Dump truck Tonar-45251. Modifications and features

Tonar-45251 is a modern heavy dump truck with a load capacity of 45 tons, designed for transporting rocks along the technological roads of quarries or open-pit mines. This model occupies the flagship position in the company’s model range of dump trucks and is designed taking into account all the main international requirements, which allows the Tonar-45251 to be used as a full replacement for more expensive foreign analogues. This machine is characterized by increased wear resistance of chassis elements, high maintainability, comfortable cabin and ease of operation. Before modernization (carried out in 2016), the Tonar-45251 dump truck was equipped with a single-seat cab purchased from China.

Specifications

Transmission

Torque from the engine is transmitted to the rear drive wheels by a 9-speed manual transmission 9JSD180, also manufactured in China. The HANDLE 25T rear axle with brake system and the HANDLE 13T front beam are supplied by a renowned European company.

TONAR-45251 and other new products from Gubino

At the annual spring presentation, the TONAR plant presented two new versions of hooded dump trucks TONAR-45251

Valery Vasiliev, photo by the author

At the next full-scale presentation, held on May 19, it was possible to get acquainted with the entire line of manufactured equipment, production, and also see for the first time the latest developments and novelties of machine builders near Moscow. At the same time, the presentation format allows absolutely every guest to personally see the equipment, learn from specialists the features and advantages of operation, communicate with the developers in the event that individual modifications for the client are necessary, and independently form a personal opinion about this or that model.

This year, the exposition brought together about 40 models of equipment, which included tipper, curtainside, flatbed, isothermal semi-trailers, semi-trailers, container and log carriers, bodies for scrap metal, a line of agricultural equipment, as well as premiere samples of the updated technological dump trucks TONAR-45251.

Main characters

Recently, mining dump trucks and special vehicles for transporting bulk cargo have become the hallmark of the TONAR plant, which has long been famous for its trailers for road transport. It must be said that mining dump trucks belong to a special category of heavy equipment that is used in the mining and coal industries. The peculiarity of these dump trucks is that they are operated on a short distance of up to 10 km and on industrial roads where there are no restrictions on weight and dimensions. Mining dump trucks are needed to work in off-road conditions; they must be extremely reliable and have maximum load capacity. Just such a machine with the designation TONAR-4525 was created some time ago. The dump truck was developed taking into account operation in various regions of Russia. Its price turned out to be lower than imported analogues, and from the list of components used on this model, you can study the geography of Russia. The engine is from a dump truck near Moscow from the Yaroslavl or Tutaevsky Motor Plants, it has Chusovsky springs, reaction rods from , and the frame and body are made of high-strength steel and are made in the Orekhovo-Zuevsky district, on. Thus, a mining dump truck was developed that met the country’s modern demands for import substitution.

At the end of December 2013, the Vladimir Quarry Administration (SUE VKU) tested the Tonar-4525 with a “bucket” type body designed for transporting rock with large diameter fractions. Tonar-4525 was put into the line for transporting dolomite rock along with imported “quarries”. The transportation distance from loading to the crushing plant was 1.2 km. After the first test drives, it was decided to replace two imported dump trucks with one Tonar-45251 with a lifting capacity of 45 tons and a body volume of 25 cubic meters.

In 2014, in addition to the Tonar-4525 with a body for rock, a mining dump truck-coal carrier was made. It was he who was the first to receive the TONAR-45251 index. At the end of July 2014, Tonar-45251 began work transporting sludge at the largest enterprise in the mining sector of Temirtau (Kazakhstan), ArseloMittal Temirtau JSC. Once on the line, Tonar replaced a pair of Chinese dump trucks.

In August 2016, TONAR presented its first hooded road train for work on industrial roads. It consisted of a TONAR-45252 tractor and a TONAR-95405 two-section semi-trailer. The customer of the road train with a carrying capacity of 116.7 tons was the largest Russian diamond mining company ALROSA.

And in the spring of 2022, TONAR presented two hooded mining dump trucks with bodies for transporting coal and rock, which replaced the hoodless models. The creators claim that the new machines are the result of a radical change in the concept and main components of the machine. Therefore, from a design point of view, the second generation Tonars are completely new machines. As noted, the new product with a lifting capacity of 45 tons retained the previously used name Tonar-45251. In fact, with the advent of these machines, Mashinostroitelny LLC became the first and only Russian manufacturer with original quarry machines of its own design. The developers are confident that their new creations will become serious rivals to the 40-ton Belaz trucks. As with the previous model, the spar frame and body for the new dump truck are the plant’s own developments. The company also manufactured the double cabin, hood and front bumper of the car.

Despite the apparent similarity, both cars differ in appearance. The first released dump truck with load-bearing frame No. 41 is being tested as Tonar-45253. But for now, both cars, according to the designation on the frames, carry the index 45251OH. The second dump truck is equipped with frame No. 52. The first sample is equipped with a V-shaped 8-cylinder turbodiesel TMZ 8437.10 with a displacement of 17.24 liters and developing 425 hp. The second car is equipped with an in-line 6-cylinder diesel six Cummins QSZ13-C450-II with a volume of 13.0 liters and a power of 450 hp. Both models are equipped with an Allison 4500 6-speed automatic transmission with retarder. The 360 ​​liter stainless steel fuel tank can be equipped with an external sheet steel protection.

Of interest is the design of the rear drive axle suspension from the Chinese company HANDE. Here, a balancer suspension with rubber elastic elements is used. This solution can work reliably under conditions of particularly large axial loads that conventional multi-leaf springs cannot cope with. The vertical load on each drive axle is transmitted through four elastic elements; longitudinal and lateral loads are perceived by reaction rods with rubber-metal hinges. The permissible load on each axle is 25 tons, while the main suspension parts have a threefold safety margin. Compared to the hydropneumatic suspensions often used on heavy equipment, the suspension on rubber elastic elements is structurally simpler, requires virtually no maintenance and ensures operation at temperatures from –60 to +50° C. To increase cross-country ability, cross-axle differentials were equipped with locking mechanisms. A similar device is built into the center differential. The locks are operated by buttons on the dashboard.

The suspension of the front axle of the coal truck and the rock skid is the same: air spring with leaf springs. But the beams of the cars are different, as is the design of the steering. On the “skalnik” it is completely hydraulic, and on the coal truck it is power-assisted. However, given the difficult working conditions, the hydraulic boosters with bipods and rods are duplicated and stand on both sides of the steered axle.

One of the main design features of the dump trucks is the cabin of our own production (all-metal, two-seater, made of aluminum), which significantly reduces the cost of the finished product. The inside of the coal tanker's cabin is a little more spacious than that of the rock truck. Dump trucks also have differences in the layout of knobs and toggle switches on the control panel. If we evaluate the level of comfort of the workplace and the passenger seat, a coal truck is no different from a “skalnik”.

The new hood TONARs differ in their dump bodies. The coal tanker is more spacious and is equipped with a tailgate with a top hinge. The body is made of steel 09G2S, the thickness of the sides is 6 mm, the bottom is 10 mm. The rock body is made from the same steel but is made more durable. A sheet of 7 mm thickness was used for the sides, and 12 mm for the bottom. Both bodies are equipped with an exhaust gas heating system and rods for removing stones stuck between the rear slopes. Hydraulic cylinders for lifting the Penta body are located outside the frame's intraspar space. Their lower ends are fixed to a transverse beam located in the base of the dump truck. This made it possible to free up space inside the frame for chassis components and lower the center of gravity of the machine. By the way, on these dump trucks many components are either covered with thick metal sheets or hidden in armored boxes. Like, for example, a battery.

Regardless of the body type, TONAR-45251 hood quarryers are equipped with a Lincoln Quicklube automatic centralized lubrication system with 24 points. It prevents abrasive particles (dust, sand, coal chips) from getting into the lubricant and significantly increases the service life of pins, pins, steering rods, spring earrings, cab suspension supports, etc.

It is worth noting that a dump truck with a Tutaev engine will be tested in the Rostov region, and a model with a Cummins engine will be tested in the Republic of Buryatia.

Not just cars

In addition to the mentioned dump trucks, other new products from the TONAR plant were presented.

Agricultural trailer PT-10, specially designed for transporting grapes. To avoid oxidation, the interior of the body is made of stainless steel. The trailer's tightness is ensured by a hydraulic roof. Body volume – 10 cubic meters.

The double-decker livestock semi-trailer TONAR-98262 is designed for transporting pigs. A distinctive feature of this model are stationary floors. The absence of hydraulics simplifies the design and ensures simplicity and ease of operation. The capacity of the semi-trailer is up to 150 heads.

TONAR-952345 is a new model in the line of lightweight dump semi-trailers for coal transportation. Body volume is 29.7 cubic meters. The design of the four-axle semi-trailer allows you to transport up to 28,550 kg of cargo without disturbances. For effective operation of the hitch, a tractor with a 4x2 wheel arrangement is required. An automatic awning with an electric drive reduces the time for “tilting” the body from half an hour to one minute, and also increases driver safety, especially in winter.

After the demonstration of the equipment, a now traditional press conference was held, at which Cummins specialist Alexey Khovaev, WABCO representative Alexander Vinokurov, head of the road construction equipment department of the Ministry of Industry and Trade of the Russian Federation Alexey Yartsev, and technical director of the Tonar plant Yuri Vainshtein spoke.

The event continued with a tour of the plant, where everyone was able to see and evaluate the degree of modernization and robotization of production: the complex for welding side members, bodies, axles, manufacturing cabins, etc.

The tour ended at the entrance to the factory canteen, where a delicious lunch and a warm atmosphere for friendly conversations, congratulations and wishes awaited guests.

The presentation that took place became clear proof that interest in domestically produced technology not only does not fade, but, on the contrary, grows every year. A large number of visitors (there were about 150 people) noted that the event was an important event for those who work in the field of cargo transportation and are in one way or another connected with the automotive industry.