HOT SEAT: Custom-built ADTs for niche applications

Bell Equipment continues to gain ground as a leading innovator in articulated dump truck (ADT) development. IMIESA speaks to Nick Kyriacos, product marketing manager: Mining and Construction, and Dawie Ras, engineering manager: Mining and Construction Specials, about pioneering work on the Bell Versa series, a derivative of the OEM’s standard ADT offering.

Where does the Versa slot in within the Bell ADT line-up?

NK: Our manufacturing centre for the global distribution of ADTs and the Versa series is based at our Richards Bay factory and head office in South Africa.

The introduction of the Versa follows intensive research and development (R&D) in the local market, where the first prototypes went through a rigorous field evaluation process.

Thereafter, commercially approved units began to roll off the production line. The local market feedback has been excellent, and we are now steadily introducing the Versa to our international customer base.

Each Versa truck is a custom build working off the proven and latest-generation Bell E-Series ADT platform, which comprises the B25E, B30E, B35E, B40E, B45E, B50E and B60E range.

So far, we’ve developed solutions for a diverse customer base within South Africa and further afield in Africa and the world. A recent example is the production of a purposebuilt solution for German OEM Streumaster, in Europe. One of Streumaster’s proprietary cement spreader systems for road stabilisation has been mounted on and integrates with a Bell B25E powerhead (or truck tractor) and its chassis.

Can customers choose different engines and drivetrains?

DR: All our ADTs and Versa units are fitted with Mercedes-Benz engines. Customers select the applicable E-Series power head as the base. From there, we modify the rear-end section – either on a standard, shortened or extended chassis – to support the solution required by the customer.

Our custom builds for timber trucks illustrate our design flexibility. We offer numerous variations because we understand that every site has its unique conditions. A case in point is the especially steep terrain that characterises the forestry region in Nelspruit, Mpumalanga.

In response, we’ve developed a more powerful 240 kW B25E equipped with the B30E engine and drivetrain that packs a real punch. For customers in this region, it’s an ideal solution – the right-sized truck for the application, with the torque to conquer the rolling elevations.

As is traditional for ADTs, all transmissions are automatic. This translates into improved fuel consumption, extended engine life, and the right level of control in rough terrain applications.

All our axles are developed in-house and here we provide the option of fitting either dry or wet disc brakes. Dry brakes are fitted as standard on our smaller trucks, but on larger trucks the wet brake option, which adds to the upfront capital cost of the machine, is favoured due to long lifespan, which justifies this expense.

Wet disc brakes provide far greater stopping power, which is especially important for heavier loads. Wet disc brakes also last far longer due to the limited contact of the friction plates. Where trucks operate in marshy conditions, wet brakes are also essential since they are designed as a fully sealed system. As a value-added offering, we now include wet discs as a standard feature on the B30E powerhead.

What type of chassis setups are available?

NK: There are various options. These comprise the standard chassis, an extended chassis, a 4x4 hauler chassis, a 4x4 short chassis, a standard chassis with crane mounting, and an extended chassis with crane mounting. The 4x4 short chassis can be fitted with a fifth wheel attachment where the intention is to tow interchangeable systems, such as trailers, grid rollers and impact rollers.

A classic example of our out-of-the-box thinking is the Versa timber truck forwarder. This model originally started out as a standard Bell ADT designed for timber haulage. However, after numerous customer requests for a forwarder unit and without having one in our product line-up at that stage, the large number of potential orders justified the R&D effort to design a new niche product.

In the end, we developed a special ADT fitted with a slightly bigger and dual-faced cab. Inside the cab compartment is the standard steering wheel. A swing-around seat arrangement then enables the driver to face to the rear and operate a set of joysticks that control a chassis-mounted crane for loading and unloading logs. As a further plus, the driver can also stay in this reversed position and drive the truck using the joysticks to manoeuvre into a better position.

Is the quarrying sector a growth market?

NK: Yes, definitely – with good traction to date from both the South African and European markets. The Bell Versa B30E 4x4 is very popular with quarry and readymix operators in France.

Locally, we demonstrated this unit for a quarry owner in Durban, where the feedback has been excellent. This client currently employs standard 6x6 ADTs, so it was interesting to do a side by side comparison. While the B30E 4x4 may not provide quite the same off-road, deep-mud performance as a 6x6, it’s still an all-wheel-drive machine.

From the client’s perspective, our 4x4 competed favourably with the 6x6 in terms of payload performance. On top of this, the 4x4 displayed superior handling within the quarry, greater fuel efficiency, and was better suited to manoeuvring the tight turns on-site. Faster cycle times contribute to a lower cost per tonne.

We plan to run further demonstrations across South Africa and believe it’s the beginning of a trend in the quarrying sector.

What can customers expect from custom builds?

DR: If it comes with a standard base, with no drivetrain modification, and a straightforward application equipment fitment, we can turn a customer order around quickly.

A Versa customer is coming to us because they have a specific solution in mind and that solution is not available in the open market. Design flexibility and class leadership on our ADT series are what make the Versa the logical choice for tailormade solutions.

We have a dedicated application equipment design team in Richards Bay working for our local and global customer base. This design team currently comprises six mechanical and two electrical engineering specialists.

What are standard features common to the Versa series?

NK: All ADTs come with a standard ROPS/ FOPS certified cab, which differentiates it from a tipper truck. Safety is key; here, features include our fail-safe park brake system. We also have an emergency steering system: if the power cuts out, the truck can still be steered using its momentum.

In cab, the controls no longer have rocker switches: they have been replaced by a sealed switch module with exceptional functionality. The central display unit is also user-friendly, enabling the operator to carry out daily checks, cross-check inspection lists, and carry out machine diagnostics.

Another interesting feature is an auto spin-down function for the turbo once the machine is parked. The engine will shut off only once temperature levels have normalised.

What is the future direction in terms of R&D?

NK: Bell Equipment was built on the specialised machinery concept. In the 1950s, our founder, Irvine Bell, offered specialised machines to meet the needs of the sugar industry and in the same way our engineering team has always worked to meet customer requirements, no matter how impossible they may seem to be. That’s the working philosophy behind our growing Versa machine population.