Fuel consumption on the Man 8x4 Dump Truck • Highly efficient gearbox

MAN TGS 41.440 8×4: Tumbler - dump truck!

A dump truck driver is a special specialty among professional drivers. The fact is that he continues to drive the car even when it is stationary and unloaded. Wrong choice of site, error in positioning, a few unnecessary or sudden movements, and here it is, capsizing, but, alas, not only of the dump body. The German bodybuilder Fliegl Baucom (the Fliegl brand is also known for its trailed equipment) proposed an interesting solution to this problem: unload the body without lifting it. And the Russian one mounted the German superstructure on the MAN TGS 41.440 chassis with an 8x4 wheel arrangement. Currently the car is certified and is in trial operation.

Antelis

TGX – truck tractors and single vehicles. Payload: 15.70 tons. Engines: 360. 680 hp. TGS – truck tractors and “single tractors”, construction equipment (based on the MAN chassis). Payload: 18.70 tons. Engines: 360. 680 hp. TGA - vehicles were supplied under this model until 2007, which were later divided into models TGX and TGS. TGM – trucks, single trucks, dump trucks. Payload: 7.20 tons. Engines: 240. 380 hp. TGL – trucks. Payload: 5.7 tons. Engines: 150. 250 hp..

Bus J1939 or J1587, diagnostic connector HD10 (Deutsch 9-pin).

To remotely monitor engine parameters (including fuel consumption and fuel level in the tank) without installing expensive external sensors, a special device “Antelis”* is used.

* “Antelis” is a device for monitoring fuel consumption and other engine parameters in real time.

Let us evaluate, for example, the possibility of installing the “Antelis” device on the TGX 18.440 4X2 BLS model with a MAN engine, produced in 2010/2011.

There are many parameters, fuel consumption is calculated with good accuracy, there is readings from the fuel level sensor in the tank.

Engine and other ECU parameters are displayed in real time

and the car owner can monitor the parameters of the engine and other vehicle systems on his computer screen; see errors detected by the engine self-diagnosis system, analyze driving style for the required period of time, and also receive reporting forms.

• Fuel consumption: driving / parked / instant;
• How much fuel is consumed when the ignition is turned on (current VVZ cycle);
• Vehicle speed at the current track point (this is a more accurate value than that obtained by averaging from trackers);
• Acceleration: acceleration, braking (jerk) - assessment of driving style (how the driver brakes and accelerates, how often the car jerks);
• Engine speed;
• Engine load;
• Gas pedal position;
• Temperature: coolant/intake manifold;
• Pressure: oil/boost;
• Shaft moment;
• Oil level;
• Fuel level in the tank;
• Errors generated by the ECU (active, inactive);
• Devices discovered on the network;

MAN truck parameters obtained in motion: (TGX 18.440.4X2.BLS, 2010, MAN D2066LF40 engine, J1939 tire)

On the real track, “labels” are displayed with the current engine parameters at track points (time - according to the satellite).

Errors detected by the self-diagnosis system:

Truck Capabilities

The 6580 dump truck with a 6x4 wheel arrangement and a load capacity of up to 25.8 tons is intended for companies in the Krasnoyarsk Territory and Khakassia engaged in quarrying, large-scale road and industrial construction, and who need a modern heavy dump truck of the European level at an adequate price and a developed network of high-tech service centers throughout Russia . By simply pressing the gas pedal and steering to load, the driver can turn on the stopping brake with a toggle switch on the right armrest or shift the gearbox to neutral by pressing a button.

MAN TGS 41.440 8×4: Tumbler - dump truck!

Review of one of the best-selling dump trucks in Russia MAN TGS 41.440 with an 8x4 wheel arrangement. However, the main thing is in the details; the truck has an unusual tipper superstructure.

A dump truck driver is a special specialty among professional drivers. The fact is that he continues to drive the car even when it is stationary and unloaded. Wrong choice of site, error in positioning, a few unnecessary or sudden movements, and here it is, capsizing, but, alas, not only of the dump body. The German bodybuilder Fliegl Baucom (the Fliegl brand is also known for its trailed equipment) proposed an interesting solution to this problem: unload the body without lifting it. And the Russian one mounted the German superstructure on the MAN TGS 41.440 chassis with an 8x4 wheel arrangement. Currently the car is certified and is in trial operation.

Chassis worthy of the body

The optimal angle and thin thickness of the A-pillars contribute to good visibility.

The MAN TGS pleased me with its spacious cabin and precise operation of the entire power unit, which started easily on the first try after a long stay on a snowy area. Everything in the workplace is in the best traditions of the brand, no need to get used to it. This is the very case when the new is not to the detriment of the old. In the interior of the cabin, notes of classic “Mans” are successfully combined with modern instruments and liquid crystal displays; the presence of cruise control in the basic configuration of the construction chassis is perceived as a little dapper.

The workplace is traditional in the good sense of the word, but personally I prefer it when the parking brake valve is located on the front panel rather than on the console between the seats.

The “pneumatic” driver’s seat took me into its arms, we take off, fastened with the seat belt integrated into the seat and begin to enjoy the ease of control and dynamics! The gears are switched perfectly (this dump truck has a double-disc clutch) according to the usual familiar pattern (lever with a flag and a toggle switch), the vehicle's power supply allows you to start even from third gear and confidently accelerate with an empty body, the dynamics are simply described as enviable!

The configuration of the axles and the weight distribution of the superstructure were also successful: even an empty dump truck is not prone to “swinging” and diagonal swinging. The only thing is that the steering wheel seemed to me too sharp for a heavy dump truck. To be honest, I would have ridden like this all day, but the hospitable owners of the site offered me to demonstrate the working process of the dump truck superstructure. However, first it’s worth describing the chassis and its features a little.

Basic basis for an innovative superstructure

At one of the industry exhibitions dedicated to the mining industry, at the MAN stand, I heard from one of the operators from the northern regions of our country that MAN trucks are taking root well with them for the simple reason that the high strength of the chassis is due to extensive experience in building army trucks this German manufacturer. Whether this is really so, and whether MAN has transferred “military” solutions to civilian equipment, I cannot say, but first impressions allow us to agree with this opinion. According to the attached instructions, the operating temperature range of a vehicle intended for use in northern countries and eastern Europe is from -40 to +40 degrees Celsius.

Technical characteristics of the 784500 dump truck on the MAN TGS 41.440 8×4 chassis

The chassis package includes such important and pleasant “little things” as fuel filters and a heated tank, air conditioning, and anti-roll bars on both front axles. The suspension of all four axles is spring. The rear spring-balancer suspension is designed for severe operating conditions. The technical load on the rear bogie is 26 tons. The front axle suspension is on separate parabolic springs. The load on them is 15 tons. The permissible technical (without taking into account national requirements) total weight of the road train is 44 tons. The indicators are decent, but not the most “combat”, but understanding the peculiarities of the mentality of the creators of the machine, it is better to be modest, but guaranteed and for a long time! However, I will return to the description of the design after a short lyrical digression.

The brake mechanisms of all wheels are drum brakes made of cast iron. From the inside, the frame is additionally strengthened in the traditional way using liners in the longitudinal side members. The dump truck is driven by an in-line six-cylinder diesel engine D2066LF69, with a power of 440 “horses” at 1900 rpm and a maximum torque of 2100 Nm at 1200 rpm. It is mated to a 16-speed ZF manual transmission.

The Fliegl push-out system is an alternative to the general construction dump body

The rear gate is of the “jaw” type.
The body is made of wear-resistant steel 400 HB, the thickness of the floor is 6 mm, the sides are 4 mm. The tipper body from Fliegl Baucom does not require lifting or tipping for unloading, so the vehicle always maintains its center of mass and external dimensions. This makes it possible to work with bulk cargo in low rooms, for example, tunnels, near power lines, and the dump truck can also unload without fear on a transverse or longitudinal slope, and on not very hard soil.

Sliding platform in operation.

The material of the body and the hydraulically controlled retractable bottom is wear-resistant steel 400 HB, the thickness of the floor is 6 mm, the thickness of the sides is 4 mm. The rear opening gate consists of two steel folding gates controlled by hydraulics. For its characteristic appearance, the creators of the machine call this shutter “jaws.” From the outside, the unloading process looks, as I expected, unusual. You expect, if not an obvious rise, then at least some movement of the body, but nothing happens, all the movements are internal. When the rear doors open, you can only see the damper, which is also a structural element of the body. It is this detail that is the portal that pushes out the rock.

Photo 1: Due to the absence of telescopic hydraulic cylinders, this design has a low need and filling volume of hydraulic oil, only about 70 liters is enough. Photo 2;3: If you approach the dump truck at the moment of unloading from the side, you can see the absence of the bottom of the body in the front part, since the portal itself moves directly.

A full understanding of the process comes at the very end of unloading, when all components can be clearly seen. But if you approach the dump truck from the side during unloading, you can see the absence of the bottom of the body in the front part, caused by the “left” portal. The idea is simple, like everything ingenious, including its German embodiment. The body control is automatic with hydraulic drive using several buttons. The system operates so smoothly and silently that you can even accidentally forget about the technological process that is happening behind the driver at this time.

The actuator is quite compact.

Follow the operating instructions and use only for their intended purpose!

This design has attracted the interest of road builders, who are now actively increasing their experience in operating the unusual dump truck. The ability to completely unload even when working with very sticky types of asphalt was highly appreciated. The dump truck also copes well with wet soil and loams, and there is no sticking of material on the walls of the body, which reduces the useful volume of transportation. According to the attached instructions, prepared by meticulous Germans, this dump body is designed for transporting bulk cargo, soil, construction waste, crushed stone, but under certain conditions - hot asphalt and other construction materials.

Fastening components of the superstructure to the frame.

For all loaded material, the maximum particle size should not exceed 500x500x500 mm. An important problem is that there is no sufficient heating of the dump body at the low temperature of the exhaust gases of modern environmentally friendly engines. But to preserve heat when transporting hot asphalt, a special heat-resistant awning with a mechanical drive is provided. The ejector flap fits so tightly to the walls that unloading is almost 100%, hence the absence of the need to manually clean the body. By the way, the instructions suggest periodically checking the gaps in the guides and adjusting them.

The dump body is controlled both from the cab (during asphalt work the driver is required to always be in the cab) and using a wired remote control. The photo of the controls from the cockpit was taken in another car.

Expensive need.

This specific car is not cheap at all, and not a single operator would dare to buy it for fun. A set of high-tech superstructure on an excellent MAN TGS 41.440 8×4 chassis will help those who specialize in non-standard and particularly complex objects: established historical buildings, proximity to power lines, difficult terrain, tunnels, overpasses, river banks, complex road construction and reconstruction. In such operation, the costs of an unusual dump truck will be able to pay off and bring profit...

Our information If the German MAN trucks do not need any special introduction, then in our case we will pay a little attention to the bodybuilding company and those who embodied the idea of ​​​​such a body and chassis in one car.

Vehicle manufacturer: JSC AVTOBAU Manufacturer of tipper superstructure: Fliegl Bau & Kommunaltechnik GmbH

Fliegl Bau & Kommunaltechnik GmbH Fliegl GmbH was founded in 1976 as a mechanical engineering company. The main activity is the production of trailed and agricultural equipment. Fliegl is now a major European manufacturer with a wide range of agricultural, utility and trailed equipment. Today, Fliegl has five large factories (four in Germany and one in Hungary), which produce over 550 models of various machinery and equipment.

CJSC AVTOBAU The main activities of the company are the production and installation of cargo and large-sized equipment, complex supplies of any type of equipment (truck, passenger, utility, road repair or construction), repair, as well as the totality of all services for maintenance of special equipment. The company designs and installs a wide range of equipment for road construction and maintenance on various chassis. Every year the company presents 2-3 new models developed by its own design department. In 2015, it is planned to commission a new service center in the Moscow region (near the city of Naro-Fominsk), with a total area of ​​more than 1,700 sq.m.

Daniil Minaev, photo by the author

Economical • High efficiency gearbox

7.5 The 12-tonne vehicles, thanks to their short wheelbase, are exceptionally easy to drive and combine maximum payload and cargo capacity. MAN Nutzfahrzeuge has developed innovative solutions for both aspects, focusing on preparing professional drivers for various situations, as well as developing electronic assistance systems that support the driver in everyday and difficult situations.

On the real track, “labels” are displayed with the current engine parameters at track points (time - according to the satellite).

Errors detected by the self-diagnosis system:

Errors detected by the self-diagnosis system:

An example of a MAN vehicle report on a 5-day trip:

Ease of operation and maintenance • High efficiency gearbox

• 62 – number of trips (VVZ), 19-, -37, -1-
• 1d22h10m/1d09h38m – engine hours total/in motion
• 2061.25/2099.77 km – GPS/CAN mileage
• 690.6/(663.25+27.35) l – total fuel consumed/(moving + parking)
• 31.6
  (l/100km) – fuel consumption only when driving
• 32.9
  (l/100km) – fuel consumption only when driving + parking
• 2382.0 – rpm max.
• 87°C – coolant temperature max.
• 8.00 km/h/s – acceleration max.
• -9.80 km/h/s – braking max.
• 10/6 – active/inactive errors

General characteristics of MAN truck tractors • The satellite must be installed in any case.

Features and Benefits

The increasing popularity of the MAN F2000 truck tractor is achieved through the use of modern high-tech solutions that improve the performance of the machine. The main advantages of a car include practicality, endurance, maneuverability, efficiency, reliability and stability on any basis. In addition, the manufacturer notes other advantages:

• variety of wheelbases;
• wear-resistant spare parts;
• aesthetic salon;
• Ease of Management;
• power and environmental friendliness of the power plant;
• large viewing angle;
• sound and vibration insulation;
• aerodynamic;
• attractive appearance;
• compactness and light weight.

Large-capacity models are in great demand in Russia.

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Design Features

- Think about the fact that sometimes there is a deliberate exaggeration of the driver in relation to the boss 34 liters 100km, the chief in relation to our sellers 36 liters 100km, because he wants to put pressure on. Well, maybe you need to set it up, contact the specialists, otherwise, think for yourself, if a Chinese 340 strong carrying 30 cubic meters eats a maximum of 50, and you have 10 cubic meters - 75 liters, if a Chinese carries under 30 cubic meters, then he doesn’t have 50 liters it will work out.

Unlike conventional cargo transportation, transportation of large and heavy cargo is a very complex process that requires special equipment. As a result, large operating companies are replenishing their fleet not only with mass-produced machines, but also with custom-made ones, created specifically for their requirements. However, there are relatively few vehicles of this class, and not every truck manufacturer will undertake the production of such exclusive, powerful and expensive equipment. However, as practice shows, the demand for such cars is increasing from year to year.

We just had the opportunity to get acquainted with one of the representatives of heavy trucks - the MAN 41.540 8×4 BBS 4-axle truck tractor. It can operate as part of a road train with a gross weight of up to 180 tons. The car is designed to transport heavy and extra-heavy loads. When coupled with a low-bed semi-trailer, the tractor is capable of transporting large construction equipment, as well as other heavy oversized equipment.

It should be noted that the car was made to order, taking into account all the client’s wishes. By the way, the customer of the tractor is a company that is engaged in the construction of Olympic facilities in Sochi. Externally, the special MAN 41.540 8×4 tractor is practically no different from mass-produced MAN trucks, except that the cab, fenders, bumper and mirror housings are painted the same color. There is an underrun protection bar under the front bumper, and protective nets on the headlights. The bumper itself is metal, consists of three parts, as a result, it does not have to be replaced entirely in case of minor damage. Along the windshield there is an impressive size sun visor, and on the roof of the cab there are two orange flashing lights, confirming the status of special equipment.

The tractor is equipped with an XXL cabin, that is, the largest and most comfortable in the MAN line. Once inside, you begin to understand that everything here is grown-up and is designed to provide maximum comfort to drivers during work and rest. The driver's workplace is equipped with an air-suspended seat. It has an integrated seat belt and armrest. The passenger seat is also air-sprung with the necessary set of adjustments. The engine tunnel is practically absent. As a result, you can move freely around the cabin at full height. For rest and overnight, there are two sleeping places of sufficient size, the lower one with an orthopedic mattress. The cabin has a refrigerator and a huge number of storage shelves, pull-out glove compartments, and coat hooks. All this suggests that all conditions have been created here for the work and rest of two drivers, because sometimes when transporting super-heavy loads you have to move at a snail’s pace, and it takes several days to cover some three hundred kilometers, and the drivers have no choice but to simply live in a car.

The cabin suspension is on four air springs. Under the front opening panel, for the convenience of daily maintenance, all the necessary necks are located, but the oil level in the engine is controlled only using the on-board computer, otherwise you will have to raise the cabin. A well-proven D2676 diesel engine is installed under the cabin of the tested tractor. This is a straight-six with a capacity of 540 hp. With. at 1900 min-1 with a maximum torque of 2500 Nm in the range of 1050–1350 min-1. The motor complies with the Euro-5 environmental standard. This is the most powerful version among MAN 6-cylinder engines. No, of course, there are even more powerful ones, but these are already top-end V-shaped eights. Manual transmission 16‑speed ZF 16S252OD with ZF intarder. The clutch is reinforced, dry, double-disc.

The frame of the MAN TGX 41.540 8×4 tractor has been seriously strengthened. The design of the pendants is also interesting. So, on the front axle there is a spring suspension with anti-roll bar, designed for a maximum load of 9.5 tons. The second steering axle is on air springs with a load of 8 tons. The rear planetary axles, again the most powerful in the MAN line, also have a reinforced leaf spring suspension with anti-roll bars designed for a load of 16 tons. As for rubber, wide road tires, so-called “loaves”, measuring 385/65R22.5 are used on the front axles.

At the rear there are “mud” tires with a stiffer tread measuring 315/80R22.5. From the above we can conclude that the car will be used not only on the highway, but also on roads with much less respectable surfaces. The brakes are pneumatic, with disc brakes at the front and drums at the rear, with ABS.

The SSU is also maximally reinforced. Its design height is 1350 mm without load and 1300 mm under load. In addition, the terrain in the vicinity of Sochi, where the machine will work, was taken into account: the saddle has an inclination angle of 7 degrees in both the longitudinal and transverse directions, so that the trailer does not bend. By the way, information about the load on the SSU is displayed in the truck cabin. In addition, provision is made for the installation of a towing device. All the necessary connectors for this are there, but the device itself will be installed by the customer. The traction force of the trailer hitch is designed for 100 tons. The tractor also has a so-called cold pack. These are Nordic cabin insulation from the cold, an additional auxiliary heater, coolant heating, an electric flare starting device and an additional Separ filter with heating and water separator. Testing such tractors is a very serious matter, since the equipment is very complex, and MAN even provides special courses on how to operate such machines. However, we could not deny ourselves the pleasure of testing the car in action.

It is worth noting the good sound insulation of the cabin. Visibility is excellent thanks to the high seating position and the presence of a full set of rear-view mirrors. The pedal unit is convenient. The controls are well located, you don’t have to reach anywhere. In general, it must be said that the driver’s workplace and the interior of the MAN XXL cabin are an example of functionality.

In conclusion, it is worth noting that MAN, like other members of the Big Seven, produces not only production vehicles, but also customized vehicles, and the MAN TGX 41.540 8x4 tractor is proof of this. The truck was manufactured in Austria at the MAN exclusive products plant for a specific trailer and certain parameters. Whatever you say, the technology is really complicated, and with an immodest price tag. However, as practice shows, in modern life one cannot do without such machines.

Factory warranty - 1 year for the vehicle itself + 2 years for the power unit Mileage between services, km - 30,000–35,000
Technical characteristics:
Wheel arrangement - 8x4 Gross weight, kg - 32,000 Permissible total weight of the road train, kg - 180,000 Fuel tank volume , l - 910

Engine: type - diesel, in-line, 6‑cylinder, Euro-5

working volume, cm3 — 12,419

power, l. With. — 540 Gearbox — mechanical, 16‑speed

Suspension: front 1st axle - spring; on the 2nd (support) - pneumatic spring rear 3rd and 4th axle - spring Brakes (front/rear) - disc / drum Tire size (front/rear) - 315/80R22.5 / 385/ 65R22.5

The car was provided to us by the official MAN dealer - Intertransservice LLC

Author of the article: Mikhail Bibichev

Odnoklassniki MAN TGA by price. Car cabin

The lift axle, which is used in the new car to distribute the load evenly across the center axle, was first used on the 65208. The ECAS electronically controlled air suspension allows the TGL frame to be raised and lowered, quickly and easily adapting the vehicle's height to ramps, low gates and arches.

Fuel consumption of MAN truck tractors. Car cabin

1. Five-cylinder engine with a volume of 12 liters and a power of 400 hp. The exhaust quality complies with Euro-2 standards. The D2866 LF21 model has become more widespread in the basic version.
2. Six-cylinder engine with a volume of 12.8 liters and a power of 460 hp. Its exhaust quality complies with Euro-3 standards. The unit contains four dampers for each cylinder, the size of the latter is 128 * 157 mm. The pistons are made of high-temperature-resistant steel, a layer of polymer material is applied to the skirt, and oil is supplied through special channels for cooling. Gas distribution is carried out by valves, each cylinder has its own head, secured with 6 bolts. The fuel supply comes from the electrical control system. Separate oil circulation circuits are provided for the cylinder block and heads, which ensures the reliability and durability of the MAN F2000 engine. A cast cover is installed for all main bearings, which ensures the strength and rigidity of the structure without the use of transverse bolts. The reduction in friction is due to the use of roller tappets to move the valves.
3. Six-cylinder turbocharged diesel engine with a volume of 18 liters and a power of 600 hp.

Versatility • Number of messages 17 Recommendations 0.

The Fliegl push-out system is an alternative to the general construction dump body

The tipper body from Fliegl Baucom does not require lifting or tipping for unloading, so the vehicle always maintains its center of mass and external dimensions. This makes it possible to work with bulk cargo in low rooms, for example, tunnels, near power lines, and the dump truck can also unload without fear on a transverse or longitudinal slope, and on not very hard soil.

The material of the body and the hydraulically controlled retractable bottom is wear-resistant steel 400 HB, the thickness of the floor is 6 mm, the thickness of the sides is 4 mm. The rear opening gate consists of two steel folding gates controlled by hydraulics. For its characteristic appearance, the creators of the machine call this shutter “jaws.” From the outside, the unloading process looks, as I expected, unusual. You expect, if not an obvious rise, then at least some movement of the body, but nothing happens, all the movements are internal. When the rear doors open, you can only see the damper, which is also a structural element of the body. It is this detail that is the portal that pushes out the rock.

A full understanding of the process comes at the very end of unloading, when all components can be clearly seen. But if you approach the dump truck from the side during unloading, you can see the absence of the bottom of the body in the front part, caused by the “left” portal. The idea is simple, like everything ingenious, including its German embodiment. The body control is automatic with hydraulic drive using several buttons. The system operates so smoothly and silently that you can even accidentally forget about the technological process that is happening behind the driver at this time.

Car cabin

The braking system is equipped with all modern devices for maximum safe driving. It has an EBS electronic control unit, which greatly helps the driver in difficult road conditions. The basic package includes ABS and ASR systems. The brakes themselves have two independent circuits and a pneumatic booster. Their effect applies to all wheels of the car. Upon request, the manufacturer can add the additional option of using the EVB engine braking system, which can significantly increase braking efficiency. The car received a reinforced chassis, which allows the small size of the platform to transport loads of significant weight. Also used are unusually small wheels for such a vehicle with large permissible rotation angles, which allows for increased maneuverability.

Technical specifications MAN TGA

MAN TGA 12.8MT

MAN TGA 18.3 MT

Chassis worthy of the body

The MAN TGS pleased me with its spacious cabin and precise operation of the entire power unit, which started easily on the first try after a long stay on a snowy area.
Everything in the workplace is in the best traditions of the brand, no need to get used to it. This is the very case when the new is not to the detriment of the old. In the interior of the cabin, notes of classic “Mans” are successfully combined with modern instruments and liquid crystal displays; the presence of cruise control in the basic configuration of the construction chassis is perceived as a little dapper. The “pneumatic” driver’s seat took me into its arms, we take off, fastened with the seat belt integrated into the seat and begin to enjoy the ease of control and dynamics! The gears are switched perfectly (this dump truck has a double-disc clutch) according to the usual familiar pattern (lever with a flag and a toggle switch), the vehicle's power supply allows you to start even from third gear and confidently accelerate with an empty body, the dynamics are simply described as enviable!

The configuration of the axles and the weight distribution of the superstructure were also successful: even an empty dump truck is not prone to “swinging” and diagonal swinging. The only thing is that the steering wheel seemed to me too sharp for a heavy dump truck. To be honest, I would have ridden like this all day, but the hospitable owners of the site offered me to demonstrate the working process of the dump truck superstructure. However, first it’s worth describing the chassis and its features a little.

Chassis

The hydraulic drive allows you to reduce the load that the operator needs to apply when operating the tractor, as well as increase the wear resistance and service life of the gearbox. MAN SX, MAN FX and MAN HX are a specialized series of heavy dump trucks designed to work in quarries, tunnels, mines and mines in complete off-road conditions.

MAN TGS 8X8. "Careerist"

After MAN TRUCK & BUS presented an all-wheel drive mining dump truck for the mining industry at the BAUMA 2016 exhibition, they decided to bring a similar version to Russian customers for display. For an initial acquaintance with the technology, the Dmitrovsky training ground was chosen, where we headed

Sergey Zhukov
MAN TGS 41.480 8Х8 BB-WW. Gross weight: 50,000 kg. Start of sales: 2014 Price: depending on configuration

As stated in the press release, this is the first all-wheel drive four-axle MAN dump truck in Russia with a Euro-5 engine and a specialized Meiller body with hydraulic lifting of the tailgate. The main purpose of the vehicle is to work in the mining industry. It is designed to compete with both oversized light-class mining machines and articulated dump trucks. The TATRA brand is trying to sell something similar, but due to various reasons it has never managed to reach any significant sales volumes. There is, of course, a completely budget option, the MZKT-652700 all-wheel drive dump truck, but that’s a slightly different story.

The spacious cabin provides good visibility from the driver's seat, and excellent ergonomics make driving easy in any conditions.

So, we present - a four-axle all-wheel drive dump truck MAN TGS 41.480 8x8 BB-WW with a Euro-5 engine and a Meiller H436 superstructure with a hydraulic tailgate lift. The maximum permissible technical gross vehicle weight, according to the factory specifications, is 50 tons. A special body is designed for transporting rock mass, slag, ore. Body volume - 21 m3. The design of the tailgate allows it to be fully opened at the beginning of the body lift. The hydraulic design of the side ensures the safety and convenience of the operator when unloading rock, even with a diameter of coarse rock masses of 1–1.5 m.

TIPPER CHASSIS

All-wheel drive chassis with permanent all-wheel drive on axles with planetary gearboxes. Load capacity of the front axles is 9 tons, rear axles - 16.

The dump truck chassis is adapted to work in the mining industry and is equipped with a reinforced frame (main frame thickness 9.5 mm, plus liners of the same thickness), special structural elements of the suspension and braking system, which allow it to cope with difficult operating conditions.

The powerful and economical D2676LF07 engine complies with Euro-5 environmental standards

The front axle suspension is made on 4-leaf springs for a load of 9.5 tons. The rear suspension design uses parabolic 16-leaf springs designed for a load of 20 tons. Permanent all-wheel drive allows the dump truck to drive into difficult dump sites, overcome long slopes and descents, as well as travel on roads with soft soil. The chassis is completely maintenance-free using silent blocks.

To improve cross-country ability in the quarry, tires of size 14.00R20 can be installed on the front axles, and the standard 325/95R24 version can be installed on the rear axles. This ensures that the front axles do not “sink” in the rut and “cut the clay”, as a result of which the vehicle’s maneuverability on soft soils improves. There is one inconvenience. When driving on public roads, it is necessary to change the front axles to comply with regulatory requirements.

The power unit is a D2676LF07 Euro-5 engine with a power of 480 hp. With. It is combined with the MAN TipMatic robotic gearbox, which improves the efficiency of the dump truck when operated by operators of different qualifications. The transfer case has a neutral, which is very convenient when towing a dump truck without the need to remove the driveshafts.

Since the engine complies with Euro-5 standards, the issue of body heating had to be resolved locally. In my opinion, the solution is not very good, but that’s how it turned out...

The fuel tank is equipped with protection from below. The AdBlue tank is integrated into the exhaust gas cleaning system. At the customer's request, the rear trolley can be equipped with stone knockers or simplified rubber aprons (metal wings are standard). To protect the wheels from rocky soil during loading, a special ramp is provided on the body. Receivers of the pneumatic brake system are also protected. The battery is also protected.

The M series cab (day cab) comes as standard with controls for a robotic gearbox and all-wheel drive transmission. For comfortable operation of the dump truck, an Eberspaecher autonomous heating system, air conditioning, Nordic insulation, as well as a number of other specialized systems are provided.

TIPPER BODY

The body, which is installed on the MAN chassis, is not new for Meiller. Despite this, until recently it was not mounted en masse on dump truck chassis due to lack of demand. The simplest and cheapest things were in use.

We can say that this is practically the first such experience of a special offer for Russian clients, taking into account the specific features of operating a dump truck in a quarry.

Not only the fuel tank is protected, but also the battery and receivers of the dump truck's braking system

The Meiller body is made of high-strength Hardox steel, which makes it resistant to rock impacts when loading with an excavator. The bottom is made of Hardox 450 steel, 12 mm thick, the side walls are made of Hardox 400, 8 mm thick. Other features worth noting are the presence of a reinforced subframe for harsh operating conditions, a folding ladder for climbing into the body on the right side with counter steps on the inside, a Rockbreaker stone breaker on the bottom and front wall of the body, connection to the body raised position indication system, hydraulics in the low-temperature version down to –45 oC, a body heating system with exhaust gases with a switch valve, as well as a FOPS protective visor, hooks for mounting the awning on the body, two wheel chocks, reflective markings and side protection.

Hydraulic board type S4. For example, in the West, almost all such cars are equipped with tail lifts. This is a kind of attempt to promote such performance on the Russian market. Let's say right away that it is not cheap. Until recently, many refused to install it.

Access for daily maintenance of truck systems is more than easy

What's the advantage? Mechanical locks sometimes cannot withstand impacts from rocky ground. The second argument in favor of a hydraulic side: even if the edge of the side is frozen at high subzero temperatures, the hydraulics will still unlock it. In addition, such a design does not “pop on the ears.” The body design allows it to be used with the tail lift removed.

Unlike the German version, this body is equipped with a stabilizer against lateral “bumpiness” in motion and serviced moving joints. The possibility of mechanical lifting of the body is provided when the car is stopped for technical reasons and access to the engine is required. First, the body is raised, then the cabin for access to the engine.

The hydraulics for the body are manufactured in Munich. All welding work on bodies is carried out at a plant near Prague. Next, everything is primed and sent to the assembly plant. There are 8–10 such enterprises in Western Europe. They paint the assembly units and carry out final assembly and installation on the chassis.

But with the tail lift, the developers still need to think a little

There are such production facilities in Russia. For example, in the Domodedovo district of the Moscow region there is a SIAZ plant. According to Meiller specialists, with fairly good equipment, production technology and workmanship. By the way, Mercedes-Benz installs Meiller bodies in Naberezhnye Chelny, Volvo Trucks uses its own truck centers.

IN ACTION

To test the dump truck in action, two sections of roads at the Dmitrovsky test site were chosen - asphalt and dirt. The asphalt included a difference in height and serpentine. No problems were found with the ballasted vehicle in this area. The behavior of the machine is predictable, the control algorithms are simple, and most importantly, well known.

The body is equipped with a stabilizer-catcher against lateral movements

On a dirt road, when going uphill, I had to use all the capabilities of the transmission, since I couldn’t get it on the first try. The culprit was the notorious grass. As soon as I slightly deviated from the track, the front wheels immediately began to slip. However, on the second try everything went like clockwork.

A couple of comments should be made after a detailed inspection of the dump truck. First of all, it is necessary to introduce engine crankcase protection as standard. Which, in fact, is what the organizers of the event agreed with. Second: the algorithm of the tail lift caused some criticism. We asked the body to be slightly raised for the shoot to show how it opens. The photo was taken, the body was lowered, but the tail lift did not close. It turns out that you need to do a full unloading cycle for everything to work properly. But since we didn’t want to “litter” at the landfill, we somehow managed to close it. The body developers promised to think about this episode and correct the “defect”.

The body heating system looks too bulky

As a summary, we note the following. The advantages of this dump truck include its lower cost and operating costs, a comfortable cabin and the ability to operate on public roads, as well as high fuel efficiency and optimal cost of ownership.

• Excellent traction and maneuverability
• The tail lift algorithm requires improvement

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High Payload Features and Benefits

• preheater;
• air conditioner;
• heating system for the cabin;
• electronic tachograph.

Basic basis for an innovative superstructure

At one of the industry exhibitions dedicated to the mining industry, at the MAN stand, I heard from one of the operators from the northern regions of our country that MAN trucks are taking root well with them for the simple reason that the high strength of the chassis is due to extensive experience in building army trucks this German manufacturer. Whether this is really so, and whether MAN has transferred “military” solutions to civilian equipment, I cannot say, but first impressions allow us to agree with this opinion. According to the attached instructions, the operating temperature range of a vehicle intended for use in northern countries and eastern Europe is from -40 to +40 degrees Celsius.

The chassis package includes such important and pleasant “little things” as fuel filters and a heated tank, air conditioning, and anti-roll bars on both front axles. The suspension of all four axles is spring. The rear spring-balancer suspension is designed for severe operating conditions. The technical load on the rear bogie is 26 tons. The front axle suspension is on separate parabolic springs. The load on them is 15 tons. The permissible technical (without taking into account national requirements) total weight of the road train is 44 tons. The indicators are decent, but not the most “combat”, but understanding the peculiarities of the mentality of the creators of the machine, it is better to be modest, but guaranteed and for a long time! However, I will return to the description of the design after a short lyrical digression.

The brake mechanisms of all wheels are drum brakes made of cast iron. From the inside, the frame is additionally strengthened in the traditional way using liners in the longitudinal side members. The dump truck is driven by an in-line six-cylinder diesel engine D2066LF69, with a power of 440 “horses” at 1900 rpm and a maximum torque of 2100 Nm at 1200 rpm. It is mated to a 16-speed ZF manual transmission.