Description
Bell B35D B40D B45D B50D ADT MK VI Service Repair Manual
This is the full Bell Equipment service manual covering the B35D, B40D, B45D and B50D MK VI Articulated Dump Trucks, together with the B40D 6X4 ADT Supertruck variants. Issued as document 874116 at Revision 5 in April 2010, it is the workshop-level reference used by Bell service personnel for diagnosis, analysis, testing and repair across the large MK VI ADT range.
The content is written for an experienced technician and follows the Bell chapter structure with step-by-step instructions, illustrated procedures, test data, adjustment values and fault code tables. Whether you are chasing an intermittent CAN fault, resetting hydraulic pump pressures, adjusting valve clearance on the OM 501 LA, or working through a 500-hour service, the relevant procedure and specification are laid out in sequence.
File Details
- Manual type: Service / Repair Manual (SERVICE MANUAL MK VI)
- Brand: Bell Equipment
- Models covered: B35D, B40D, B45D, B50D MK VI ADTs; B40D 6X4 ADT Supertruck
- Document number: 874116
- Revision: Rev 5 (amendment record follows Rev 1 through Rev 5)
- Issue date: April 2010 (latest amendment 05-08-2010)
- Language: English
- Format: PDF
Chapters Covered
- Operational Check-Out Procedure
- Engine (OM 501 LA / OM 502 LA, EUI fuel system, valve clearance, exhaust brake adjustment, compression and fuel pump pressure tests)
- Electrical System (schematics, earth connections, fuse and relay layout, control units, CANBUS J1939, connectors, ADM / PLD-MR / CCU / MDU / OEU fault codes, MDU3 menu structure, OBW troubleshooting)
- Transmission (Allison 4560R, 4500 and 4600, planetary gears, power flow, hydraulic circuits, speed sensors, TCU, autodetect, stall testing, diagnostic codes)
- Pneumatic System (schematic, operation, fault finding, main pressure test, park brake pressure and adjustment, Grammar seat test)
- Hydraulic System (schematics for B35D/B40D and B50D, main pump and control valve, steering valve, secondary steering pump, manifold, fault finding, all pressure setting procedures, suspension calibration, cycle time test)
- Heating, Ventilation and Air Conditioning
- Service Schedules and Lubrication Chart
- 150 Hours Service and Checks
- 500 Hours Service and Checks
- 1 000 Hours Service and Checks
- 2 000 Hours Service and Checks
- 3 000 Hours Service and Checks
- 4 000 Hours Service and Checks
- As Required Service
- Miscellaneous Service and Checks
- Storage and Preservation
- Trouble Shooting
Between the covers a technician gets the full flow of the machine: from a cold start operational checkout, through engine mechanical adjustment and electronic unit injector theory, into the electrical schematics and the CAN J1939 network with its 60-ohm termination measurement and open/short fault cases. The transmission chapter breaks the Allison Gen 4 power flow down range by range with solenoid apply charts and the fail-to-range behaviour. The hydraulic chapter carries the pressure setting procedures for residual, compensating, steering, brake, fan and bin circuits, plus the accumulator charge check, articulation and height sensor calibration, and the cycle time test.
What This Manual Lets You Do
The Bell B35D, B40D, B45D and B50D MK VI are ground-engaging machines, and mistakes on the hydraulic, brake or transmission circuits are expensive. This manual gives you the correct pressure settings, the correct torque values, the correct fault code interpretation, and the correct order of operations for each service interval, so the job is done once and done right.
With this service repair manual on hand you can carry out scheduled services at every interval from 150 up to 4 000 hours, diagnose electrical faults against the ADM, PLD-MR, CCU, MDU and OEU code tables, test and set the main hydraulic pump residual and compensating pressures, charge and check brake accumulators, set the emergency steering pump, calibrate the bin position, articulation and height sensors, service the Allison transmission, and troubleshoot the HVAC and pneumatic systems.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Bell B35D B40D B45D B50D ADT MK VI Service Repair Manual 2010 Rev 5 PDF” are as follows:
+TABLE OF CONTENTSp. 7
+SAFETY 15p. 15
Specification 15p. 15
General 15p. 15
Safety Features 15p. 15
Material Safety Data Sheet (MSDS) 16p. 16
Unauthorised Modifications of ROPS and FOPS 16p. 16
Loosening or Removal Of ROPS and FOPS 16p. 16
Noise Emission Levels 16p. 16
Safety Regulations 17p. 17
General Safety 17p. 17
+TYRE INFORMATION 28p. 28
Tyres and Rims 28p. 28
Tyre Pressures – General 28p. 28
Tyre Pressures – Inflation Pressure, Hot vs. Cold 29p. 29
+CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE 33p. 33
Operational Check 33p. 33
Ignition Button Pressed ONCE, Engine OFF 33p. 33
Ignition Button Pressed (Second Stage), Engine Start 34p. 34
Engine Stop Button Pressed 36p. 36
+CHAPTER 2. ENGINE 37p. 37
Engine Description 37p. 37
Diagnose Engine Malfunctions 41p. 41
Adjustments 43p. 43
Valve Clearance Adjustment 43p. 43
Exhaust Brake Adjustment 44p. 44
Tests 45p. 45
Cylinder Compression Test 45p. 45
+Fuel Pump Pressure Test 45p. 45
Oil Pump Pressure Test 47p. 47
+CHAPTER 3. ELECTRICAL SYSTEM 49p. 49
Schematics 49p. 49
Electrical Schematic Symbols 49p. 49
Electrical Schematics 50p. 50
Earth Connections 73p. 73
+Fuse and Relay Layout 73p. 73
Control Units 74p. 74
SSM Inputs and Outputs 83p. 83
CCU2 J1 Inputs and Outputs 84p. 84
CCU2 J2 Inputs and Outputs 85p. 85
CCU2 J3 Inputs and Outputs 86p. 86
OEU J1 Inputs and Outputs 87p. 87
OEU J2 Inputs and Outputs 88p. 88
OEU J3 Inputs and Outputs 89p. 89
+ADM-Mercedes ECU Inputs and Outputs 90p. 90
MR-Engine ECU Inputs and Outputs 91p. 91
Allison TCU Inputs & Outputs 92p. 92
Memory Module Inputs & Outputs 93p. 93
Connectors 94p. 94
Multiple Wire Colours 94p. 94
Wire Colour 94p. 94
Relay 95p. 95
Connectors 95p. 95
Engine Fault Codes (ADM) 129p. 129
Engine Fault Codes (PLD-MR) 133p. 133
+CCU, MDU & OEU Fault Codes 149p. 149
MDU3 Menu Structure 157p. 157
Default Display 160p. 160
Accessing Service Mode 162p. 162
Main Menu 163p. 163
Specifications and Tests 191p. 191
On Board Weighing (OBW) Troubleshooting Guide 198p. 198
+CHAPTER 4. TRANSMISSION 203p. 203
General Description 203p. 203
+Planetary Gears Sets 208p. 208
Transmission Cross Sectional Diagram 210p. 210
Power Flow 211p. 211
+Functional Description Hydraulic System 212p. 212
General Description 218p. 218
Speed Sensors 221p. 221
+Control Module 221p. 221
Wiring Harnesses 222p. 222
+Autodetect Feature 225p. 225
Hydraulic Circuits 227p. 227
Neutral to Drive Transition 229p. 229
1st Range Operation 229p. 229
1st Range to 2nd Range Transition 230p. 230
Torque Converter And Lube Pressure Circuits 241p. 241
Exhaust Backfill Pressure 241p. 241
Definitions And Abbreviations 242p. 242
+Oil Level Sensor (OLS) 248p. 248
Diagnostic Code Memory 250p. 250
Identification of Potential Circuit Problems 257p. 257
+CHAPTER 5. PNEUMATIC SYSTEM 259p. 259
+Pneumatic System Schematic 259p. 259
Pneumatic System Operation 261p. 261
Fault Finding 266p. 266
Adjustments and Tests 268p. 268
Pneumatic System Main Pressure Test and Adjustment 268p. 268
Park Brake Pressure Test 268p. 268
Park Brake Adjustment 269p. 269
Grammar Seat Functional Test 271p. 271
+CHAPTER 6. HYDRAULIC SYSTEM 273p. 273
Hydraulic System Circuit Symbols 273p. 273
Hydraulic Schematic B35D and B40D 274p. 274
Hydraulic Schematic B35D and B40D Wet Disc Brake with Adaptive Suspension 275p. 275
Hydraulic Schematic B35D Dry Disc Brake with Adaptive Suspension 276p. 276
Hydraulic Schematic B50D 277p. 277
+Hydraulic System Operation 279p. 279
Main Hydraulic Pump B35D/B40D 281p. 281
Main Hydraulic Pump Control Valve B35/B40 282p. 282
Main Hydraulic Pump B45D/B50D 284p. 284
Main Hydraulic Pump Control Valve B45D/B50D 285p. 285
Steering Valve Operation 287p. 287
Secondary Steering Pump Operation 289p. 289
Manifold Schematic 295p. 295
General Description 296p. 296
Service Brake System Operation 296p. 296
Steering And Secondary Steering System Operation 298p. 298
Fan Drive System 298p. 298
+Bin Operation 299p. 299
Tests and Adjustments 311p. 311
Digital Thermometer Installation 311p. 311
Digital Analogue Pressure / Temperature Analyser Installation 311p. 311
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy 311p. 311
Hydraulic System Warm-Up Procedure 312p. 312
Setting Hydraulic Pressure 313p. 313
Activate the Hydraulic Pressure Setup Mode: 313p. 313
Calibrate the Bin Position Sensors: 314p. 314
Set the Emergency Steering Pump Pressures 314p. 314
Set the Emergency Steering Pump Residual Pressure 314p. 314
Set the Emergency Steering Pump Compensating Pressure: 315p. 315
Set the Main Pump Residual Pressures B35/B40 315p. 315
Set the Main Pump Residual Pressures B45/B50 316p. 316
Set the Main Pump Compensating Pressure B35/B40 317p. 317
Set the Main Pump Compensating Pressure B45/B50 319p. 319
Set the Steering Pressure B35/B40 320p. 320
Set the Steering Pressure B45/B50 321p. 321
Set the Brake Circuit Pressures: 321p. 321
Accumulator Charge Pressure Check and Re-charge Procedure 323p. 323
Set the Bin Tip Pilot Pressure 324p. 324
Set the Bin Up Pressure Limiting Pressure 325p. 325
Set the Fan Drive Pressures B35/B40 325p. 325
Set the Fan Drive Pressures B45/B50 327p. 327
Suspension Calibration Procedure B45/B50D Only 328p. 328
Calibrate the Articulation Sensor 329p. 329
Calibrate the Height Sensors 329p. 329
Cycle Time Test 330p. 330
+CHAPTER 7. HEATING, VENTILATION AND AIR CONDITIONING 331p. 331
Air Conditioning System Cycle Of Operation 331p. 331
+Heater Core Operation 332p. 332
Fault Finding 333p. 333
HVAC Component Location 335p. 335
Tests 337p. 337
Operational Checks 337p. 337
R134A Air Conditioning System Test 338p. 338
Air Freeze Control Switch Test 340p. 340
Air Compressor Clutch Test 340p. 340
Air High/Low Pressure Switch Test 340p. 340
Air Expansion Valve Test 341p. 341
Expansion Valve Bench Test 342p. 342
Refrigerant Leak Test 343p. 343
+CHAPTER 8. SERVICE SCHEDULES & LUBRICATION CHART 347p. 347
Hydraulic System Overview 347p. 347
De-pressurising the Hydraulic System 347p. 347
Engine Oil 349p. 349
+Service Schedules 354p. 354
Lubrication Chart 359p. 359
+CHAPTER 9. 150 HOURS SERVICE AND CHECKS 361p. 361
Service Instructions 361p. 361
Change Engine Oil And Replace Filter 361p. 361
Lower And Raise The Belly Plate 361p. 361
Replace Primary Fuel Filter (Water Separator) 362p. 362
Replace Secondary Fuel Filter 363p. 363
Replace Fuel Depth Filter B50D Only 363p. 363
+CHAPTER 10. 500 HOURS SERVICE AND CHECKS 367p. 367
Service Instructions 367p. 367
Change Engine Oil And Replace Filter 367p. 367
Check Engine Air Intake System 367p. 367
Drain the Primary Fuel Filter 367p. 367
Check The Coolant Level 367p. 367
Replace Fuel Tank Breather Filter 368p. 368
Replace Both Fan Belts 368p. 368
Check Tyre Pressures 368p. 368
Tilt and Lower the Cab 368p. 368
Check Transmission Fluid Level 370p. 370
Check Park Brake Pad Wear 371p. 371
Check Service Brake Pad Wear (Dry Brakes) 372p. 372
Check Transfer Case Fluid Level 372p. 372
Check Front Axle Suspension Struts B35D & B40D 372p. 372
Check Bin Shock Pad Clearance 373p. 373
General Check Drive Line & Suspension Fasteners 373p. 373
Inspect, Clean And Replace Cab Air Filter 374p. 374
Check Electrical Connectors, Harnesses And Looms 375p. 375
Check Work Lights, Reverse Buzzer 375p. 375
Record & Delete Fault Codes On MDU Display 375p. 375
Check Operator Controls And Instruments 375p. 375
Check The Air Conditioner Receiver Air Drier Site Glass 375p. 375
Grease All Lubrication Points 375p. 375
Check Grease Level Of Auto Greasing System 376p. 376
Check Hydraulic Oil Level 377p. 377
Replace Hydraulic Reservoir Breather B50D 378p. 378
Clean Hydraulic/Transmission Cooler Fan 378p. 378
Replace Hydraulic Reservoir Breather B35D & B40D 379p. 379
Clean Headlights 379p. 379
+CHAPTER 11. 1 000 HOURS SERVICE AND CHECKS 381p. 381
Service Instructions 381p. 381
Adjust Engine Valve Clearance 381p. 381
Replace Fuel Depth Filter (B50D Only) 381p. 381
Replace Primary Fuel Filter (Water Separator) 381p. 381
Replace Secondary Fuel Filter 381p. 381
Replace Fuel Tank Breather Filter (B50D Only) 381p. 381
Change Primary Air Filter Element 381p. 381
Check Coolant Conditioner In Radiator 382p. 382
Check The Fan Belt Condition B35D & B40D Only 382p. 382
Clean Crankcase Breather Filter 382p. 382
Drain Transmission Oil Cooler 383p. 383
Replace Transmission Filters 383p. 383
Change The Transfer Case Filter 384p. 384
Replace Hydraulic Reservoir Breather 384p. 384
Check Condition Of All Drive Shafts 385p. 385
Check Axle Oil Level B35D & B40D Only 385p. 385
Check Final Drive Oil Levels B35D & B40D Only 385p. 385
+CHAPTER 12. 2 000 HOURS SERVICE AND CHECKS 387p. 387
Service Instructions 387p. 387
Change the Secondary Air Filter Element 387p. 387
Change Transfer Case Oil 387p. 387
Change Axle Oil 388p. 388
Change Final Drive Oil 388p. 388
Check Service Brake Disc Thickness 389p. 389
Check Transfer Case Breather 389p. 389
Check Transmission Breather and Axle Breathers 389p. 389
Replace Transmission Oil 390p. 390
Replace Wet Disc Brake Cooler Oil And Filter 391p. 391
Replace Wet Disc Brake Cooling Oil Filter 391p. 391
Check Wet Disc Brake Cooling Oil Reservoir (B40D) Only 392p. 392
Replace Pneumatic System Drier Filter 392p. 392
Change Axle Oil (B35D & B50D With Bell Wet Brakes) 393p. 393
+CHAPTER 13. 3 000 HOURS SERVICE AND CHECKS 395p. 395
Service Instructions 395p. 395
Change Jockey Pulley Bearing (Tensioner Pulley) 395p. 395
Change The Air Conditioner Pulley Assembly 395p. 395
Change All Axle Driveline Cross and Rollers 395p. 395
Replace Suction Screen 395p. 395
+CHAPTER 14. 4 000 HOURS SERVICE AND CHECKS 397p. 397
Service Instructions 397p. 397
Replace Fan Belt B35D & B40D Only 397p. 397
Change Hydraulic Oil 398p. 398
Change Pneumatic Block Breather Filters 398p. 398
+CHAPTER 15. AS REQUIRED SERVICE 399p. 399
Introduction 399p. 399
Service Instructions 399p. 399
Check the Engine Compartment Components 399p. 399
Clean/Replace Primer Pump Fuel Screen 400p. 400
Change Engine Coolant 400p. 400
Clean Cooling System 401p. 401
Check for Oil and Fuel Leaks 401p. 401
Clean the Air Cleaner Pre-cleaner Bowls B35D & B40D Shown 402p. 402
Clean Air Conditioning Filters 402p. 402
Grease Hinges 402p. 402
Check And Clean All Coolers 402p. 402
Hydraulic Oil Cleanliness Sampling Procedure 402p. 402
+CHAPTER 16. MISCELLANEOUS SERVICE AND CHECKS 403p. 403
Service Instructions 403p. 403
Inspect Serpentine Belt 403p. 403
Change Wheels 403p. 403
Using Battery Charger 403p. 403
Replace Batteries 404p. 404
Replace Front Turn Signal Bulb, Headlight Bulb and Front Park Light Bulb 404p. 404
Adjust Headlights 405p. 405
Maintenance of Automatic Grease System 407p. 407
+CHAPTER 17. STORAGE AND PRESERVATION 409p. 409
Introduction 409p. 409
General 409p. 409
Category 1 – Laid up for up to 12 months 409p. 409
Category 2 – Laid up for 12 to 36 months 410p. 410
Category 3- Laid up for up more than 36 months 410p. 410
CHAPTER 18. TROUBLE SHOOTING 411p. 411
Delivery is instant. This Bell B35D B40D B45D B50D ADT MK VI service repair manual is supplied as a PDF download with no shipping and no waiting. Open it on a laptop in the workshop, a tablet on the machine, or print the pages you need for the job in front of you. The full 874116 Rev 5 manual is yours the moment checkout completes.
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