Truck-ballast tractor MAN TGS 40.540 6×6 BВS-WW

True Potential

Daniil Minaev, photo by the author

We continue to introduce readers to MAN heavy equipment, capable of moving road trains with a gross weight of up to 250 tons in space. Last fall, we examined the MAN TGH 41.680 8×6 BВS semi-ballast tractor, today it is the turn of another no less exclusive machine - the MAN TGS 40.540 6× 6 BВS-WW.

You need to make a strongman out of a simple tractor

Unlike the 8x6 vehicle tested in the fall, the 6x6 tractor is not a special converted version, but a deep serial specialization of the vehicle. For the MAN TGH 41.680 8×6 BВS, in order to implement a complex axle arrangement and at the same time meet the requirements of dimensional standards, it was necessary to manufacture a special “stepped” frame with variable height of the side members; in the case of 6x6, such complications were avoided. The subject of today's test - the MAN TGS 40.540 6x6 BВS-WW was first shown in Hannover in 2012, but was shod with a toothed single slope, therefore it did not fit into the 2500 mm permissible overall width for public roads.

Signs of chic and care for the driver of heavy equipment: a high LX cab with two sleeping bags, climate control, two autonomous heaters, electric windows, a refrigerator, a folding table and a lot of other pleasant little things

Such simple controls for a complex transmission with many locks and modes

Additional characteristics of the BCM 57.6 dump truck

External sun visor | Electrically heated exterior mirrors with a wide-angle section on both sides and a low-view mirror on the passenger side | Driver's seat “Comfort” with air suspension and electrical heating | Passenger seat “Standard” | Electric windows for driver and passenger doors | Manual air conditioning | Cabin sunroof 12V socket on instrument panel | Rechargeable batteries 2 x 225 A/h

Tire brand and size 1 axle - Satoya 385/65 R22.5 remaining tire profile height - 60% Tire brand and size 2 axle - Satoya 315/80 R22.5 remaining tire profile height - 60% Tire brand and size 3 axle - Satoya 315/80 R22.5 remaining tire profile height - 60% Spare wheel - Kama 315/80 R22.5 remaining tire profile height - 99%

Benevolent image

The version brought to Russia is equipped with wheels measuring 325/95 R24, which is why the image of a harsh and powerful tractor does not suffer from a touch of brutality and gigantism, and this is noticeable from the first moments of acquaintance.

Before starting to consider the details, let me allow myself a little emotion. The height of the lowest additional step from the ground level is “only” 670 mm, and in front there is a massive push block looking at me menacingly, behind the cabin on the frame there is a “tower” of additional equipment, an additional trailer hitch in the stern, a coupling system for connecting hydraulics in the front and rear - all these attributes indicate the unusual purpose of a powerful and stately truck. But at the same time, its heavenly blue-and-white paint, the stylish flutes of chrome horns and the sly squinting of the headlights give it the image of an elegant and driver-friendly car: it is strong and courageous, and not scary and aggressive.

Effortlessly carries a couple of hundred tons

The high ceiling of the LX cabin, two wide berths, a transformable table, a refrigerator, two autonomous heaters - liquid and air “hairdryer”, air conditioning, 12 and 24 V sockets and even, contrary to propaganda, ... an option called “smoker’s kit”. This is only for life when the road train sleeps peacefully in the parking lot. Here's what's needed for work.

First of all (I noted this right away) the seat of not only the driver, but also the passenger is air suspended. And an amazing set of mirrors and the finest heating threads on the windshield, additional retractable lights for illuminating oversized cargo will not allow the designers to be blamed for not taking care of excellent visibility. A rather complex transmission, which has five driving modes (three forward and two reverse) and ten locking options, is controlled by simply turning two handles.

It’s a pity that today I don’t have the opportunity to try this tractor as part of a road train, to realize how, with the help of just one person in tandem with modern technology, you can move hundreds of tons and cubic meters of non-standard, heavy and oversized cargo in space. Here you can focus a little on the numbers. In the specification MAN TGS 40.540 6×6 BВS-WW, in the section “permitted weights and axle loads” there are three columns with numbers. The first is data taking into account national requirements, the second is technically possible values, and the most interesting third column is the fundamentally possible weight, based on safety margins, without taking into account the characteristics and design data of some vehicle systems. So, the maximum possible total weight of the tractor can reach 40,000 kg, the total weight of the road train can be 250,000 kg, the load on the front axle and rear bogie is 9,000 and 32,000 kg, respectively. Quite a lot! Now let's go for a ride.

Overall dimensions of the MAN TGA 40.480 6×4 dump truck

Length - 8,050 mm | Width - 2,500 mm | Maximum height - 3,350 mm Wheelbase - 3,900 mm | Center distance - 1,400 mm | Rear overhang - 825 mm Ground clearance - 340 mm Suspension type - Spring Front axle VO-09 straight | Front springs 9.5 tons | Increased ground clearance | Front suspension stabilizer Rear springs 20 t | Execution in the form of a 2-axle trolley | Rear axle MAN AP HPD-1682/HP-1652 | Rear axle differential lock | The rear axle crankcase breather is brought up | Rear suspension stabilizers

Brake type – Drum Brake system MAN BrakeMatic | Rear axle brake linings 220 mm | Anti-lock braking system (ABS)

Cabin type – day, 2-seater (without berth)

Roll and slide

The maximum power of 540 horses and 2500 Nm of torque simply cannot pass from the engine to the wheels when we are talking about such colossal loads. That's why the transmission has a ceramic clutch and a WSK440 torque converter. The task of the torque converter is only to slightly roll out the road train, allow it to move, then it is blocked and the ceramic clutch begins to work, ensuring gear shifting of the automated ZF 12 AS 2540 OD MAN TipMatic gearbox.

For a driver who finds himself behind the wheel of this weightlifter for the first time, the moment of starting off is a little scary. The fact is that without a load, that there is a mass of the tractor outside the road train, the torque converter operates quite sharply: I turn on the “drive”, after a moment I feel a push and a decent acceleration occurs for a couple of seconds, the car literally explodes from its place, then the moment of blocking, and “peaceful” begins life” when the truck becomes smooth, and obediently agrees with the actions of its driver.

Yes, but what are these driving modes “Dm” and “Rm”? So this is an imitation of a partially depressed clutch to ensure precision in performing maneuvers in a confined space, and if I had applied them right away, I could have avoided the frightening acceleration when starting off.

When I had driven enough, I noticed another delicate feature of this heavy truck in relation to the driver. In the cabin, despite the springs on all axles and the cab suspension on springs, without pneumatics it does not shake at all on uneven surfaces, does not notice the tractor and speed bumps, and we crossed the railway crossing calmly, without dropping to a snail's speed and without jumping to ceiling. Respect!

Chassis

Do you want maximum ride comfort and maximum cargo safety? The optional Electronically Controlled Air Suspension (ECAS) makes this possible. To precisely adjust the height of the frame, the chassis can be lowered by 90 mm and raised by 190 mm. The 15-tonne MAN TGM, for example, with 19.5-inch tires, is distinguished by its economical operation. This truck can be classified as a truck up to 11.99 tons, which is not subject to (road) duties in Germany.

Maximum stability with minimum weight

The MAN TGM frame is designed for maximum stability and load capacity, while being exceptionally light. The flat top edge frame design allows for exceptionally quick and easy installation of accessories and attachments - without the need for drilling holes, which can compromise corrosion protection. And thanks to MAN Tronic, an electronic system with a CAN bus, and an interface for external data exchange (KSM), the vehicle is optimally prepared for retrofitting with various equipment and body modifications.

Optimal fit

To match the frame length to any body length, MAN TGM has a ready-made solution: the universal frame tailgate. Thanks to the narrow perforated frame rail, the frame overhang can be adapted to the body without the need for drilling holes. The end cross member is screwed in and the cross members can also be moved without any problems.

Double cabin

The 4-door double cab provides comfortable travel even in the rear seats. With an additional row of 4 seats in the rear, the cabin can accommodate max. 7 people (including driver). All seats are equipped as standard with a three-point seat belt. Versatile, large shelves guarantee proper order inside the cabin.

Driving comfortably means driving more confidently and safely. Therefore, ergonomic seats in the construction industry are very important. The TGM offers a choice of an ergonomic standard seat, a comfort seat with air suspension or a comfort seat with lumbar support and heating function. The most comprehensive option is the innovative air-conditioned seat, which creates airflow in the seat cushion and backrest to keep the driver warm or cool during hard work. A middle seat is available as an option. The cabin will always have a pleasant microclimate - this is ensured by highly efficient heating systems, air conditioning with climate control function and an optional diesel air heater (auxiliary heater).

Aggregate construction

Every truck starts with a frame. The MAN TGS 40.540 6×6 BВS-WW initially has a standard frame designed for construction equipment and is reinforced with additional gussets and inserts in the side members. But unlike the frequently used inserts on all kinds of dump trucks, mixers and truck cranes, here they are used locally, not over the entire length. Behind the cab, on a special subframe, additional components of the cooling system, a hydraulic unit, an antifreeze tank and coupling equipment are located.

The engine on the subject of our test, model MAN D2676LF06, is in-line, with separate cylinder heads, has 4 valves per cylinder, a timing drive on the flywheel side, a displacement of 12.4 liters (the V8, which was installed on the 8x6 tractor tested last fall, has already been removed from production). Environmental class five is achieved by using SCR exhaust gas recirculation and AdBlue injection. Power supply system – Common Rail.

The engine, as already mentioned, is coupled with a 12-speed automated gearbox of the ZF 12 AS 2540 OD MAN TipMatic model via a WSK440 torque converter and a ceramic clutch. Then, with the help of cardan drives designed for heavy loads (index 029GC), the torque comes to the transfer case of the G 253 MAN model, which has an asymmetrical differential, which is responsible for the unequal distribution of torque between the front and rear axles, which makes it possible to realize greater traction weight. This “transfer case” is also two-stage: the gear ratios are 1.582 and 0.981, respectively, with “neutral”.

The front axle is a drive axle, with a plug-in drive, with a load capacity of 9 tons, on four-leaf parabolic springs, the second and third axles are also driven, 16 tons, on springs. The gear ratio of the drive axles is 5.33. Anti-roll bars are used on all three axles.

Ballast capabilities

In addition to a truck tractor, our tractor can also be ballasted. This is evidenced by the additional ROCKINGER 56 E trailer hitch at the rear and the height-adjustable front ballast hitch (push-pull unit) at the front, and in both cases they did not forget about quick-release connectors for hydraulic lines. The push-pull unit provides additional capabilities not only for traction, but also for braking, restraining a heavy road train on a slope and controlling traction. In the case of such an operating scenario, it is necessary to install an additional ballast module on the fifth-wheel coupling, which is a compact but heavy superstructure that has a king pin for engagement with the saddle, and a set of fasteners is installed on the frame for reliable fixation. The fifth wheel here is JOST JSK 38 G-1 3.5'' with a design height of 190 mm, the fifth wheel plate has a thickness of 16 mm, the size of the hitch pre-installation is 1075 mm from the center of the last axle.

This tractor can be either a truck tractor or a ballast one.

PS

Surprisingly, the MAN TGS 40.540 6×6 BВS-WW was imported to Russia in a single copy “to the warehouse”, and not ordered by a specific client; this car must prove to future buyers the true potential and capabilities of the German concern from Nuremberg...

Technical characteristics of the car MAN TGS 40.540 6×6 BВS-WW

TGS 6x4 and 8x4

They are large-tonnage trucks with a 6x4 or 8x4 wheel arrangement. They perform well not only on asphalt roads, but also in off-road conditions. The car is equipped with an ergonomic driver's seat equipped with pneumatic shock absorption. A large range of adjustments makes it convenient for drivers of any type of build. There is no sleeping place, since the car is not designed for long trips.

The dump truck has a fairly rich basic package, which includes:

• – Electronic tachograph.
• - Air conditioner.
• – ABS.
• – Electric windows.
• – Autonomous heating.
• – Electric drive and heated mirrors.
• - Luke, etc.

The car is based on a durable spar frame. By default, the modification with a 6x4 wheelbase is equipped with an 18-cc body measuring 5200x2300x1425 mm. The carrying capacity of this model is 25 tons.

The 8x4 version has a 20-cc body whose dimensions are 6100x2300x1400 mm. Under the cabin there is an in-line four-hundred-horsepower turbocharged diesel engine with a volume of 10.5 liters. Load capacity is 27 tons.