ( Checking the oil level) 92-96
Diagnostic codes 97
Transmission plugs
SECTION 3
HYDRAULICS
Hydraulic components 10
Main pump 10
Emergency steering pump 11
Steering control valve 12
Brake accumulator 13
Check valve 14
Voac Block 15-17
Top view 25
Right view 25
Rear view 26
Front view 26
Bottom view 27
Left view 27
Hydraulic schematics 44
SECTION 4
PNEUMATICS 1
Compressor 2
Unloader valve 3-6
Park Brake 7-9
Suspension 10
Leveling Vlave 11
Tip control 12
Exhaust Brake & Hydraulic retarder 13-14
Inter axle lock 15
Air suspension seat 16
Schematics
Location of components 17
Pipe flow Diagram 18
System schematic 19
SECTION 5
Propshafts 1
Maintenance 1-2
Lubrication 3
Propshaft layout 4
Retaining bolts and lock nut torque check 5
Troubleshooting 6
Dropbox 7
Technical Data 8
Differentials 51-52
Brakes 74-81
USER COMMENTS FORM
1. Should you as the user of this manual, have any suggestions for improving
the manual, or you find any errors or omissions, then we would like to know.
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LUBRICATING OILS VISCOSITY GRADES
Due to continuous development, Daimler Chrysler engines are constantly
revising their oil recommendations.
To obtain the latest oil recommendations, please refer to our general
service bulletins ( SIB ) on approved consumables or consult your nearest
oil company for their advice.
SERVICE GUIDE
HOW TO READ THE RSG: For example when performing a 500hr service
everything in the 500hr column must be carried including everything in the
previous columns eg.250hr and daily checks. Any additional faults must be
addressed as maintenance problems.
The employees of Bell Equipment take pride in the Equipment we manufacture. Customer:
With the Customer, Customer Service Centre and Bell Equipment working together, VIN (Vehicle Identification Number):
we can continue to improve the quality of our products. BFL Serial Number:
Complete the checklist below using procedures specified in the Operator and Satis- As
a Daily Every Every Every Every Every
Maintenance Manual. factory Required
Unsatis-
r 250 hrs 500 hrs 1000 hrs 2000 hrs 3000 hrs
Details factory
1 Engine
1.1 Adjust the valve clearance x
1.2 Change the primary fuel filter x
1.3 Change the secondary fuel filter x
1.4 Change the oil and filters x
1.5 Change the crankcase breather x
1.6 Change air cleaner secondary filter x
1.7 Change the coolant x
1.8 Check the oil level x
1.9 Check the coolant level x
1.10 Check the coolant specification x
1.11 Check the tension of the drive belts x
1.12 Check the engine compartment components x
1.13 Check the air cleaner primary filter x
1.14 Clean pre-cleaner assembly x
1.15 Drain the primary fuel filter x
1.16 Flush and renew coolant x
1.17 Service injectors on # 300 / #400 engines x
2 Transmission - Allison HD / MD
2.1 Change the filters x
2.2 Change the oil x
2.3 Check the oil level x
3 Transmission - ZF 210
3.1 Change the filters x
3.2 Change the oil x
3.3 Check the oil level x
4 Transfer Case
4.1 Change the oil x
4.2 Check the oil level x
5 Hydraulics
5.1 Change the oil x
5.2 Change the filters x
5.3 Change the breather filter x
5.4 Check the oil level x
6 Axles and Chassis
6.1 Change the oil in differential and final drive x
6.2 Change brake fluid * if applicable x
6.3 Check the oil in differential and final drives x
6.4 Check service brake pads x
6.5 Check park brake pads x
6.6 Check brake fluid level * if applicable x
7 Cab, Pneumatics and Electrical
7.1 Change the air drier filter x
7.2 Check operator contols and instruments x
7.3 Check working lights,reverse buzzer x
7.4 Check electrical connections x
8 Lubrication
8.1 Grease the Hinges x
8.2 Grease the Propshafts x
8.3 Thru drive bearings x
8.4 Grease PTO propshaft x
8.5 Grease all remaining lube points x
9 General Walk Round
9.1 Check for oil,air and fuel leaks x
9.2 Check for loose or damaged components x
9.3 Clean coolers x
Refer bulletin 93/695 regarding water and coolant specification Change intervals can be extended by oil sampling (use kit 261677 for sampling the Allison transmission)
If sulphur content above 0.5% Service between 1200 hrs and 1800 hrs As per bulletin - 99/120
Allison Transmission filters to be changed 1st 1000 hrs service, thereafter every 2000 hrs Every 250 hrs if operated in excessively wet conditions
Rev: Date19/02/2001