MAN at bauma 2013
Under the motto "Consistently efficient", the new Euro VI vehicles for traction transport are in the limelight at MAN's bauma stand. MAN has been producing all-wheel-drive vehicles for over 75 years and its competence in this segment and knowledge of the industry are unmatched.
At bauma 2013, MAN engines complying with the Euro VI exhaust standard are celebrating their world premiere in construction vehicles. Further innovations are the cabs with steel bumpers, the crew cab for the MAN TGL and TGM series and a heavy-duty four-axle tipper with a gross weight of 50 tonnes for operation in open-cast mining. For many decades now, MAN has been a strong partner for the construction industry. At the trade fair, customers will see MAN construction vehicles complying with the Euro VI standard and combining economy with reliability. The focus is on efficient construction logistics with rugged and economical vehicles and a comprehensive portfolio of services.
The new MAN TGS and TGX show themselves with a completely newly designed front end boasting a harmoniously integrated steel bumper. The TGL series with conventional on-road drive and the TGM series with on-road as well as all-wheel drive are both available with the new three-piece steel bumper. Customers responded very positively to the new interior design of the MAN TGL and TGM when the on-road versions were introduced. It offers more comfort and functionality, thanks to the high-quality finish and easy-to-use instruments. MAN rounds off its appearance at the trade fair with the presentation of its re-engineered crew cab for the TGL and TGM series. On the outside, it exhibits the new design of the Euro VI vehicles, while the interior is brand new.
The special challenges facing construction vehicles
Besides efficient operation and ruggedness, high payload and thus the lowest possible unladen weight are very important to companies active in the construction sector, because ideally they operate their vehicles fully laden. The objective of MAN's engineers during the development of the Euro VI engines and their associated exhaust-gas aftertreatment systems was to specify and design the components so the least possible payload was lost. A second aspect concerned the ease of mounting bodies, given that MAN vehicles are employed in a great number of different variants in the mining and construction industries. For this reason, the new exhaust technology had to be developed so that it would not impose any restrictions on the vehicle bodies. The result is convincing: not a single component of the vehicle that could hinder the mounting of a body protrudes above the top edge of the frame. In addition, however, the installation spaces on the sides also had to be designed in a manner suitable for the sector. Supports on loading-crane tippers, hydraulic-oil tanks and pumps for powering bodies and implements such as snow ploughs, road sweepers and silo compressors are just a representative few of the challenges that had to be met. MAN's engineers rose to these challenges with the result that bodies and implements are as easy to mount as to operate. The model-specific location of exhaust silencers, fuel and AdBlue tanks or upswept tailpipes shows that the vehicles have been ideally matched to the demands of the industry and the body builders.
Pulling power at low revs, so important for construction and all-wheel-drive vehicles, was one of the focal points in developing the driveline. By comparison with Euro V engines, the new units develop their maximum torque at lower engine speeds. Full torque is thus available earlier.
A distinguishing feature - the steel bumper
In the course of the new vehicle design for Euro VI, the rugged steel bumper - a typical feature of the equipment on vehicles operated by municipalities and in the construction industry - has been given a new form. In all MAN series, this bumper is in three parts so as to keep down the cost of repair incurred by replacing individual parts. The big cooling-air intakes ensure the cooling of the Euro VI engine under all operating conditions. An integrated step makes it easier for the driver to climb up to clean the windscreen. In the TGS and TGX series, the number plate covers the front coupling jaw and reduces soiling. The number plate holder is hinged and can be swung down as necessary.
Striking design and new lion for Euro VI vehicles
In addition to being visually appealing, the new design of the vehicle front also takes the technical necessities of the Euro VI standard into account. The cooling air intakes on the front of the vehicle occupy a greater area in order to maximise the inflow cross-section and thus increase the engine cooling power. Aerodynamic optimisations conducted on the A posts, wind deflectors and bumpers contribute to improved routing of cooling air and minimisation of fuel consumption.
The upper edge of the front panel has been moved down, so that the windscreen wiper cover is now exposed. In this way, the design of the area including the windscreen wipers in black serves to visually enlarge the windscreen surface. The interplay between the wide-open wind deflectors and the V of the radiator panel and cooling-air intakes gives the front end of the vehicle its own dynamic design. The recognition value of MAN trucks is preserved. Nevertheless, differences in the proportions and the lines contribute to visually differentiating the Euro VI vehicles within the MAN TG family.
Whether it's on the construction site, in distribution transport or on long hauls, across the board from Euro II to Euro VI engines, the new MAN lion has its prominent place on the chrome trim of the radiator grille. The lion, a traditional figure of world renown and symbol of MAN's strength, has undergone a significant revaluation. It now radiates even more agility and power. The three famous letters, MAN, also gain by the new design of the logo: they are slightly bigger and stand out more visibly from the center of the radiator grille.
The competence of nearly a century in the construction industry
MAN was making tipper trucks as far back as almost one hundred years ago. Collaboration with the Munich-based Meiller company, renowned for the tipper bodies it manufactures for construction vehicles, stretches back to 1916. Starting in 1925, MAN had trucks with Meiller tipper bodies in its range of products.
Not only that, but MAN also draws on more than 75 years' experience in manufacturing all-wheel-drive vehicles. In 1937, MAN began with its development of an all-wheel-drive three-axle vehicle. Known as the "Einheitsdiesel" (roughly "standard truck"), it was produced for military applications. Three years later, the MAN ML 4500 A, a two-axle truck with all-wheel drive, was also launched on the market. In the post-war years, MAN's tractor production profited from this development: the company wrote tractor history when it introduced all-wheel-drive to the agricultural tractor in 1948. From 1952 on, MAN offered all-wheel drive versions in its MK range, and again more widely from the end of the fifties with the generation of short-hood trucks. At the same time, large numbers of MAN Type 630 were produced for military applications. This was the foundation of MAN's reputation as a manufacturer of reliable and rugged all-wheel-drive vehicles, a reputation the company consolidated with its development and production of a family of mountain off-road wheeled vehicles for the German Federal Armed Forces and other armies. Since then, all-wheel-drive trucks have always been a part of the MAN product range.
Just as much a part of MAN's competence in the construction industry is the company's long experience in configuring chassis and drives for special applications, experience that shows in the sector-specific chassis design for transport mixers, for example. As a matter of course, the technical innovations of the past decade, such as MAN HydroDrive® for the front axle or the MAN PriTarder® water retarder are installed in the new construction-sector vehicles with Euro VI engines.
"Consistently efficient" is the motto of MAN's stand at bauma, where the new Euro-VI-compliant vehicles for the construction industry and off-road operation are the center of attraction.
Striking design for MAN series with Euro VI engines
The interplay of the new lion in the chrome-plated panel of the radiator grille and the wide-open wind deflectors results in a new, dynamic design for the front end of the vehicles. Moving the upper edge of the front flap further down has now exposed the windscreen wiper cover for better visibility. In this way, the windscreen wiper cover's design in black serves to visually enlarge the windscreen surface. This change to the proportions of the front view contributes significantly to differentiating MAN's Euro VI truck. At the same time, however, the recognition value of MAN trucks has been preserved.
New lion dominates MAN radiator grille
Whether it's in distribution transport, on long hauls or on the construction site, across the board from Euro II to Euro VI engines, the new MAN lion has its prominent place on the chrome trim of the radiator grille. The lion, a traditional figure of world renown and symbol of MAN's strength, has undergone a significant revaluation. It now radiates even more agility and power. The three famous letters, MAN, also gain by the new design of the logo: they are slightly bigger and stand out more visibly from the center of the radiator grille.
In addition to being visually appealing, the new design of the vehicle front also takes the requirements of the Euro VI standard into account. The cooling-air inlets at the vehicle's front have a larger surface area in order to maximise the incoming air flow cross-section and hence to increase engine-cooling performance. The aerodynamic optimisations conducted on the A posts, wind deflectors and bumpers all contribute to improved routing of cooling air.
In the course of the new vehicle design, the rugged steel bumper - a typical feature of the equipment on vehicles operated by municipalities and in the construction industry - has also been given a new form. An integrated step makes it easier for the driver to climb up and clean the windscreen. The radiator screen has been optimised so that it ends flush with the steel bumper. Steel bumpers in all MAN series are in three parts so as to keep down the cost of repair incurred by replacing individual parts. The big cooling-air intakes ensure the cooling of the engine under all operating conditions. In the TGS and TGX ranges, the number plate covers the front coupling jaw, preventing it from becoming dirty. When required, the number plate holder can be folded downwards.
Construction vehicles with Euro VI engines from MAN
Euro-VI-compliant engines are being introduced for MAN's entire range of products from TGL to TGS as well as TGX. MAN relies on an efficient concept comprising electronically regulated exhaust-gas recirculation (EGR) and exhaust-gas aftertreatment employing a CRT soot filter system and selective catalytic reduction (SCR). To this end, MAN combines sophisticated technologies, matching them optimally to each other. The key technologies necessary for Euro VI - common-rail injection system, exhaust-gas recirculation, two-stage turbocharging with intercooling, diesel particulate filter and SCR system - have for years successfully been proving their suitability for practical operation in MAN vehicles. Cooled exhaust-gas recirculation has been standard on trucks since 2000, SCR technology since 2005. The developers' primary goal was to keep fuel consumption down to the recognised low levels of Euro V without loss of power or torque. This means that MAN can continue to offer its customers efficient and reliable vehicles for daily operation.
By comparison with the Euro V standard, Euro VI requires a reduction of 80 percent in NOx emissions (from 2 g/kWh to 0.4 g/kWh) and a reduction of 66 percent in particulate mass (from 0.03 g/kWh to 0.01 g/kWh) with effect from 2014. This is why exhaust-gas aftertreatment consists of an oxidation catalytic converter in conjunction with a closed diesel particulate filter as well as SCR catalytic converters and associated sensors. MAN positions this entire system, known as SCRT (Selective Catalytic Reduction Technology), compactly on the right side of the vehicle behind the front mudguard in the exhaust silencer.
Euro VI engines with outputs of 220 hp (162 kW) up to the current maximum of 480 hp (353 kW) employ a combination of two-stage turbocharging with primary cooling and cooling and intercooling of the boost air. MAN consciously bases its strategy on two separate rugged and reliable turbochargers that share the job of increasing boost-air pressure instead of a single more complex turbocharger with variable turbine geometry. The result is a very high degree of efficiency with input power delivered fast across the whole engine-speed range and a longer service life for the system.
The maximum torque of MAN's new Euro VI engines is available at low engine speeds across a wider speed range than Euro V engines. In the heavy-duty series, the 320-hp (235-kW) engine outputs a maximum torque of 1,600 Nm at an engine speed as low as 930 rpm and maintains it up to 1,400 rpm. The same applies to the 360-hp (265-kW) engine with 1,800 Nm, the 400-hp (294-kW) engine with 1,900 Nm, the 440-hp (324-kW) engine with 2,100 Nm and the 480-hp (353-kW) engine with 2,300 Nm. The Euro VI vehicles can thus show their teeth off-road while being economical in on-road operation. These two aspects are demonstrated in a particularly impressive manner at 440 hp, which in Euro VI is now delivered by the engine with the largest capacity, 12.6 litres.
In formulating its regeneration strategy for the diesel particulate filter, MAN also paid special attention to maximum operational reliability. Regeneration in normal operation takes place independently and automatically. This enables almost all the particles that have been collected in the filter to be broken down while the vehicle is being driven. The particularly large surface of the ceramic filter elements enables long filter service lives. The oil-ash residue that collects in the diesel particulate filter after several hundred thousand kilometres is removed by replacing the filter element during servicing. The vehicle's service interval calculator recommends the intervals between cleaning, taking into account the operating conditions and the continually monitored exhaust-gas backpressure.
MAN positions the Euro VI exhaust silencer on the right side of the vehicle. This means that the well-known ease of mounting bodies on MAN chassis is retained because, as in the past, no parts protrude above the top edge of the frame. As industry-specific equipment, at bauma 2013 MAN is presenting upswept exhaust pipes at the rear of the cab. This is important primarily for vehicles that run the power take-off while stationary as it considerably reduces the exposure of an operator next to or behind the vehicle to exhaust emissions. MAN stays light - the weight of the system increases by only around 150 kg for the MAN TGL with a four-cylinder engine and by around 200 kg for TGL and TGM vehicles equipped with six-cylinder engines. The Euro VI exhaust-gas cleaning components similarly add only around 200 kg to the unladen weight of the TGS and TGX.
Leading trade fair hosts MAN's world first crew cab in Euro VI design with new interior for MAN TGL and TGM series.
bauma world premiere: crew cab with new interior for MAN TGL and TGM
A new interior concept for more comfort and functionality – this is the statement with which MAN introduced the cabs for the TGL and TGM series at the IAA 2012. At bauma 2013 MAN is for the first time showing the crew cab in the Euro VI version, which convinces with its high-grade materials. The new cab with its seven seats will be exhibited mounted on a Euro-VI-compliant MAN TGL 12.180 with a three-way tipper body. This vehicle proves how efficient it is in operation as a transporter of people and material. It demonstrates its efficiency with its big payload.
On the Euro VI version of its cabs for the TGL and TGM series, MAN relocated the air intake, which is now upswept on the rear wall of the cab with the air filter above the gearbox. This makes space on the frame for other fittings, such as supports on crane tippers.
The interior cladding has been completely newly designed: brushed aluminium decorative trim, surfaces in grained plastic and satin chromed door handles reflect the premium concept familiar from upmarket passenger cars. The interior door cladding is made from washable materials and is thus easy to clean. Being able to remove dirt and dust quickly and easily from the cab is particularly important in the construction industry.
The MAN trucks in the light and medium-weight series now also offer the driver the same instrument panel that has become well known from the heavy series, whose quality is equalled only by its ergonomic functionality. The heating / air-conditioning control panel has been fitted with new control elements and a display. Even in the dark, the function of the rocker switches can be recognised quickly and correctly, thanks to the restrained lighting. This means that the driver can concentrate more fully on what is happening on the road. Controls for the electric window lifters in the front and the electrically adjustable external mirrors are now conveniently located in the door module.
There is a variety of storage facilities to keep the cab tidy and provide fast access to items that are often needed. A refreshment holder integrated in the door keeps bottles always within reach, while the center console has a cup holder. A specially shaped version of the dashboard ensures that cab variants equipped with a center seat offer the second co-driver more freedom of movement. MAN has optimised the ventilation and the air streams with automatic air-conditioning in the cab: the distribution of the air creates no draughts, a characteristic of the air-conditioning system that has already become very highly valued in the big cabs.
Both the new TGL and the TGM are equipped as standard with the MAN BasicLine CD player with radio and MP3-capable CD drive with title display. Speed-dependent control keeps the volume at the right level. The new MAN Media Truck (MMT) Advanced presented at the IAA 2012 is also available for the TGL and TGM series. Besides the combination of radio and satnav, it also offers other functions: the optional USB/AUX interface positioned in the center console allows the straightforward connection of an external audio source, such as an MP3 player. The 5-inch touchscreen monitor simplifies operation of the navigation device and provides a clear, informative view of the proposed route.
MAN has been producing all-wheel-drive vehicles for over 75 years and its competence in this segment is unmatched. Technologies such as MAN HydroDrive®, MAN PriTarder® or the steering brake are efficient customer solutions for the construction industry.
What characterises an efficient construction vehicle? The speed of transport and reliable traction in difficult terrain also play big roles in the construction industry. Engines with plenty of pulling power and a large payload are similarly important factors. Where optimum traction is needed, all-wheel drive gets the vehicles in the MAN TGM and TGS ranges moving. In 2012, MAN was able to look back at 75 years of experience in designing and producing trucks with all-wheel drive. This includes not only the various drive configurations but also the production of planetary axles with high ground clearance and the type of axle suspension and axle guide with leaf or air suspension.
Few competitors offer the choice that MAN does between engageable and permanent all-wheel drive. The 4x4, 6x6 and 8x6 vehicles have engageable all-wheel drive as standard. Permanent all-wheel drive with length compensation and pneumatically engaged inter-axle differential is an option on these vehicles, on the MAN TGS 8x8 it comes as standard. Power is distributed by transfer cases developed and produced by MAN.
The great advantage of engageable all-wheel drive is that the vehicle's operational profile makes it equally suitable for on- and off-road use. The option of being able to run as a purely rear-wheel drive vehicle on paved roads makes itself positively felt in reduced fuel consumption, lower tyre wear and easier handling. A rotary switch makes it convenient for the driver to engage front-wheel drive when the vehicle is stationary. Here, the transfer case connects front and rear axles with each other by means of a dog clutch. The off-road ratio doubles the number of gears available when all-wheel drive is engaged. This eases the load on the driveline and enables the vehicle to be driven at low speeds when not on paved roads.
Permanent all-wheel drive provides maximum traction and a high level of driving stability during lengthy periods of driving on relatively level surfaces where the grip varies greatly. This is the ideal solution, particularly for coping with the exacerbated conditions of construction sites and in municipal operation, as well as for winter service and emergency organisations. Here too, an inter-axle differential lock can be manually engaged.
MAN HydroDrive® for a big extra helping of traction
MAN was the first truck manufacturer in the world to put an intelligent supplement to classic all-wheel drive on the market: the MAN HydroDrive® provides more traction and safety on demand when driving into or out of unpaved construction sites, on slopes and slippery roads. The engageable hydraulic front-wheel drive gives you the driving power to operate safely in these situations, forwards and in reverse. MAN HydroDrive® is a system of hydraulic motors installed in the hubs of the front wheels. A hydraulic pump flanged onto the gearbox output generates a drive torque of around 7000 Nm per wheel. Hydraulic lines transmit the maximum 420-bar pressure to the wheel-hub motors.
Representative of the outstanding transport efficiency attained by MAN HydroDrive® are the high-traction 4x4H semitrailer tractors, which operate with tipper or concrete-mixer semitrailers. MAN trucks are distinguished by their low unladen weight. As a roll-off and set-down skip loader, this version of the MAN TGS in conjunction with a steered trailing axle really makes its mark in terms of manoeuvrability, weight and traction. More than 8,000 customers have already been convinced by the advantages of the MAN HydroDrive® since its market launch in 2005.
When you're driving downhill with the HydroDrive® engaged, the sustained-action brake also acts on the front axle to stabilize the vehicle. The MAN HydroDrive® can be activated by merely turning a rotary switch, both while driving and under load – the driver can thus master gradients safely without having to stop. By comparison with conventional rear-wheel drive, MAN HydroDrive® scores top marks, weighing only slightly more. By contrast to a classic all-wheel drive, however, it saves several hundred kilograms. Neither fuel consumption nor turning circle is negatively affected relative to a rear-wheel-drive vehicle, while the design height similarly remains unchanged. That means easy access, low overall height, low center of gravity and optimum driving stability.
Manoeuvrable and safe off-road thanks to the steering brake from MAN
MAN offers a steering brake as special equipment for 6x4 versions in the TGS and TGX series. This enhances manoeuvrability and improves handling behaviour off-road. Selective braking of the rear wheels on the inside of the bend, depending on how far the steering wheel is turned, reduces the tendency to push over the front wheels when cornering. The system is available only from MAN and is activated by a button on the dashboard, preventing understeering at speeds of up to 30 km/h. Exclusively the Euro VI variant of the MAN TGS tipper chassis with 6x4 configuration and a 3,300-mm wheelbase is equipped with steering brake as standard.
Safe and efficient braking with the MAN PriTarder®
With the MAN PriTarder® the MAN TGS is equipped with a highly efficient primary braking system that is unique of its kind. On all-wheel and HydroDrive® vehicles in particular, the braking force provided by the MAN PriTarder® can be optimally used because it acts on all driven wheels – an advantage especially on slippery surfaces.
The sustained-action braking system is integrated into the coolant circuit and flanged directly onto the engine. MAN PriTarder® operates on the crankshaft. Its effect thus depends on the engine speed and even at low vehicle speeds it provides high braking power. In conjunction with the engine brake EVBec this water retarder delivers braking power of up to 600 kW. The MAN PriTarder® shows its strengths particularly in situations where heavily laden vehicles in construction-site operation have to be braked at low driving speeds. The maintenance-free system results in 64 kg more payload by comparison with an Intarder. Moreover, it doubles the service life of the service-brake linings. The MAN PriTarder® is integrated in the MAN BrakeMatic® electronic sustained-action brake management system. Its braking power can be conveniently applied at six levels by means of the steering-column stalk switch.
Compact and versatile – the MAN TGM all-wheel drive at bauma
At bauma 2013 MAN will be exhibiting a Euro-VI compliant all-wheel-drive TGM equipped with the new steel bumper. This MAN TGM combines the versatility of a classic equipment carrier with great manoeuvrability and optimal handling both on- and off-road. The exhibit represents greatest flexibility in everyday operation, because the tasks that have to done on construction sites and in municipal service are widely different and vary according to season: street and site cleaning, winter services, operation with cranes and general transport tasks. The MAN TGM 13.290 4x4 BL with single tyres on show meets all these requirements, in addition to having outstanding off-road operating characteristics.
The modern cab has a new interior design and is fitted with top quality equipment. It takes up to three people. The dashboard is especially designed for this purpose so that the passenger in the middle seat has plenty of space and legroom. With its short wheelbase of 3,250 mm the TGM shows its agility on narrow construction sites and in winter service on streets in residential areas parked full of cars. Its turning circle is 14.3 metres. Different types of equipment such as road sweepers or snowploughs can be attached to the front mounting plate, which complies with DIN EN 15431. A remote-controlled loading crane is located behind the cab. The fittings and tanks required for the exhaust-gas treatment system as well as the tanks for diesel fuel and hydraulic fluid have been positioned by MAN's engineers so that the loading crane's hydraulic supports can be suitably located on the frame.
The 2.35-m wide three-way tipper body contributes to the compactness of the vehicle. Narrow access roads on construction sites or residential areas do not constitute a bottleneck. Depending on the task and the time of year, the loading platform can be fitted with a salt spreader plus tank for a de-icing agent or a compact spray unit with a tank for up to 4,000 litres of fluid. An MAN TGM equipped like this can be operated all the year round: in winter, at temperatures below -5°C, de-icing agent can be applied by means of a rear spray bar, while at other times of the year, water for cleaning purposes flows from the tank on the loading platform to the front road-sweeper. Roads and construction sites can be cleaned with the front road-sweeper.
Air suspension as standard on the all-wheel drive TGM with its gross weight of 14.1 tonnes means that the loading platform remains at a constant height, irrespective of how much is in the spreader hopper. The spreading pattern thus stays exactly as it was set for the entire winter-service shift. All the hydraulic consumers are operated via a single hydraulic pump in a so-called load-sensing system that occupies only a single power take-off. Low consumption, low noise, low wear - these three merits suffice to describe the hydraulic system, which achieves the required level of performance at low engine speeds. This new technology also enables the continuous operation of implements requiring high power inputs, such as front road-sweepers.
MAN realised the vehicle on show in cooperation with the following companies: Meiller, which was responsible for the three-way tipper, Palfinger, which was responsible for the loading crane, and Aebi Schmidt, which was responsible for the front road-sweeper, the tank with spray bar and the load-sensing hydraulic system.
Just-in-time delivery is the norm for concrete, so reliability and speed are crucial aspects of transporting it from the mixing plant to the construction site. Maximum transport capacity contributes to cost effectiveness. MAN has the right chassis for transport-mixer bodies and concrete pumps in its TGM, TGS and TGS-WW series. In addition there are also semitrailer tractors for mixer semitrailers.
In Europe, four-axle chassis with rear-axle drives have become established as transport concrete mixers. In the 8x4 segment, MAN has three load variants from the TGS series in its range of products. The 32-tonner is optimised for weight and offers the greatest payload advantage, the 35-tonner is outstanding for its low unladen weight and high load reserves, while for heavy-duty operation there is also a 41-tonner
For all these tasks, MAN offers transport mixer chassis with two, three and four axles, configured especially for the sector. Safety in transport is very important to the customer and thus also to MAN. As far back as bauma 2004, MAN was the first manufacturer to equip transport mixer chassis with ESP (Electronic Stability Program) in order to eliminate as far as possible the vehicle turning on its side when cornering. Just as important is the adjustment of suspension and stabilisers to the high center of gravity of the body with its load.
In its 32-tonner from the TGS series, MAN offers customers an especially big payload. The rigorous weight-saving work put in by the engineers makes it possible to transport eight cubic metres of concrete with Europe's lightest four-axle transport mixer chassis with an 8x4 drive configuration. Its unladen weight is minimally more than nine tonnes (excluding driver and fuel). Despite this, MAN didn't make any cuts to safety or comfort for the driver, who will find the vehicle equipped with an M cab, complete with all the well-known, comprehensive array of fittings. The hypoid drive axles are fitted with twin tyres on aluminium wheels.
Although the vehicles are offered in normal-height design in all weight classes, they are also suitable for driving on hard-surfaced roads on construction sites The steel bumpers and stable underride protection are capable of absorbing occasional accidental contact with the ground, while the extremely resilient planetary axles provide high ground clearance. The 35- and 41-tonners from the MAN TGS series can also be delivered in medium-height design with up to seven centimetres more ground clearance. Mixer operation is enabled by an adapted engine control unit for the high-torque MAN engines and engine-speed preselection. Even at low driving speeds, the combination of MAN TGS series engines and MAN PriTarder® (primary retarder) ensures great braking performance and optimal safety.
Thanks to the MAN electronics structure, designed especially for the sector, body and vehicle are always in touch with each other. The speed set for the drum remains constant, being independent of the vehicle's driving and engine speeds. As a result, fuel is saved, wear is reduced and there is no unnecessary noise - particularly important on inner-city construction sites. Energy for the mixer's hydraulic system is supplied by engine-dependent power take-offs. On site, operators don't have to walk around to the cab and climb in every time the mixer has to be stopped or started. They can switch the engine on and off using the control panel on the frame end of the body. The upswept exhaust pipe protects operators and other people in the vicinity of the vehicle from exposure to exhaust gases. Ease of body mounting is an important prerequisite for combining chassis and body. To this end, MAN prepares the frame by equipping it with sliding shackles for attaching the body's subframe.
A route profile with a very high percentage of operation on hard-surfaced roads and only occasional operation on construction sites with loose surfaces and short uphill gradients means that the MAN semitrailer tractors with mixer semitrailers are predestined for the utilisation of the innovative MAN HydroDrive® drive technology. All its components are well protected, being located between the frame side members. This means continued ease of body mounting.
New: light and economical four-axle MAN TGM
In its TGM 32.340, MAN is offering a light chassis capable of carrying 8.5 cubic metres of concrete in combination with a light-duty mixer. The four-axle MAN TGM is leaf-sprung all round and is also available in a right-hand-drive version. It is a compact, agile transport mixer designed for delivering concrete to inner-city construction sites. Several factors contribute to its big payload, among them its high-torque D08 common-rail engine with an output of 340 hp, automatic MAN TipMatic® transmission with off-road transmission software, the two hypoid drive axles and twelve aluminium wheels. The sector-specific configuration includes a three-piece steel bumper, suspension and stabilisers adjusted to the mixer drum's high center of gravity, parameterisation of the engine control unit for operating the mixer as well as a flywheel-side PTO for running the mixer's hydraulic system.
MAN chassis for concrete pumps
Complementing truck mixers, many construction sites also employ concrete pumps. The range of products in MAN's TGM, TGS and TGS-WW series includes chassis with outstandingly stable frames for mounting concrete pumps together with their masts. Thanks to its size and manoeuvrability, the MAN TGM with its maximum permissible gross weight of 18 tonnes is suitable primarily for tasks in halls and tunnel systems and on smaller construction sites. Systems with masts up to 24 metres in length and booms extending up to 20 metres are often mounted on this two-axle chassis. Medium-sized to large construction sites employ concrete pumps mounted on three- and four-axle MAN chassis in the TGS series. Their masts have lengths of up to approximately 48 metres. For even bigger concrete pumps and masts a five-axle chassis is also available. The chassis is completed with the addition of the fifth axle by MAN Support Modification. In some cases, the design height of the masts and the installation of the supports necessitate lowering the roof of the cab, relocating frame attachments and changing the wheelbase. These adaptations are similarly carried out by MAN Support Modification. Powerful PTOs provide the high levels of drive energy required by the pumps from the high-performance MAN engines.
With regard to meeting the demand for increased traction when driving into or out of construction sites while at the same time retaining a frame height that is as low as possible, the ideal solution for concrete pumps is the integration of the MAN HydroDrive® system.
Another type of vehicle is the concrete pump mixer, which combines a concrete mixer with a concrete pump and a placing boom. The four-axle chassis in the MAN TGS series are preferred for this task as they offer the payload and vehicle size necessary for realising this combination. In many cases, vehicles of medium-height design are selected for this purpose because they will be used on construction sites and the supports require ground clearance.
From exploration to recultivation: safe, robust and economic MAN trucks score points in the mining industry
MAN vehicles are omnipresent throughout the entire life cycle of a mining area: from the exploration stage and setting up the operating facilities, through the actual mining of the mineral resources, to the recultivation phase. With the diversity of its product range, MAN is positioned as a provider of complete solutions to mining enterprises worldwide.
The life cycle of a mining area begins with exploration. The search for mineral resources often takes place in sparsely populated regions with low infrastructure density. Prospectors and geologists set out in rugged, off-road vehicles. A variety of geophysical methods and exploratory drilling techniques are used for detailed exploration of the viability and the scope of the potential mining area. All-wheel drive MAN vehicles from the series TGM, TGS and TGS WW are on offer for the transport of equipment, drilling rigs and their accessories. Since their work is carried out far from service centres, the entrepreneurs place great emphasis on reliability and robustness in the choice of vehicle. Drilling rigs are usually mounted on all-wheel-drive trucks. The drive power of the drilling rigs and auxiliary equipment can be drawn from high-performance power take-offs of vehicle engines. MAN works in close collaboration with leading body builders to provide a commercially viable and permanently functional working device.
If the decision to set up a mining facility is taken, the second step in the life cycle is the setting up of the mining site. The establishment of an effective infrastructure consisting of wagon trails, roads, railway tracks, bridges and airfields involves a wide range of transportation tasks. The same applies to the construction of administrative buildings and staff accommodation and facilities for processing the mineral resources. Three-way tippers and dump trucks, concrete mixers and trucks are used to transport the material. MAN provides vehicles that are suitable for the respective tasks, from two to five axles, with road drives and all-wheel-drives. They are from the series TGL, TGM, TGS and TGS WW, as well as CLA. Heavy-duty transport vehicles bring mining machinery and equipment to the site. MAN has acquired an outstanding reputation for reliability and performance in this field of heavy duty transport vehicles. This is why the MAN TGX range includes heavy-duty semi-trailer tractors with a maximum output of 680 HP (500 kW) and a total gross weight of 250 tonnes.
The third and most complex section of the life cycle is the winding down phase. Huge quantities of overburden, waste rock and materials containing natural resources occur here. They all have to be transported from where they were excavated to where they are further processed or to the spoil heap, often along steep, unpaved roads. Trucks offer more flexible usage options than mine rail roads or conveyor systems and are significantly less expensive in terms of procurement costs than articulated or heavy-duty dumpers. Dumpers or rear tippers on three- or four-axle chassis are used for this purpose. The demands are daunting: Tough multi-shift operation at maximum daily output, strict safety requirements, maximum loading, off-road use and high dust factor. That is why mining vehicles have to be very rugged with big payloads and powerful engines, while at the same time being economical to run.
The reliability and safety of the fleet is of great importance for entrepreneurs, because vehicle downtime results in losses in terms of the volume transported. In order to meet the stringent requirements of mining operations in terms of short downtimes, MAN offers service facilities tailored to local needs, extending even up to mobile solutions for servicing of the fleet.
However, MAN trucks are not only used in the mining industry, for the transportation from the point of extraction to the point of further processing. The minerals have to be moved between processing stations such as crusher, screener and mixer units as well as stockpiles and subsequently transported to railway stations or harbours for shipping. Depending on the weight and physical form of the cargo, the distance and the condition of the roads, vehicles designed specifically for maximum transport load and speed are utilised. For these purposes, mining companies put together trains consisting of semi-trailers and trailers, which can carry very high overall loads. In multiple-shift operation, these vehicles run almost round the clock. The companies depend on the ruggedness and reliability of their fleets. MAN trucks have successfully proved themselves for many years in the mining industry.
There are many more tasks in the framework of mining operations where trucks are used, for example, as water tankers to sprinkle the paths to minimise dust swirled up or as pump trucks for drilling sludge. Heavy-duty platform trucks deal with the transport of machines and materials. Container vehicles can be used as mobile workshops, service vehicles supply the mining machinery with fuel and lubricants. Employees are transported to their place of work in buses or personnel transporters. The fire protection service provides fire-fighting vehicles on off-road chassis.
The last section of the life-cycle of a mining site is the decommissioning of the mining site, as well as its recultivation. Large quantities of earth and soil have to be moved to shape the post-mining landscape as well as to stabilise the slopes in abandoned open-cast mining areas and on slag heaps. The implementation of afforestation operations and agricultural land also requires transportation of soil in very large quantities. These are typical tasks for tippers and pump trucks in spray-seeding areas for recultivation. MAN vehicles are suitable for this purpose too.
To cope with this diverse range of applications, MAN offers suitable chassis in its range of vehicles with the CLA, TGM, TGS and TGS.WW series. The MAN CLA series, which is manufactured in India, comprises vehicles with gross weights from 15 to 31 tonnes equipped with engines delivering from 220 HP (162 kW) to 280 HP (206 kW), complying with the Euro II or Euro III emission standards. The MAN TGM, TGS and TGS WW series produced in Europe are more powerful and offer more variants. Two to five axles, engines from 250 HP (184 kW) to 540 HP (397 kW), compliance with emission standards from Euro II onwards and gross weights from 12 to 50 tonnes characterise this series. The climatic conditions make further demands on the vehicle configuration because surface mining is conducted from the Arctic to the tropics.
MAN TGS WW as a 50-ton rear tipper at bauma 2013
MAN will exhibit a TGS.WW 50.440 8 x 4 BB, precision matched to the requirements of Chilean open cast copper mining at the bauma 2013 trade fair. Chassis and body are perfectly matched to each other for this application. In connection with a reinforced auxiliary frame, the four-axle rear tipper is designed for a total permissible weight of 50 tons. The volume of the tipper trough is 20 cubic meters. The floor panel and side walls are made of highly wear-resistant steel.
MAN's engineers have configured the vehicle to carry out the tasks required in this sector: Its powerful yet economical six-cylinder in-line engine is Euro-IV emissions standard compliant and has an output of 440 HP (324 kW). The power generated by this engine is transmitted via MAN TipMatic® automated transmission to the two driven rear axles with their 24-inch twin tyres.
Rugged and efficient trucks from MAN Truck & Bus meet the highest demands of markets outside Europe.
The differences in typical requirements from region to region are far bigger in overseas markets than they are in European markets. Amongst other things, these have to do with climatic conditions, the state of the roads or the great stresses on vehicle and axles in daily use. This is why MAN has the TGS, TGS WW and CLA series in its range of products; they are designed especially to cope with the challenging transport tasks outside Europe.
MAN TGS-WW – the premium truck for the toughest of operations
Particularly rugged suspension and frame components distinguish the MAN TGS WW as semitrailer tractor, chassis and tipper. For the most demanding operation outside Europe, the MAN TGS WW has been equipped with attention to the many details that have proven themselves in practice. These include a stoneguard in front of the radiator, radiators suitable for the tropics, protective grilles on headlights and rear lights, air intakes directed upwards with pre-filter, stone guards for the fuel tank or 24" tyres.
Whether it's two, three or four axles, gross weights of 19 to 44 or 50 tonnes, on-road or off-road drive, the range of choices is a big one. Customers can choose from three different design heights, hypoid or planetary hub reduction axles, and leaf or leaf/air suspension – in the product range of the robustly designed TGS WW, the efficient tool can be found for on-road transport in short- and long-haul as well as off-road on construction sites or surface mines.
MAN offers cabs in three different sizes for the TGS WW series: the compact M cab is suitable for work on construction sites and surface mines. It is also fitted on municipal vehicles or trucks operating in short- and long-haul transport. If the driver occasionally has to sleep over or rest in the vehicle, or if space is needed to store equipment in the cab, then the 400-millimetre longer L-cab is the one to choose. It has a comfortable 2,050-millimetre long and 750-millimetre wide bunk behind the seats. On longer trips, the high LX cab provides the optimal space for alternating between work and relaxation. And what's more, this cab has space for a multifunctional shelf or a second bunk. Both longer cabs, the L and the LX, have two capacious stowage compartments that can be accessed from the outside via big flaps. The driver can also reach the contents of the left-hand stowage compartment comfortably from the inside.
As far as power is concerned, operators can rely on efficient MAN D20 and D26 series in-line six-cylinder engines with the common-rail injection that has demonstrated its reliability thousands of times over. Depending on registration regulations, the TGS WW engines comply with the Euro II, III or IV exhaust-gas emission standards. The developers of the engines have taken into account that fuel quality varies, in particular that the proportion of sulphur in diesel fuel outside Europe is often higher (up to 2,000 parts per million). MAN offers engines with outputs of 360 hp (265 kW), 400 hp (294 kW), 440 hp (324 kW) as well as 480 hp (353 kW) and for certain applications, 540 hp (397 kW). In the Euro II and Euro III versions, the exhaust-gas treatment of these MAN engines does not require the additive AdBlue®. This makes the driver's daily routine easier. For compliance with the Euro IV standard, MAN uses maintenance-free SCR (selective catalytic reduction) technology. Wherever a rugged chassis that meets the requirements of the Euro V or Euro VI emission standards is needed, in many cases the MAN TGS series fits the bill.
The engines are coupled with precise, comfortably shifting transmissions. The synchronised manual transmission has 16 speeds. Twelve-speed MAN TipMatic® automated transmission provides the highest level of shifting comfort. For off-road vehicles, the MAN TipMatic® in off-road mode offers a performance-orientated shift strategy with faster shift times.
At the IAA 2012, MAN presented the TGS WW for heavy-duty operation with a torque converter clutch. This enables 250 tonnes gross train weight. The driveline comprises a Euro-IV-compliant 540-hp engine, an automated 12-speed MAN TipMatic® transmission and WSK 440 torque converter clutch with primary retarder and auxiliary radiator. This makes it possible for the driver to execute precisely controlled and practically wear-free starting and manoeuvring with heavy loads. In automatic mode, drivers don't have to operate the clutch or change gears, so they are able to concentrate fully on driving with their heavy and oversized cargo.
MAN CLA – rugged and reliable, made by MAN
With its MAN CLA series, MAN is aiming at markets in Asia, the Middle East and Africa. The MAN CLA is successfully operated in over 25 countries. These are extremely resilient two-, three- and four-axle chassis for a multitude of various usages as platform trucks or semitrailer tractors. Customers can also obtain complete vehicles via MAN, with tipper, refuse collection or concrete-mixer bodies. MAN rounds off the CLA range at the top with a four-axle tipper chassis for a gross vehicle weight of 31 tonnes, initially for the Indian market. This vehicle is especially suitable for heavy-duty work on construction sites or surface mines.
Reliable MAN components are the basis of the MAN CLA. With its robust chassis, economical engines and 20 and 22.5-inch tyres designed for poor roads, the MAN CLA covers the weight class from 15 to 31 tonnes. Day and sleeper cabs provide the driver with an ergonomically designed workplace equipped with air-sprung seat and optionally available air-conditioning system. MAN also produces the reliable six-cylinder in-line engines, renowned for their long service life, as well as the rugged, resilient planetary axles. Alternatively, hypoid rear axles are installed for long-haul operation.
Available engines range from 220 hp (162 kW) to 280 hp (206 kW). The engines comply with the Euro II and III exhaust-gas standards and can be run on diesel fuel with a maximum sulphur content of 500 parts per million.
Production of the MAN CLA takes place in one of India's most modern commercial vehicle plants, in Pithampur, Madhya Pradesh. This plant delivers either complete vehicles with or without bodies to customers or CKD kits to the regional assembly plants for MAN vehicles.
At Stand 209/307 in Hall B4, MAN is showing five trucks from the TGL, TGM, TGS, TGX and TGS WW ranges for the construction, mining and municipal sectors. This year for the first time, MAN is presenting complete transport solutions to visitors.
MAN TGL 12.180 4x2 BB
With this compact, agile vehicle MAN is exhibiting the new crew cab for six to seven persons as well as the new three-piece steel bumper in the Euro VI version. It is the ideal vehicle for construction companies, handicraft businesses and municipalities who want to transport both people and cargo. The maximum load on the front and rear axle suspension of this 12-tonner gives its operator great flexibility in distributing the payload. With toll-free operation on German motorways in mind, its maximum permissible gross weight is 11.99 tonnes. Equipping with a three-way tipper body is proof that frame and body are optimally harmonised.
|Engine||D08 common rail, four cylinder, 4580 ccm capacity, Euro VI|
|Engine output||180 hp (132 kW) at 2300 rpm|
|Maximum torque||700 Nm at 1400 rpm|
|Transmission||MAN TipMatic® 6-speed|
|Cab||Crew cab with three-piece steel bumper|
|Body||Three-way tipper body from KH-Kipper with Hyva tipping hydraulics|
|Permissible gross vehicle||11,990 kg|
TGM 13.290 4x4 BL
With this vehicle, MAN is showing the all-wheel version of the TGM range in Euro VI for the first time. The three-piece steel bumper is combined with a front plate for mounting winter-service equipment, complying with DIN EN 15431 and deliverable ex works. As standard, MAN fits air suspension on the rear axles of TGM all-wheel vehicles in the 13-tonne weight class. The traction of the permanent all-wheel drive can be improved still further by means of engageable interaxle and transverse differential locks. The remote-controlled loading crane and three-way tipper body ensure that the vehicle's capacity can be fully utilised the whole year round, whether in the construction industry or in municipal service. In this concept, the focus is on modularity. The three-way tipper's ex works front mounting plate and loading platform make it possible to attach implements and add-on modules for just about every type of road and winter service. MAN thus presents a chassis for all the jobs that have to be done in a municipality. The vehicle on show is equipped for its variety of tasks with, for example, a front road-sweeper as well as a tank for fluid with a spray bar on its loading platform. A load-sensing hydraulic system supplies energy to the attached implements. Thanks to its short wheelbase of 3250 millimetres, the very agile MAN TGM is ideally suited for tasks in residential areas with narrow streets and a lot of parked cars, as well as on construction sites.
|Engine||D08 common rail, six cylinder, 6871 ccm capacity, Euro VI|
|Engine output||290 hp (213 kW) at 2200 rpm|
|Maximum torque||1150 Nm at 1200 to 1750 rpm|
|Transmission||MAN TipMatic® 12-speed OffRoad transmission with software for off-road operation|
|Design||High, with planetary drive axles|
|Cab||C cab with three seats, construction access step, three-piece steel bumper and winter-service fittings|
|Body||Three-way tipper body from Meiller
Loading crane from Palfinger
Front road-sweeper and fluid tank from Aebi Schmidt
|Permissible gross vehicle weight||14,100 kg|
MAN TGX 18.480 4x4H BLS
Euro VI engine, three-piece steel bumper and HydroDrive® are the highlights of this tipper semitrailer tractor from the MAN TGX range. The wide, spacious XL cab and air-spring rear axle offer a high level of driving comfort. The MAN TGX tipper semitrailer tractor with HydroDrive® is the perfect solution for meeting the demand of maximum traction at short notice without having to meet the increased cost of an all-wheel drive vehicle. Fitting the vehicle with the MAN PriTarder® for powerful continuous braking even at low speeds ensures safe transport with big payloads.
|Engine||D26 common rail, six cylinder, 12,419 ccm capacity, Euro VI, MAN PriTarder®|
|Engine output||480 hp (353 kW) at 1600 to 1800 rpm|
|Maximum torque||2300 Nm at 930 to 1400 rpm|
|Design||Medium-high with planetary drive axle, front axle powered hydrostatically by MAN HydroDrive®|
|Cab||XL with three-piece steel bumper|
|Permissible gross train weight||44,000 kg|
MAN TGS 26.480 6x4 BB
The version of the three-axle vehicle with a three-way tipper body, widely used on construction sites, is also shown here in the new design with three-piece steel bumper and Euro VI exhaust-gas technology. Automated MAN TipMatic® transmission with software for off-road operation, MAN PriTarder® as effective continuous brake and engine-dependent power take-off for operating the tipper body are all regarded as standard equipment on MAN construction vehicles. Typically for such vehicles, the tailpipe is swept up behind the cab in order to reduce exposure to exhaust gas and dust in the vicinity of the vehicle.
|Engine||D26 common rail, six cylinder, 12,419 ccm capacity, Euro VI, MAN PriTarder®|
|Engine output||480 hp (353 kW) at 1600 to 1800 rpm|
|Maximum torque||2300 Nm at 930 to 1400 rpm|
|Transmission||MAN TipMatic® 12-speed OffRoad transmission with software for off-road operation|
|Design||Medium-high with planetary tandem axle|
|Cab||M cab with construction access step and three-piece steel bumper|
|Body||Three-way tipper body from Dautel|
|Wheelbase||3300 mm + 1400 mm|
|Permissible gross vehicle weight||28,000 kg|
MAN TGS 50.440 8x4 BB
This four-axle vehicle in the MAN TGS-WW range with rear tipper body from Meiller is designed for operation in open-cast mining the world over. It is employed primarily on paved roads between the point at which overburden or raw material is extracted and the loading facility. Ruggedness, m