John Deere / Bell Articulated Dump Truck B25C Operation & Test Service Manual (TM1811)
Complete Operation & Test manual with Electrical Wiring Diagrams for BELL Articulated Dump Trucks Models B25C , with all the shop information to maintain, diagnose, and rebuild like professional mechanics.
John Deere / Bell Articulated Dump Truck B25C workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM1811 - Bell Articulated Dump Truck B25C Operation & Test Technical Manual.PDF
TM1811 - Bell Articulated Dump Truck B25C Operation & Test Technical Manual.EPUB
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Total Pages: 1,022 pages
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Language: English
MAIN SECTIONS
Foreword
Technical Information Feedback Form
Machine Number Identification
General Information
Safety
General Specifications
Torque Values
Fuels and Lubricants
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
Diagnose Engine Malfunctions
Adjustments
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
References
Power Train
Theory of Operation
Diagnostic Information
Tests
Pneumatic System
Theory of Operation
Diagnostic Information
Tests
Hydraulic System
Theory of Operation
Diagnostic Information
Tests
Heater and Air Conditioner
Theory of Operation
Diagnostic Information
Adjustments
Tests
TABLE OF CONTENTS................1
Section 9000: General Information................18
Group 01: Safety................18
Handle Fluids Safely-Avoid Fires................21
Prevent Battery Explosions................22
Prepare for Emergencies................23
Prevent Acid Burns................24
Handle Chemical Products Safely................26
Avoid High-Pressure Fluids................27
Park Machine Safely................28
Support Machine Properly................29
Wear Protective Clothing................30
Work in Clean Area................31
Service Machines Safely................32
Work in Ventilated Area................33
Illuminate Work Area Safely................34
Replace Safety Signs................35
Use Proper Lifting Equipment................36
Remove Paint Before Welding or Heating................37
Avoid Heating Near Pressurized Fluid Lines................38
Service Tires Safely................39
Practice Safe Maintenance................40
Use Proper Tools................42
Dispose of Waste Properly................43
Live With Safety................44
Group 02: General Specifications................18
B25C Articulated Dump Truck Specification................47
B25C Drain and Refill Capacities................49
Group 03: Torque Values................18
Hardware Torque Specifications................51
Metric Bolt and Cap Screw Torque Values................52
Additional Metric Cap Screw Torque Values................54
Unified Inch Bolt and Cap Screw Torque Values................56
Metric Cap Screw and Nut Torque Values................58
Imperial and SAE (Inch) Cap Screw and Nut Torque Valves................59
Check Oil Lines and Fittings................60
Service Recommendations for O-Ring Boss Fittings................62
Service Recommendations for Flat Face O-Ring Seal Fittings................64
Service Recommendations for Metric Series Four Bolt Flange Fitting................66
Service Recommendations For Inch Series Four Bolt Flange Fittings................68
Group 04: Fuels and Lubricants................19
Diesel Fuel................71
Low Sulfur Diesel Fuel Conditioner................72
Handling and Storing Diesel Fuel................73
Diesel Fuel Storage................74
Fuel Tank................75
Diesel Engine Oil................76
Hydraulic Oil and Transfer Case Oil................77
Transmission Oil................78
Multipurpose Lubricant (Axles and Final Drives)................79
Grease................80
Alternative and Synthetic Lubricants................81
Lubricant Storage................82
Mixing of Lubricants................83
Section 9005: Operational Checkout Procedure................84
Group 10: Operational Checkout Procedure................84
Operational Checkout................191
Section 9010: Engine................297
Group 05: Theory of Operation................297
OM 366 LA Engine Sectional View................303
Engine Operation................307
Fuel Circuit................308
Cold Weather Start System................310
Group 15: Diagnose Engine Malfunctions................320
Diagnose Engine Malfunctions................320
Group 20: Adjustments................297
JT05801 Clamp-On Electronic Tachometer Installation................886
Engine Exhaust Brake Valve Adjustment................330
Fuel Shutoff Solenoid Adjustment................337
PRO-LINKPRO-LINK is a trademark of Micro Processor Systems. 9000 Microprocessor Installation................297
Slow and Fast Idle Adjustment Using PRO-LINKPRO-LINK is a trademark of Micro Processor Systems. 9000 Microprocessor................297
Throttle Position Sensor Adjustment Using PRO-LINKPRO-LINK is a trademark of Micro Processor Systems. 9000 Microprocessor................297
Reset Throttle Calibration Using PRO-LINKPRO-LINK is a trademark of Micro Processor Systems. 9000 Microprocessor................297
Slow and Fast Idle Adjustment Using Tachometer................352
Throttle Position Sensor Adjustment-Manual Method................357
Injection Pump Timing for Original Pump................359
Injection Pump Spill Timing for New Pump................362
Alternator and Water Pump Belts Adjustment................369
Bleeding Fuel System................371
Group 25: Tests................297
JT05801 Clamp-On Electronic Tachometer Installation................886
JT05800 Digital Thermometer Installation................887
Fuel Injection Nozzles Test................375
Engine Compression Test................381
Inspect Thermostat and Test Operating Temperature................383
Viscous Drive Fan Check................385
Fuel Line Leakage Test................387
Fuel Supply Pump Test................388
Air Intake System Leakage Test................391
Radiator Cap and Cooling System Pressure Test................393
Section 9015: Electrical System................396
Group 05: System Information................396
Electrical System Visual Inspection................401
Electrical Circuit Malfunctions................402
High Resistance Circuit................404
Open Circuit................406
Grounded Circuit................408
Shorted Circuit................410
Sensor Circuit Shorted to Power................412
Sensor Circuit Shorted to Itself................414
Sensor Circuit Shorted to Ground................416
Multimeter................418
Seven Step Electrical Test Procedure................419
Schematic, Wiring Diagram, and Component Location Information................421
Reading a System Functional Schematic................422
Reading a Wiring Diagram................424
Reading a Component Location Diagram................426
Reading a Connector End View Diagram................428
Electrical Schematic Symbols................429
Group 10: System Diagrams................396
Explanation of Wire Markings................433
Component Identification Table................434
Functional Schematic and Component Location Legend................436
Functional Schematic Section Legend................440
Power, Start, and Charging System Functional Schematic................441
Display Module, and Transmission System Functional Schematic................442
4-Way Flasher, Turn Signal, Horn, and Light System Functional Schematic................443
Brake Light, Exhaust Brake, and Indicator Light System Functional Schematic................444
Transmission Range Hold, Radio, Reverse Lights, Cigar Lighter, Converter or Battery Balancer and Cooling Fan System Functional Schematic................445
Air Conditioner, Dome Light, Inter-Axle Lock, Wiper/Washer, and Rotating Beacon System Functional Schematic................446
Cab Harness (W5) Component Location (1 of 4)................447
Cab Harness (W5) Instrument Panel Component Location (2 of 4)................448
Cab Harness (W5) Dash Panel Component Location (3 of 4)................450
Cab Harness (W5) Breaker Panel Component Location (4 of 4)................451
Engine Harness (W6) Wiring Diagram................452
Engine Harness (W6) Component Location................453
Cold Start Harness (W7) Wiring Diagram................454
Cold Start Harness (W7) Component Location................455
Front Light Harness (W8) Wiring Diagram................456
Front Light Harness (W8) Component Location................457
Cab-to-Manifold Block Harness (W9) Wiring Diagram................458
Cab-to-Manifold Block Harness (W9) Component Location................459
Rear Chassis Harness (W10) Wiring Diagram................460
Rear Chassis Harness (W10) Component Location................461
Transmission Control-to-Vehicle Interface Harness (W11) Wiring Diagram................462
Transmission Control-to-Vehicle Interface Harness (W11) Component Location................463
Vehicle Interface Harness (W12) Wiring Diagram................464
Vehicle Interface Harness (W12) Component Location................465
Vehicle Interface Module Schematic................466
Transmission Control Harness (W13) Wiring Diagram................467
Transmission Control Harness (W13) Component Location................468
Transmission Control-to-Cab Bulkhead Harness (W14) Wiring Diagram................469
Transmission Control-to-Cab Bulkhead Harness (W14) Component Location................470
Cab-to-Transmission Harness (W15) Wiring Diagram................471
Cab-to-Transmission (W15) and Speed Sensor Harness (W16) Component Location................472
Transmission Speed Sensor Harness (W16) Wiring Diagram................473
Group 15: Sub-System Diagnostics................397
Power Circuit Operational Information................475
Power Circuit Theory of Operation................476
Power Circuit Schematic................477
Starting and Charging Circuit Operational Information................483
Starting and Charging Circuit Theory of Operation................484
Starting and Charging Circuit Schematic................485
Display Module Circuit Operational Information................492
Display Module Circuit Theory of Operation................493
Display Module Circuit Schematic................495
Transmission Circuit Operational Information................499
Transmission Circuit Theory of Operation................500
Transmission Circuit Schematic................501
4-Way Flasher, Turn Signal, and Horn Circuit Operational Information................511
4-Way Flasher, Turn Signal, and Horn Circuit Theory of Operation................512
4-Way Flasher, Turn Signal, and Horn Circuit Schematic................513
Light Circuit Operational Information................519
Light Circuit Theory of Operation................520
Light Circuit Schematic................521
Brake Light Circuit Operational Information................529
Brake Light Circuit Theory of Operation................530
Brake Light Circuit Schematic................531
Exhaust Brake Circuit Operational Information................535
Exhaust Brake Circuit Theory of Operation................536
Exhaust Brake Circuit Schematic................537
Indicator Light Circuit Operational Information................541
Indicator Light Circuit Theory of Operation................542
Indicator Light Circuit Schematic................544
Transmission Range Hold Circuit Operational Information................557
Transmission Range Hold Circuit Theory of Operation................558
Transmission Range Hold Circuit Schematic................559
Radio and 12V Circuit Operational Information (Machine No. -408812.02)................564
Radio and 12V Circuit Theory of Operation (Machine No. -408812.02)................565
Radio and 12V Circuit Schematic (Machine No. -408812.02)................566
Radio and 12V Circuit Operational Information (Machine No. 408812.03- )................571
Radio and 12V Circuit Theory of Operation (Machine No. 408812.03- )................572
Radio and 12V Circuit Functional Schematic (Machine No. 408812.03- )................573
Air Conditioner Circuit Operational Information................578
Air Conditioner Circuit Theory of Operation................579
Air Conditioner Circuit Schematic................580
Reverse Light Circuit Operational Information................587
Reverse Light Circuit Theory of Operation................588
Reverse Light Circuit Schematic................589
Cigar Lighter Circuit Operational Information................592
Cigar Lighter Circuit Theory of Operation................593
Cigar Lighter Circuit Schematic................594
Cooling Fan Circuit Operational Information................596
Cooling Fan Circuit Theory of Operation................597
Cooling Fan Circuit Schematic................598
Dome Light Circuit Operational Information................600
Dome Light Circuit Theory of Operation................601
Dome Light Circuit Schematic................602
Inter-Axle Lock Circuit Operational Information................605
Inter-Axle Lock Circuit Theory of Operation................606
Inter-Axle Lock Schematic................607
Wiper/Washer Circuit Operational Information................610
Wiper/Washer Circuit Theory of Operation................611
Wiper/Washer Circuit Schematic................612
Rotating Beacon Circuit Operational Information................616
Rotating Beacon Circuit Theory of Operation................617
Rotating Beacon Circuit Schematic................618
Park Brake Circuit Operational Information................622
Park Brake Circuit Theory of Operation................623
Park Brake Circuit Schematic................624
Group 20: References................399
Battery Operation................629
Battery Specifications................631
Diagnose Battery Malfunctions................632
Check Battery Electrolyte Level and Terminals................633
Procedure for Testing Batteries................636
Using Booster Batteries-24 Volt System................637
Replacing Batteries................639
Adding 12 or 24 Volt Accessories................640
Adjusting Headlights................641
Section 9020: Power Train................643
Group 05: Theory of Operation................643
Transmission External Components................646
Transmission Control System................648
Transmission Cross Sectional Diagram................650
Torque Converter Operation................651
Transmission Planetary Operation................652
Transmission Clutch Engagement................655
Group 15: Diagnostic Information................643
Diagnostic Procedure................871
Diagnose Power Train System Malfunctions................694
Power Train Component Location Diagram................704
Group 25: Tests................643
Transmission Warm Up Procedure................707
Transmission Pressure Test................709
Transmission Clutch Drag Test................714
Torque Converter Stall Test................717
Torque Converter Stator Tests................720
Torque Converter Lockup Test................722
Park Brake Test (Machine No. -408812.03)................723
Park Brake Test (Machine No. 409812.00- )................725
Park Brake Pad Thickness Check................727
Park Brake Adjustment................729
Diagnostic Codes................734
Diagnostic Code Display Procedure................736
Transmission Diagnostic Codes................738
Section 9022: Pneumatic System................764
Group 05: Theory of Operation................764
Pneumatic System Operation................766
Pneumatic System Supply Circuit Operation................767
Air Drier and Unloader Valve Operation................769
Inter-Axle Lock Circuit Operation................772
Park Brake Circuit Operation (Machine No. -408812.03)................773
Park Brake Circuit Operation (Machine No. 409812.00- )................774
Park Brake Valve (Machine No. -408812.03)................776
Park Brake Valve (Machine No. 409812.00- )................779
Exhaust Brake and Hydraulic Retarder Circuit Operation................782
Front Suspension Leveling Circuit Operation................784
Body Control Circuit Operation................786
Air Suspension Seat Circuit Operation................787
Pneumatic System Schematic Diagram (Machine No. -408812.03)................788
Pneumatic System Schematic Diagram (Machine No. 409812.00- )................790
Group 15: Diagnostic Information................764
Diagnostic Procedure................871
Diagnose Pneumatic System Malfunctions................798
Diagnose Pneumatic System Malfunctions................798
Pneumatic System Component Location (Machine No. -408812.03)................802
Pneumatic System Schematic (Machine No. -408812.03)................804
Pneumatic System Component Location (Machine No. 409812.00- )................806
Pneumatic System Schematic (Machine No. 409812.00- )................808
Group 25: Tests................764
Unloader Valve Pressure Test and Adjustment................814
Park Brake Valve Pressure Test................818
Section 9025: Hydraulic System................822
Group 05: Theory of Operation................822
Articulated Dump Truck Hydraulic System Overview................825
Articulated Dump Truck Hydraulic System Operation................826
Main Hydraulic Pump Operation................829
Main Hydraulic Pump Load Sense Operation................831
Hydraulic System Manifold Operation................841
Body Control Valve Operation................854
Brake Accumulator Charge Circuit Operation................856
Service Brake Valve Operation................860
Steering and Secondary Steering System Operation................862
Steering Valve Operation................865
Secondary Steering Hydraulic Pump Operation................868
Group 15: Diagnostic Information................822
Diagnostic Procedure................871
Diagnose Hydraulic System Malfunctions................872
Diagnose Steering System Malfunctions................875
Diagnose Service Brake System Malfunctions................878
Hydraulic System Circuit Symbols................879
Hydraulic System Component Location................880
Hydraulic System Schematic................882
Group 25: Tests................822
JT05801 Clamp-On Electronic Tachometer Installation................886
JT05800 Digital Thermometer Installation................887
JT02156A Digital Pressure/Temperature Analyzer Installation................888
Hydraulic Oil Filter Inspection Procedure................889
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy................890
Hydraulic System Warm-Up Procedure................892
Cycle Time Test................893
Main Hydraulic Pump Residual and Compensator Valves Test and Adjustment-(S.N. -200152)................897
Main Hydraulic Pump Residual and Compensator Valves Test and Adjustment-(S.N. 200153- )................904
Body Lower Circuit Relief Valve Test................911
Body Raise Circuit Relief Valve Test................915
Brake Accumulator Pressure Reducing Valve Test and Adjustment................919
Brake Accumulator Charge Valve Band Test and Adjustment................925
Brake Low Pressure Switch and Brake Accumulator Test................929
Service Brake Valve Test................934
Secondary Steering Pump Residual and Compensator Valves Test and Adjustment-(S.N. -200152)................938
Secondary Steering Pump Residual and Compensator Valves Test and Adjustment-(S.N. 200153- )................951
Steering Load Sense Relief Valve Test and Adjustment................964
Steering Cylinder Leakage Test................968
Section 9031: Heater and Air Conditioner................971
Group 05: Theory of Operation................971
Proper R134a Refrigerant Handling................1026
R134a Refrigerant Cautions................1027
R134a Refrigerant Operation................976
Air Conditioner Compressor Operation................978
Condenser Operation................979
Receiver-Dryer Operation................980
Expansion Valve Operation................982
Thermocouple Operation................984
Temperature Control Operation................985
Evaporator Operation................986
Heater Core Operation................987
High/Low Pressure Switch Operation................988
Heater and Air Conditioner Electrical Circuit Operation................989
Heater and Air Conditioner Circuit Schematic................990
Group 15: Diagnostic Information................971
Diagnose Air Conditioner Malfunctions................994
Diagnose Heater System Malfunctions................997
Heater and Air Conditioner Component Location................999
Group 20: Adjustments................971
Proper R134a Refrigerant Handling................1026
R134a Refrigerant Cautions................1027
R134a Refrigerant Oil Charge Check................1003
Compressor R134a Refrigerant Oil Removal................1004
R134a Refrigerant Oil Component Charge................1005
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure................1008
Recover R134a System................1010
Evacuate R134a System................1012
Charge R134a System................1015
Air Conditioner Compressor Belt Tension Check and Adjustment................1017
R134A Air Conditioner System Cleaning Procedures................1019
Purge R134a Air Conditioner System................1020
Flush R134a Air Conditioner System................1021
Group 25: Tests................972
Proper R134a Refrigerant Handling................1026
R134a Refrigerant Cautions................1027
Refrigerant Hoses And Tubing Inspection................1028
R134a Air Conditioner System Test................1029
Operating Pressure Diagnostic Chart................1039
Pressure Diagnostic Chart................1039
Thermocouple Test................1040
Leak Testing R134a Air Conditioner System................1042
John Deere / Bell Articulated Dump Truck B25C Operation & Test Service Manual (TM1811)
