LARGE ADT’s MK III

PNEUMATICS

Issue: 3
(April 2004)

Technical Training Documentation

BELL EQUIPMENT COMPANY

Richards Bay
Chapter 4 PNEUMATICS LARGE D-SERIES MK III
PNUEMATIC SYSTEM

Port numbering definition for pneumatic components.

1 = Inlet port
2 = Delivery
3 = Exhaust
4 = Signal pressure

If more than one digit is used, the first digit refers to one of the above definitions and the
Second digit refers to the circuit. Example : 21 First digit refers to air delivery from a supply
source. The Second digit refers to circuit 1.

The list below is a list of abbreviations that are used on the pneumatic block, which can be
found on the right hand side of the cab, against the front firewall. The pneumatic block is
accessed from the right hand panel on the side of the cab, for the internal side, and by opening
the bonnet, to access the external side.

ABBREVIATIONS

TVU ..........................Tip valve up

TVD ..........................Tip valve down
TC ............................Transfer case
TC2 ..........................Transfer case port 2
AT ............................Auxiliary through connetion
AS ............................Main air supply
H...............................Horn
EB ............................Exhaust brake
PB ............................Park brake
AA2 ..........................Auxiliary air supply port 2
TLA ..........................Tip lever air supply
TLX ..........................Tip lever exhaust
TLD ..........................Tip lever down
TLU ..........................Tip leverup
PBS..........................Park brake solenoid feed
PBA..........................Park brake air supply
PBX..........................Park brake exhaust
S...............................Seat
AA3 ..........................Auxiliary air supply port 3

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Chapter 4 PNEUMATICS LARGE D-SERIES MK III
COMPRESSOR

PURPOSE
To supply compressed air for the pneumatic
system.

OPERATION
The compressor is an engine driven single
cylinder piston type compressor.
As the piston moves downward clean air
from the engine intake manifold is drawn in
through the inlet valve. As the piston moves
upward the inlet valve closes and air is com-
pressed and passes through the delivery
valve into the pneumatic system.

UNLOADER VALVE WITH INTEGRAL AIR DRIER

PURPOSE
To control the air pressures in the pneumatic
system and unload the compressor.
To dry the compressed air supplied by the
compressor by extracting the moisture
present in the air.

CHARGING
Compressed air supplied by the compressor
flows into chamber A port l. Due to the re-
duction in temperature, condensed water
collects here and will reach outlet port (f) via
duct C.The air flows via a fine filter integrat- 1
ed in the cartridge and annulus (k) to the up- 21
per side of desiccant cartridge (b). As the air 22
flows through desiccant (a), moisture is ex-
tracted and absorbed by the surface of des-
iccant.The dried air will reach the pressure
protection valve via non-return valve (c),
and port. At the same time, dried air also
flows to the regeneration air reservoir via or-
ifice (d) and port 22
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UNLOADING THE COMPRESSOR

Cut-off pressure will reach chamber D via

port L, acting on diaphragm (m). As soon as
the spring force is overcome chamber D is
opened to chamber B; this will inturn force
piston (e) down opening port f to atmos-
phere via the exhaust port 3.
The air delivered by the compressor is now
emitted via chamber A, duct C and outlet 3.
Piston (e) also acts as a pressure relief
valve. If the pressure is excessive, piston
(e) will automatically open port (f).
1
21
22

3 TR000095

PURGING THE AIR DRIER

Air from the regeneration air reservoir will

now flow to the lower side of desiccant car-
tridge (b) through oriface (d). As it expands
and flows through desiccant cartridge (b),
the moisture adhering to the surface of des-
icant (a) is removed by the air and emitted
through outlet (3) after passing duct C and
outlet f. If, due to air consumption, the sup-
ply pressure in the system falls below cut-in
pressure, chamber D will closed off from
chamber B will be reduced via the outlet port 1
of the unloader. Outlet port f closes and the 21
drying process will start again.If the passage 22
of air through the cartridge is prevented due
to a blocked filter, valve (h) will open and the
air will reach port (21) without being dried. In
normal operation, the valve remains closed.
The purging phase occurs at the same time
as the unloading phase but only lasts for
about ½ a minute.
X Is the electrical grid (purging unit) which is 3 TR000096

used to keep the outlet warm so that the duct

C does not freeze up in cold climates.

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Chapter 4 PNEUMATICS LARGE D-SERIES MK III
PNUEMATIC BLOCK VIEWS (SOLENOID & PRESSURE SWITCHES)

8
6
9
5
4

10
3

TR000097

1 ...............................HORN SOLENOID
When energised directs air through the airhorn circuit.
2 ...............................TC SOLENOID
Provided the accelerator pedal is less than 10% of its travel the CCU
energised TC solenoid which directs air to the actuator for the interaxle
lock ,applying interaxle lock.
3 ...............................CTD SOLENOID
When energised directs air to the actuators on the diffs,engaging the diff
locks.
4 ...............................CTD PRESSURE SWITCH
This pressure switch will close once the solenoid has been energised
and the pressure begins to build up in the CTD circuit. It will direct an
earth to the MDU closing the cicuit to the diff lock warning light,
illuminating it.
5 ...............................TC PRESSURE SWITCH
This pressure switch will close once the solenoid has been energised
and the pressure begins to build up in the TC circuit .It will direct an earth
to the MDU closing the cicuit to the interaxle lock warning light,
illuminating it.
6 ...............................BIN UP PRESSURE SWITCH
Once the bin tip lever has been activated for bin up, the pressure begins
to build up in its circuit.This pressure will act on the bin up pressure
switch opening electrical cicuit to the bin float solenoid de-enegising
it.This will allow the hydraulic oil to be directed to the bin tip cylinders.
7 ...............................PB PRESSURE SWITCH
This pressure switch is closed when the park brake is applied supplying
an earth to the CCU which intern sends a CAN signal to the MDU
activating the park brake light on the MDU.When the park brake is re -
leased the air building up in the park brake circuit brakes the contact in
the pressure switch braking the earth signal to the CCU which intern via
CAN switches off the park brake light on the MDU.

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Chapter 4 PNEUMATICS LARGE D-SERIES MK III
8 ...............................PB SOLENOID
Once the CCU has recieved the signal from the VDO that the air pressure
is above 6 bar or 87 Psi ,which can be read on the MDU.
Park brake must be released, applied and released again.This will direct
an earth signal to the CCU via a momentry switch each time the PB is
applied.Once the CCU has recieved this signal it will direct a positive
signal to the PB relay energising it.This will intern close the circuit to the
PB solenoid energising it ,allowing the air to be directed to the park brake
actuator releasing it. Once this has occured the park brake will function
normally.Only if the system pressure drops below 6bar or 87 Psi will the
park brake will apply.
9 ...............................EB & EVB SOLENOID
Once the machine is traveling in lock up and the acclerator pedal is
released the EB & EVB solenoid is energised. The air is directed onto the
EVB valves and into the EB actuator,opening the combustion chambers
to exhaust and closing the butterfly.This will retard the engine which will
inturn retard the machine as the lock up clutch is applied.
10 .............................SYSTEM PRESSURE SENDER UNIT
This is a VDO sender unit which measures the system pressure.It var-
ies the resitance according to pressure sending the signal to the CCU.
The CCU interprets these signals and via a CAN line sends them to the
MDU were they are displayed as decimal figures eg: 6bar

PNEUMATIC VIEWS (FILTERS ,CHECK VALVES & QUICK COUPLER)

12

13

11

View

14

15

TR000099

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Chapter 4 PNEUMATICS LARGE D-SERIES MK III
11 .............................PB CHECK VALVE
The check valve protects the park brake if there is a system pressure
loss.
12 .............................PB ORIFICE
The function of the orifice is to allow the air to escape to atmosphere
gradually from the park brake actuator when the park brake is released.
13 .............................PNEUMATIC QUICK COUPLER
This is a fitting made available externally for when air is required for
auxiliary use.
14 .............................EXHAUST FILTERS
These exhaust filters are used to stop the entry of dirt and to reduse
sound.
15 .............................SOLENOID EXHAUST FILTERS
These exhaust filters are used to stop the entry of dirt and to reduse
sound.

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Chapter 4 PNEUMATICS LARGE D-SERIES MK III

REMOVE AND INSERT A3 SCHEMATIC DRAWING

DRAWING NO: TR000091

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Chapter 4 PNEUMATICS LARGE D-SERIES MK III

REMOVE AND INSERT A3 SCHEMATIC DRAWING

DRAWING NO: TR000092

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