A dump truck manufacturer identified the need to integrate pneumatic manifolds to achieve dramatic reductions in components and assembly times for its new D-Series articulated dump trucks.

Dump truck manufacturer Bell Equipment identified the need to integrate pneumatic manifolds to achieve dramatic reductions in components and assembly times for its new D-Series ADTs (Articulated Dump Trucks). Global pneumatics expert Norgren worked in close cooperation with Bell Equipment to deliver the desired results. Located in Richards Bay in South Africa, Bell Equipment is a manufacturer of specialised loading and haulage plant for use around the world in the construction and many other industries.

Its latest product, the new state of the art D-Series ADT was launched worldwide at the end of 2001, reinforcing Bell Equipment's solid reputation for rugged, reliable products with outstanding customer satisfaction.

No leaks or failures during stringent tests From the early concepts of the D-Series ADT, the pneumatic system design and selection of components has been of prime importance.

Supplier and customer alike worked in close co-operation to establish a radical new installation layout for the D-Series.

The requirement therefore was for a totally new approach to the compressed air system.

Says Andrew Staniland, leader of the D-series ADT design team responsible for the pneumatics at Bell Equipment: 'We deemed it imperative to reduce the number of components in order to speed up assembly, reduce maintenance and eliminate possible air leaks in the system.

Norgren identified opportunities to consolidate the component requirements and by the introduction of their IPM (Integrated Pneumatic Manifold) vastly reduced the quantity of fittings and tubing previously required.

'We reduced the number of components by 75 per cent, reduced assembly times to a fraction of that previously spent on this task, and no leaks or component failures have been recorded during stringent tests in the past 16 months.' Supplied by Norgren's distributor NorGrip in South Africa, pneumatic components include Norgren's V44 and V05 solenoid valves, D18 pressure switches, sensors, Fleetfit fittings and a variety of connectors and hoses.

Pneumatics are used to control exhaust brake actuators, parking and ancillary brake systems, transmission shifting, remote hydraulic valves and supplementary equipment such as air horns and driver's seat adjustment.

Previously, control components have been distributed around a vehicle with each one requiring a separate mounting with associated hoses and electrical wiring.

The IPM is a single manifold block, which is used to physically mount all pneumatic components and serves as the transfer port between engine and driver controls.

By locating all of the critical components inside the driver's air-conditioned cab, only a single electrical connection harness is required, resulting in a notable increase in expected service life.

The interfaces for valves and pressure switches are machined directly onto a single manifold block, eliminating normal sub-bases, fittings and hoses.

In addition, the elements of several Norgren components such as non-return valves, throttle assemblies, shuttle valves and an overflow valve are incorporated into the manifold block.

Fitness for purpose Each IPM is pre-assembled with all of the pneumatic components and then tested, certified and engraved with port identification and a unique serial number.

During the three year development phase Norgren was able to specify the client's precise requirements and the final result is evidence of the support and options offered from the vast Norgren product range, supported by Norgren's global truck group.

Peter Bell, Group Technical Director of Bell Equipment, reiterates Norgren's excellence: 'The pre-assembled and tested IPM fits in with the Bell philosophy of increased participation by specialist suppliers.

Every major machine component is selected on fitness for purpose, not from a limited house brand source, but from the best the world has to offer.' Reflecting the innovative design of the IPM, it received a prestigious award in the prototype category from the South African Bureau of Standards Design Institute 2001.