Construction, agricultural and industrial work always requires mobile cargo transportation. Transporting small volumes of materials by rail is difficult, expensive and not always convenient. To solve these problems, functional dump trucks are used, among which foreign and domestic models are common.
Dump trucks Tonar
is a broadly oriented enterprise producing units for various purposes. The history of the plant goes back more than twenty years and dates back to the assembly of ordinary car trailers. Now Tonar is one of the well-known manufacturers of equipment and supplies products abroad and to domestic markets.
Advantages and disadvantages of units
The advantages of Tonar dump trucks include:
- availability of models with rear and side unloading, which expands their range of applications;
- the ability to treat bodies with anti-freeze coating (for working in difficult weather conditions);
- design adapted to domestic conditions;
- high reliability of components and a large margin of safety.
Despite the successful layout, the models sometimes have shortcomings:
- a more complex design than its foreign counterparts, making it difficult to carry out independent repairs;
- In some samples, isolated breakdowns occur during the warranty period.
The cost of transporting large quantities of bulk material is higher than rail transportation. This increases the cost of work and the cost of production.
Design features
The fundamental difference between domestic Tonar dump trucks and models from competing manufacturers is the choice between a trailed and semi-trailer design. The mining dump truck, which has a relatively low price and high technological capabilities, deserves special mention.
The load-bearing components of the units are reinforced, which improves the possibilities for their use in off-road conditions and high loads.
In order to reduce the total weight of the machine, original technical solutions are widely used, with the help of which the weight and bulkiness of components are reduced without loss of strength. This allows you to transport impressive loads without exceeding the new standards established for the maximum weight of trucks.
Safety in parking and on the move is ensured by an additional braking system. Spare wheels are located at the bottom of the tipper compartment or in the front compartment of the body. The trailed design is usually equipped with a three-axle wheel unit, which increases overall operational reliability.
The total operating weight of modern six- and five-axle Tonar dump trucks does not exceed 44 and 40 tons, respectively (usually 10-12 tons less). A large number of wide wheels reduces ground pressure and allows the units to be used even on roads with thin surfaces. The use of dual wheelsets maintains the stability of the machine when one or more wheels are punctured.
Tonar-45251. New Russian
Mashinostroitelny is expanding its line of heavy-duty bonneted vehicles. Designers of a Moscow region enterprise have created a new technological dump truck Tonar-45251 with a two-seater cabin. A hooded truck can be equipped with both imported and domestic power units
Mikhail Ozherelyev
The 6x4 mining vehicle serves as a continuation of the new model range, which began with the Tonar-45252 truck tractor, designed and built in 2016 by order of the diamond mining company ALROSA (for details, see “Vehicle Fleet” No. 7/2016). In fact, with the advent of these machines, it became the first and so far the only Russian company with original mining equipment of its own design. The curb weight of the dump truck is 23.5 tons, the load capacity is 45 tons, and the maximum speed is up to 50 km/h.
Two body options are offered: for transporting bulk cargo and for working with large-sized rocks
The main feature of the new product is the design of the cabin. The 2017 model year vehicle uses a two-seat, two-door all-metal cab located behind the engine. The production of cabins for new trucks will be carried out directly at Tonar, where preparations for the launch of the corresponding section are in full swing. It is planned to organize a full cycle production - from the manufacture of molds to the production of panels and final assembly. This decision will reduce the cost of manufacturing the car, plant representatives say. Let us remind you that the previous version of the dump truck (model Tonar-4525) used a single-seat cabin, which was purchased in China. In general, by penetrating deeper into the niche of off-road dump trucks, the company plans to maintain a “budget price.” It is for this reason that, as an alternative to the 450-horsepower Chinese Cummins QSZ13-450-II engine, customers can order a car with a “Tutaev” diesel engine TMZ-8437.10 with a power of 425 hp. With.
Placing hydraulic cylinders under the body saves space behind the cab
Of the key components of the aggregate base, only the Allison 4500 automatic transmission, 25-ton drive axles with final drives and a 13-ton front axle with a forged beam remain imported - they are manufactured by the Chinese company Hande Axle. Plus also components of the pneumatic braking system from WABCO and hydraulic equipment from the Italian company Penta. The main structural elements of the dump truck, including the frame and body, are manufactured independently at the production site in Gubino (Orekhovo-Zuevsky district, Moscow region).
The new model of the dump truck uses a two-seater cab
The machine body, containing 27 m3 of rock, is welded from alloyed wear-resistant steel 09G2S. Two options for the superstructure are possible: for the transportation of bulk cargo, the dump platform is equipped with a rear hinged side with an upper swing axis, and for working with large-sized rocks, the bottom and sides of the body are welded from sheets of increased thickness (7 and 12 mm, respectively), while there is no tailgate. In both options, in order to prevent cargo from sticking, the body is heated with exhaust gases. Tipping of the body is provided by two hydraulic cylinders, which are located under the bottom on the outside of the frame side members. This layout solution is mostly due to the lack of free space near the rear wall of the cabin.
Rear suspension with rubber elastic elements requires virtually no maintenance
Since the start of production of Tonar-4525 mining dump trucks, changes have been constantly made to their design to improve reliability, simplify maintenance and increase driver comfort. For example, the dump truck in the 2022 model year version received a front air spring suspension (a pair of air springs are located along the axis of the front beam). The use of pneumatics between the frame and the cab also makes a great contribution to improving the driver’s work. As for the driver’s workplace, all the nuances of ergonomics are taken into account: an adjustable seat with air suspension, the ability to adjust the steering column angle, space for a tachograph, a walkie-talkie and even a radio. Air conditioning is provided as standard. There is one inconvenience: the cabin floor is at the height of a person, getting in and out of the workplace is not easy even by the standards of a truck.
The rear suspension on the dump truck is balanced - using rubber elastic elements. There are no usual springs here, and certainly no pneumatics. This decision is due to the task of increasing reliability when working under conditions of particularly heavy loads, which conventional multi-leaf springs cannot cope with. The vertical load on the middle and rear drive axles is transmitted through four elastic elements; longitudinal and lateral loads are perceived by reaction rods with rubber-metal hinges. In comparison with the hydropneumatic suspension often used on heavy equipment, the suspension on rubber elastic elements is structurally simpler, requires virtually no maintenance and ensures operation in a wide temperature range: from –60 to +50 °C. Significant work to reduce dynamic loads on the body and cab of the dump truck is performed by the wheels. The truck is equipped with durable 14.00R25 radial tires. An optional TireBoss tire pressure management system is available.
To increase comfort, the cabin is attached to the frame using pneumatic elements
The vehicles use Lincoln Quicklube centralized automatic lubrication. The use of systems of this type is economically feasible: the labor and time costs that are present in the conventional method of lubrication of components are reduced, and the amount of lubricant consumed is reduced due to its more efficient dosing at 24 points combined into the system.
The first copy of Tonar-45251 will go for testing in the Rostov region. Another truck from this series will be tested at a quarry in Buryatia. Already this year, the plant will begin designing hooded dump trucks with 8x6 and 8x8 wheel arrangements. “We have found an open niche for off-road dump trucks and are trying to penetrate into it,” said Yuri Vainshtein, technical director of MZ Tonar LLC, at the presentation of new products.
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Discussion Cancel
1 comment
- Rabinovich:
01/17/2020 at 14:30
I don’t understand what prevented TONAR from buying the cab stamps from ZIL and making mining hoods with ZIL cabs?
Answer
The lineup
The company's annual presentations are distinguished by showing serial samples to the public, rather than prototypes. Their range includes trailers and semi-trailers, as well as a modification of the new mining dump truck.
Semi-trailers
Semi-trailer-type units for transporting bulk materials often have 2-3 wheel axles. An increase in their number leads to an increase in the maximum transported weight. Some models have 4 or more axles and are used for transporting coal and other heavy products.
Technical characteristics of Tonar dump trucks and semi-trailers:
| Characteristics | 9523 | 95239 1 | 9523 (91-93) | Unit measurements |
| Number of axes | 3 | 3 | 4 | PC. |
| Unloading | back | lateral (on the right side) | back | |
| Load capacity | 31320 | 31500 | 31320 | kg |
| Maximum weight (empty) | — | 8,5 | — | T |
| Gross weight (max) | — | 40 | — | T |
| Mass distribution (total): | ||||
| - on the saddle | — | 13 | — | T |
| - on a wheeled trolley | — | 27 | — | T |
| Emergency braking system | + | + | + | |
| Parking brake | + | + | + | |
| Support device | 24 | 24 | — | T |
| Body volume | 28 | — | 43 | m3 |
| Body rotation angle | — | 117 | — | hail |
Note. 1) Sealed body. Video review of the Tonar semi-trailer dump truck:
Trailers
Trailed equipment is almost always made in a three-axle version, stable without coupling to the main machine. Unloading is carried out backwards, which slightly narrows the scope of use of the units.
The use of trailed dump trucks has a number of difficulties in management, but allows for the mobile transportation of bulky and heavy loads.
Specifications:
| Characteristics | 85792 | 85791 | Unit measurements |
| Unloading | back | back | |
| Load capacity | 11750 | 12750 | kg |
| Vehicle towbar height (permissible) | 0,96; 0,65 | 0,62; 0,73; 0,84 | m |
| Maximum weight (empty) | 7,01 | 5,4 | T |
| Gross weight (max) | 25 | 18,15 | T |
| Mass distribution (total): | |||
| - on the rear axle | 16 | — | T |
| - to the front axle | 9 | — | T |
| Body lift angle | 50 | — | hail |
| Emergency braking system | + | + | |
| Parking brake | + | + | |
| Dimensions | 8644 ? 2545 ? 3162 | 6460 ? 2540 ? 2700 | mm |
Photo of the Tonar-85791 dump truck trailer
Mining trucks
The first and so far the only full-fledged domestic dump truck is the Tonar 45251 model. Its purpose is to transport large and heavy rocks (blocks of rock) during the development of mineral deposits.
Technical characteristics of Tonar mining dump trucks:
| Characteristics | 4525 (45251) | Unit measurements |
| Number of axes | 3 | PC. |
| Unloading | back | |
| Load capacity | 45000 | kg |
| Maximum weight (empty) | 21,3 | T |
| Gross weight (max) | 63,0 | T |
| Fuel consumption: | ||
| - per shift | 140 | l |
| — per 1 t/km of cargo | 0,053 | l |
| Mass distribution (total): | ||
| - on the rear axle | 50 | T |
| - to the front axle | 13 | T |
| Auxiliary brake | + | |
| Parking brake | + | |
| Body volume | 25 | m3 |
| Wall thickness: | ||
| - bottom | 12-16 | mm |
| - sides | 6-10 | mm |
| Speed )max) | 41 | km/h |
Tonar dump trucks are an adequate replacement for expensive foreign equipment and have good characteristics. The relatively low cost allows you to choose a model not by price, but by performance. Economical fuel consumption and adaptation to difficult working conditions make Tonar dump trucks one of the favorites on the domestic market. Video review of the Tonar 4525 mining dump truck:
“Made with us” and on Yandex.Zen
From the first days of November, the car assembly shop of Mashinostroitelny began to work. And if earlier the assembly of trucks was carried out at the posts of the experimental site, now automobile production has taken on a larger-scale serial nature. Photo source: tonar.info
Mashinostroitelny is the largest Russian manufacturer of full-size semi-trailers. The basis of the enterprise is a production complex in the village of Gubino, Orekhovo-Zuevsky district, Moscow region. Its territory exceeds 19 hectares. They house workshops that house a number of technological lines that ensure the production of:
– Flatbed and awning semi-trailers, as well as chassis of semi-trailers and trailers; – Axles, axle units and trolleys – both for own needs and for sale; – Isothermal panels and, accordingly, isothermal bodies and refrigerators; – Dump bodies and, accordingly, dump units; — Special add-ons for agricultural machinery.
These directions come together on two assembly lines, on which semi-trailers, as well as Tonar trailers, are born.
Photo source: tonar.info
Thus, the purchase of an automatic coupler (tractor and semi-trailer) implies a significant discount on the price. This removes many questions. In particular, the issue of matching the height of the tractor saddle to the semi-trailer disappears. The time required to register a vehicle with the traffic police is halved: both the tractor and the trailer/semi-trailer can be registered at the same time. The great advantage of such a coupling is that the service of the tractor and the trailer/semi-trailer is carried out in one place at the same time, which in itself adds several days to the work of the road train on the line over the course of a year.
This year, 2011, the Tonar fleet of cars and road trains gradually increased, and now it will grow even faster. Cars and road trains with our brand operate in the Belgorod, Kemerovo, Moscow regions, and Krasnodar Territory. The most popular among motor transporters are the Tonar-6428+9523 (3-axle semi-trailer) and Tonar-6428+95234 (4-axle semi-trailer) tipper semi-trailer road trains.
Photo source: tonar.info
Photo source: tonar.info
Designers and technologists of Mashinostroitelny closely monitor the company’s products through service centers - both trailers and road trains, and these in particular. According to our estimates, some of them work with overload, carrying up to 50 tons, while fuel consumption does not exceed 47 l/100 km, although a significant part of the route passes through quarries, construction sites and other unimproved roads that require driving in lower gears. Of course, no manufacturer can support or approve such practices, which will void the warranty. But since this does not entail serious repairs, the plant cannot intervene in the process of such transportation.
Photo source: tonar.info
In places where, due to loading or unloading conditions, it is difficult or impossible to use Tonar road trains, Tonar-6528 dump trucks with a body volume of 16 m3 have proven themselves well. They work on almost any site, and can be used both independently and with a Tonar-85792 trailer with a turntable, also with a volume of 16 m3.
A hydraulically powered truck tractor for towing semi-trailers and dump trucks is not the only tractor option. In a simpler, non-hydrogenated version, the three-axle Tonar-6428 can work with any Tonar semi-trailers, if the load on the saddle or road conditions require it. In snowy road conditions in rough terrain, a 6x4 tractor provides serious advantages over 4x2 vehicles.
Tonar road trains with three-axle tractors made a safe run to Vladivostok and back in the summer of 2010. At the same time, they were traveling towards the Pacific Ocean with a load. The return trip included presentations, and the program as a whole was designed for a month. And this became the only obstacle to loading back. The run showed the high reliability and performance of Tonar road trains: it passed without delays for technical or other reasons.
Photo source: tonar.info
Still, in the conditions of populated highways, the capabilities of 6x4 tractors are in many cases excessive, while they have to be paid for with greater weight and increased fuel consumption and tire wear. For such transportation, the plant’s program includes a Tonar-5422 truck tractor with a 4x2 wheel arrangement. These are powerful and reliable machines that work perfectly with any non-tipping semi-trailers "Tonar": flatbed, awning, isothermal and refrigerator trailers, container ships... They can also work with dump trucks, but lighter ones from the Tonar model range (for example, with an aluminum body), since Heavy models of semi-trailers have too much load on the saddle for a two-axle tractor.
Photo source: tonar.info
All Tonar vehicles are equipped with Yaroslavl YaMZ-650.10 diesel engines, 12-speed gearboxes and comfortable MAN F2000 cabs, manufactured under license from the German concern. Thanks to this, Tonar trucks combine a reasonable price with dynamic characteristics and comfort of the European level. A European class engine (Renault license) and units manufactured under license and under the control of the world's leading manufacturers guarantee Tonar cars high reliability.
