This year, the TONAR plant held a demonstration for consumers of a new and original for the Russian Federation model of a dump truck for quarries. The TONAR-7501 dump truck has a 6 by 4 wheel arrangement. It is designed to transport a record weight of cargo—sixty tons. However, by and large, any dump truck for quarries produced by the TONAR company can be called the owner of a record carrying capacity in Russia, since in our country there is simply no longer a single enterprise that produces such special equipment.
Load capacity
TONAR-7501, except for the layout, differs from its predecessor (TONAR-45351 with a lifting capacity of 40 tons) in all other characteristics. Unlike the latter, the new dump truck received a more massive and longer frame, axles with a higher load capacity and a power plant with higher power. The increase in the curb weight of the TONAR-7511 relative to the TONAR-45251 turned out to be not very significant in comparison with the increase in carrying capacity: from 24,200 kg to 27,500. Thus, the carrying capacity increased by 20 tons, while the curb weight was only by a little over 3.
Why was the carrying capacity significantly increased then? The massiveness of the frame was increased, the suspension was strengthened, and drive axles weighing 35 tons were used, replacing axles weighing 25 tons. The possible load on the steered axle was increased to 17,500 kg instead of 13,000. Each axle for any TONAR quarry dump truck is supplied by Hande Axle from China.
Tonar-7501: price
On the Russian market, the Tonar-7501 in its basic version (technological rock dump truck, front axle - 17.5 tons, middle and rear axles - 35 tons each) is offered at a price of ~15 million rubles (however, the final cost depends on the customer’s preferences, as well as the operating conditions and terrain of the truck). The basic configuration of a mining dump truck includes: air conditioning, driver's seat air suspension, autonomous cabin heater, radio, steering column adjustable in two positions, rear-view mirrors, halogen optics and other equipment.
Cabin
The cabin differs from the cabin of the first model of this type of equipment from this company in that it is double. The instrument panel has a somewhat simple appearance, but is made quite well. The body is produced by the TONAR plant itself. Due to the increased carrying capacity, the capacity of the platform has increased: for rocks - up to 27 cubic meters. m, for coal - up to 48.
On the right side of the steering wheel there is a place where a smartphone is mounted - thanks to this it is more convenient to use it as a navigator or a monitor that allows you to receive information from the system with which the fleet is managed. At the bottom there is a panel for controlling the automatic transmission. The center console became the location of the lever for controlling the retarder. Below it are levers that activate the center differential locking mechanism.
Tonar-7501: technical characteristics
The truck is equipped with a steering mechanism with two hydraulic boosters, as well as a braking system with pneumatic drive and drum devices on all wheels. The car is equipped with a 700-liter fuel tank and tubeless pneumatic tires measuring 16.00 R25.
Suspension
Another interesting distinctive feature of the TONAR bonnet dump truck is (if there is an air spring suspension in the front part) a suspension, original for Russian and European-made special equipment, located at the rear of the vehicle, which includes elastic elements made of rubber. Its peculiarity is the transmission of vertical load to any individual bridge using four elements with high elasticity, with the perception of the load by reaction rods on which rubber-metal hinges are installed.
As a result, such a suspension has greater endurance than a classic spring-balance suspension, while it is distinguished from a hydropneumatic type suspension, usually installed on similar special equipment, by its simplicity of design, higher cold resistance and the virtual absence of the need for maintenance.
Debut of the TONAR-7501 off-road dump truck at the Kuzbass coal mines
Since July, a new off-road dump truck TONAR-7501 with a lifting capacity of 60 tons has been tested at the Shestaki open-pit mine. This is the first and only domestic dump truck of this class. It has been cooperating with MZ TONAR LLC for several years now, since the company knows firsthand that domestic equipment can be a worthy competitor to imported quarry equipment.
When MZ TONAR produced the first 45-ton dump truck TONAR-4525 for the mining industry, pessimists argued that the plant would fail with its idea. But very little time passed, and even ardent skeptics admitted that the plant had produced a simple and reliable off-road dump truck. Now the demand for equipment is constantly growing, and subsequently the volume of its production is growing.
In 2022, the plant’s engineers went further and designed the Tonar-7501 off-road dump truck with a payload capacity of 60 tons and a gross weight of 88 tons. The second generation model combined all the developments and new products that were tested on the first generation dump trucks.
It was not by chance that the Kemerovo region was chosen to test a new dump truck. Kuzbass is the leader in the country's coal mining industry, where such equipment is in great demand. CJSC Stroyservis is the largest buyer of TONAR equipment. 25 first-generation off-road mining dump trucks with a lifting capacity of 45 tons have been operating here for a long time. The technical specifications for the first machines were drawn up by the plant's engineers together with highly professional specialists from Stroyservis CJSC. Based on the results of operating TONAR mining dump trucks at the enterprises of JSC Stroyservis, it was possible to improve and make positive design changes to domestic equipment.
They are interested in improving the economy and optimizing coal production. Reducing the cost of cargo transportation, active implementation of the latest developments and domestic equipment under the state import substitution program are some of the main principles of the work of one of the largest coal companies in the region.
- When driving in a straight line with a load of 60 tons in 6th gear, the vehicle speed is 40 km/h; engine speed 1,300 rpm.
- When climbing from a face on a slope of 6° with a load at a speed of 10 km/h, the car moves in 2nd gear; engine speed 1800-2000 rpm. In this area, the Lock up fluid coupling is activated (mechanical blocking of the automatic transmission clutch).
Specifications
The technical characteristics of TONARA-7501 fully correspond to the task that such a machine should perform. The front suspension is air spring, reinforced, the rear suspension is balanced on rubber elastic elements. It allows the machine to have a significant reserve of carrying capacity, requires virtually no maintenance and ensures operation in the range from -60 ºС to +50 ºС. This “temperature reserve” is extremely important for the weather realities of the Kemerovo region.
This suspension scheme allows reliable operation under conditions of particularly large axial loads, which 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 drive axle is 35 tons, while the main suspension parts have a threefold safety factor.
The power unit on the new dump truck is a 6-cylinder 15-liter Cummins QSX15 turbodiesel with a power of 540 hp. With. (at 2,100 rpm) and a maximum torque of 2,344 Nm at 1,400 rpm. Specific fuel consumption according to the speed characteristic at maximum power does not exceed 210 g/kWh. The Allison 4700 hydromechanical transmission with torque converter and retarder has already proven itself well on the Tonar-45252 tractor. The 700 liter fuel tank capacity is enough to work for a full shift.
Hande front axle beam – 17.5 t, Hande middle and rear axle – 35 t. Open drive shaft with needle bearings.
The transmission uses inter-wheel and inter-axle locks; final drive ratio – 14.298. Tubeless tires, pneumatic 18.00R25, the largest of all that were used at the TONAR plant,
Lincoln's Quicklub 24-point automatic lubrication system improves the durability of components such as kingpins, pins, tie rods, spring shackles, suspension and cab mounts, and more.
The all-metal body with rear unloading and a hydraulic body lifting system is equipped with an exhaust gas heating system to prevent the cargo from freezing. The bottom and walls are made of low-alloy steel grade 09G2S. Two body designs are possible: 48 cubic meters (with a head of 2:1 - 60 m3) with a tailgate with an upper axis of rotation and a bucket type for transporting 27 cubic meters (with a head of 2:1 - 37 m3) of rock.
Import substitution is a priority
Support of the state import substitution program is of great importance for Stroyservice CJSC. The company is socially and economically focused on supporting the Russian economy, first and foremost. Stroyservis is interested in seeing that mechanical engineering in Russia strengthens and develops. That is why MZ TONAR LLC was given the opportunity to test an off-road dump truck in real conditions at one of the company’s coal mines. Thanks to technical characteristics, such as low fuel consumption compared to competitors’ equipment, the use of the new 60-tonne dump truck TONAR-7501 can significantly reduce the cost of coal transportation.
Cooperation with a domestic manufacturer will allow the company to significantly reduce the cost of purchasing mining dump trucks, transporting coal, crushed stone, sand and similar cargo, which will ultimately have a positive impact on the final cost of the product and the economy of the enterprise.
CJSC Stroyservis is a group of enterprises that unites enterprises for the extraction and enrichment of coal, coke production, and sales of products on the Russian market and for export. It ranks 6th in the Russian Federation in coking coal production. The total number of employees of the company is more than 11,200 people.
The corporate management of ZAO Stroyservis includes:
Coal mining enterprises: Open-pit mine Berezovsky LLC, Open-pit mine Permyakovsky LLC, JV Barzasskoe partnership LLC, Shestaki open-pit mine JSC, Shakhta N12 LLC and 4 processing plants;
Coke-chemical;
Railway enterprise LLC Belovopromzheldortrans, automobile repair LLC Beltrans.
CJSC Stroyservis – indicators for 2022
The volume of coal production in 2022 is 13.07 million tons (an increase of 24.5% compared to 2022).
11.9 million tons of coal were shipped to consumers, which is 21.1% more than a year earlier. Including export supplies increased by 8% - to 3.5 million tons of coal, sales of coal on the domestic market increased by 25% - to 8.4 million tons of coal. The company's processing plants processed over 7 million tons of coal, crushing and screening complexes - 4 million tons of coal (an increase of 12.2%). The volume of stripping work increased by 18.5% compared to 2022 and exceeded 220 million cubic meters.
According to current plans, in 2022 it is planned to produce 15.7 million tons of coal.
Briefly about the main improvements and changes
The brainchild of Moscow region machine builders is so original and unique that only its creators can properly service and repair the equipment, which is why the operation of dozens of machines takes place under the tireless watchful eyes of designers and technologists from the Gubino estate near Moscow, in the urban district of Orekhovo-Zuyevo.
All comments are recorded and translated into improvements literally on the next production copy. If we talk about the family of off-road dump trucks (as indicated on the nameplate) TONAR-7501 for transporting coal, which we are considering today as an example, then we can list the most significant large-scale changes in 2022.
The first thing that is visible during an external inspection of the dump truck is the hydraulic tailgate drive: a tribute to safety and a tool for increasing efficiency. The second thing that catches your eye when the body is raised is the massive heat exchange equipment for the transmission and fuel system. Third, a centralized automatic fire extinguishing system. Fourth - air suspension of the driver's cab with a stabilization system.
Gubino continues to experiment with the power line. This year, under the hood of the TONAR-750100K, Cummins QSХ15 or QSZ13 engines can be installed, upon request, an Allison 4700 automatic transmission (7-speed with increased throughput torque).
Solutions for external lighting devices are constantly being refined
Solutions for external lighting devices are constantly being refined
The technically permissible gross weight of the 7501 family dump truck has increased from 87 to 93 tons.
The rear axle tires have also changed; their size has been increased to 18.00R25. The load capacity of the dump truck increased to 60 t (+15 t), and the nominal volume of the body to 48 m3 (+3 m3). Now let's talk more about the innovations.
The car is disassembled before being sent to the consumer. The body and outer wheels will be placed on one semi-trailer, and the car itself will travel on a second low-bed semi-trailer
In the office
Five steps of an inclined lattice staircase, and it was as if there had not been a year separating me from the last test drive. And yet the car is different inside, you don’t even need to put last year’s model next to it. Quilted upholstery in non-staining gray shades covers the metal walls, and the sun's rays still play on the polished steel dashboard. The kingdom of round analog devices is being squeezed out by a scattering of monitors and small LCD displays. A block for indicating the temperature conditions of the transmission has appeared on the left, and information about the thermal stress of the unit is provided in two stages - at the entrance to the heat exchanger and at the exit.
The interior of 2022 (TONAR-750100K) has matured again; at the request of operators, many temperature indicators have been added, necessary for the operational control of heat-loaded points of a whole galaxy of components and assemblies, and the temperature is now controlled at the inlet and outlet of heat exchange equipment
As before, the giant 750100K has a regular Allison automatic transmission selector on the right hand, which is now successfully displayed in the armrest box
There are now three monitors broadcasting various information: one minimizes “blind” spots using cameras, the other is responsible for navigation, and the third is diagnostic Multitronix. The Allison automatic transmission control key block has been moved under the driver’s right elbow, the bulky “bedside table” that was previously adjacent to the “dashboard” has been transformed into a convenient box-armrest.
The door upholstery has gained solidity, bare metal is practically absent, the door panel gives the feeling of a noble automobile classic half-stellar in the American style, rather than a formal interior designed to “cover up the shame”, characteristic of narrowly targeted special equipment.
The dump truck cabin and workplace are brutal in design and decoration, but continue to improve, this can be seen in many small details
The new steering column with a steering wheel of very small diameter strongly hints that driving a car with a gross weight of 93 tons does not require extraordinary physical development. Very friendly!
While driving, the first thing I noticed was that the smoothness of the ride had become noticeably better; this information was confirmed to me by the plant’s specialists. Since 2019, a new 4-point cab suspension with elastic pneumatic elements, telescopic shock absorbers and diagonal reaction bars has been introduced.
New cab suspension components
Getting into the cabin has become more convenient due to the vertically placed door handle - another innovation for 2022.
