A power piece

2/2014
International
Top truck engine D38
A power piece
man magazine
2/2014
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04
Artwork on wheels
Robert Mahrle is proud of his individually
designed MAN truck.
Jungle trials
06
Volksbuses built by MAN Latin America shuttle
Brazilian children to school.
masthead
MAN magazine is published three times a year
in 16 languages.
published by MAN Corporate Communications
Andreas Lampersbach,
Ungererstraße 69, 80805 Munich, Germany
editor in chief Florian Wöst
Editor Joachim Kelz
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editors & Authors Klaus-Peter Hilger (resp.),
Yasmine Sailer (dep.), Tobias Birzer, Markus Boden,
Martin Kaluza, Richard Kienberger, Jenni Roth,
Marcus Schick
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Asa C. Tomash
project management Marlene Freiberger,
Sara Austen
concept Stefan Lemle, A New Kind
Art direCtor Michael Weies, A New Kind
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Four hearts for a dream boat
08
The Viking Star is fitted with four clean engines
from MAN Diesel & Turbo.
for ios
Red-hot responders
10
The history of MAN fire engines
18
cover story
For more than a century, expertise and innovative strength have
been at the core of MAN’s engine development. The new D38 engine
combines commanding performance with utmost efficiency.
Navigating the world of MAN
16
At the IAA commercial vehicles show, MAN
makes an emotional brand appearance.
30
Looking out for the future ahead
26
Within the UR:BAN project, MAN developers
explore ideas for the traffic of the future.
30Turn old into new
In Nuremberg, MAN upgrades pre-used MAN
units into premium “Genuine Parts ecoline”.
26
40
technology with fascinating topics drawn from
the realm of trucks and buses, all the way to the
developers while exploring the urban traffic
turbines and engines that are deployed in ships
patterns of the future? And how is an old en-
or power plants.
gine transformed into a new one? This second
We wish you an enjoyable read while dis-
issue of MANmagazine offers answers to all
covering the following pages. Or simply down-
these and many more interesting questions. It
load the digital tablet version. It is free and
reflects the world of MAN: a world shaped by
available as an app for iOS and Android.
Photos: APPLE INC. Pr
Which Innovations is MAN going to present at the 2014 IAA? What is the focus of MAN
18A power piece
Powerful and efficient as never before:
The new D38 enhances MAN’s engine range.
22Heavy metal
MAN trucks master tough challenges
in South Africa.
The best of MAN’s world
02
News
12
Current events in MAN’s world
Trucks are us
36
During the Trucknology Days, visitors enjoyed
a hands-on experience of 170 trucks.
40Offshore
Commuting to windparks per boat: in transit
with a service team
46Professionals drive MAN
Football teams around the world enjoy the
travel comfort of coaches made by MAN.
48The mileage masters
Even with more than a million kilometres on
the odometer, MAN trucks operate flawlessly.
03
man magazine
2/2014
Historic reflections: The
airbrush motif on the driver’s side
depicts the first truck made by
Büssing as well as the MAN lion.
my man
Artwork
on wheels
Robert Mahrle, aged 29, is a fervently dedicated driver of MAN trucks. This passion is also
reflected by his own MAN TGA, which he has
configured in a rather singular way.
Mr Mahrle, what are these images on
your truck? They are historical motifs from
MAN’s past – or, more specifically, that of the
old truck manufacturer Büssing, which MAN
acquired back in 1971. The founder of the company, Heinrich Büssing, is depicted on the
One of a kind: The original TGA was transformed
to adopt the look of a TGX truck.
right, next to his factory, and on the left is the
first Büssing truck and the famous trademark
logo, the MAN lion.
Did you design the truck all on your
own? I came up with the airbrush design myself. MAN shared the original imagery of the
motifs with me. The actual realisation was
then done by a friend of mine, who is an airbrush artist.
Where did you get the idea for these historic images? I am a fourth-generation truck
driver – it’s a family tradition going back to
my great-grandfather. Even as a child I was
already enthusiastic about trucks, especially
the ones made by MAN. Naturally, I’ve also
always been interested in the history of cars
in general.
What other changes have you made to
just a few navigation lights. Then I added
a custom-made stainless steel sunshade, a
protective grille on the windscreen and the
chromium wheel rims. And the entire TGXstyle front, of course. Over time, this truck
has become quite unique.
04
MAN fan: Robert Mahrle
is a passionately
committed truck driver.
Photos: Michael Hudler
the MAN vehicle? I started back in 2005, with
05
man magazine
2/2014
Mobile education: The yellow Volksbus
picks up children in rural districts of
Brazil and gets them safely to school.
06
Pedro is 12 years old, and lives on the
Volksbus models for the programme, with
periphery of Mata de São João in Brazil’s fed-
powerful suspension springs and reduced
eral state of Bahia. Not too long ago it would
overhang at the front and rear, features that
have been impossible for him to attend school
are particularly suitable for coping with the
every day, as there are no public transport
difficult roads. The school buses feature
services in his suburb. Since 2007, however, a
extra-large doors, emergency windows,
yellow Volksbus has been negotiating the un-
comfortable seats with safety belts and a
surfaced gravel roads in the outlying districts
built-in speed limit, as the safety of young
of Mata de São João. Every morning, it takes
passengers is always a top priority.
Pedro and other children to school, and
Today, more than 14,000 Volksbus vehicles
brings them back home in the evening.
are servicing various regions of Brazil under
Known as Caminho da Escola (“road to
the auspices of the Caminho da Escola project.
school”), the initiative was launched by the
MAN Latin America provides the majority of
Brazilian government and aims to get chil-
the buses, thus promoting the country’s edu-
dren from rural districts to school with the
cational development. Without these buses,
assistance of a modern bus fleet. These buses
Pedro and thousands of other schoolchildren
therefore contribute to regular school attend-
would never be able to manage the long and
ance. MAN Latin America developed two
hazardous trip to school.
Photo: Fernando Vivas/MAN Latin America pr
Jungle
trials
07
man magazine
2/2014
Up in the air: Lifted by a
crane, the engine is hoisted
on board the cruise liner.
Four
hearts
for a dream boat
with a length of 230 metres, 29 metres
in width and offering room for 944 passengers, the Viking Star – the latest addition to the
fleet of Viking Ocean Cruises – is actually one
of the smaller super-luxury vessels. The luxury liner is powered by four 32/44CR engines
from MAN Diesel & Turbo. At the Italian shipyard Fincantieri-Cantieri Navali Italiani S.p.A.,
the engines were lifted on board the ship by
crane and installed in the engine room.
MAN Diesel & Turbo – in co-operation
with Alfa Laval, which provides the exhaust
gas purification systems to remove sulphur
oxides – supplies a total of eight engines for
the Viking Star and a sister ship. By combining
the ultra-efficient MAN engines with the exhaust gas purification system, the new luxury
cruisers can most economically meet the
­increasingly stringent regulations for sulphur
Made to measure: In the ship’s
engine room, mechanics install
the first of four MAN engines.
08
Photos: Fincantieri/MAN, Viking Star PR
oxide emissions all over the world.
Visionary future: From 2015
onward, the “Viking Star” will be
cruising the global oceans.
Watch a video about the
spectacular engine installation
via crane on the app.
09
man magazine
2/2014
Red-hot
1985
responders
In case of emergency,
MAN technology steps right
up to the plate: For 99 years,
MAN has remained a reliable
partner of fire brigades.
Since 1915, the expertise
and know-how in this field
has evolved continuously –
right up to today’s ultra­
modern firefighting vehicles
with Euro 6 compliance.
As a result of the strategic “Fast Plan”,
a measure aimed at reducing the number of
­automobile types, MAN was no longer
permitted to build anything other than heavy
trucks as of 1938. Fire brigades, however,
­required primarily lighter vehicles. Thus, MAN
did not succeed in solidly repositioning itself
in the firefighting sector until the late 1950s.
In the 1960s, MAN provided two-wheel- and
all-wheel- drive vehicles to fire departments
with the “bonnet” generation, including powerful 150-hp engines. Emergency teams could
therefore move out without delay.
1937
10
1960
1915
2013
Photos: MAN, Ziegler
In partnership with Swiss manufacturer
Saurer, MAN began offering the first
fire engines as cardan or chain cars in
1915. In addition to a crew of ten men,
the vehicle provided room for ladders, a
pump, hoses and an array of other
­extinguishing equipment.
With the cab-over-engine
configuration, MAN opened a
new chapter in the history of
firefighting vehicles in 1985.
The new medium-weight
series earned MAN an
excellent reputation. These
emergency vehicles often
remain in service for
decades, responding to
alarms on a daily basis.
Today there are real multitalents
among firefighting vehicles, such as
rescue vehicles and airfield fire engines. With its TGL, TGM and TGS
series, MAN is well-represented on
the market for fire-extinguishing
vehicles. In the autumn of 2013,
MAN became the first commercial
vehicle manufacturer to offer
emergency-vehicle chassis in all
exhaust categories, ranging from
Euro 3 to Euro 6.
Find more on the history of MAN fire engines at
> www.man.eu/discovermanfirefighting
11
man magazine
2/2014
Saving space: With their compact
dimensions and low weight, the MAN engines
can be accommodated on the railcar roof.
Masterful merriment
in an MAN Truck
Record-breakers deserve
a suitable victory vehicle.
FC Bayern München chose
a converted MAN TGX.
Alstom orders another 200 rail engines
German football champion FC Bayern
München celebrated its 24th championship
title in style, with a triumphal procession
the French rail-vehicle maker Alstom has ordered 200 MAN engines for the diesel electric
through the centre of Munich. Converted into
drive of its Régiolis railcar. In a first serial order, Alstom had already received 500 engines for
an open-top, an MAN TGX with the champi-
the regional train of its French rail operator SNCF. Deliveries of the railcars began in April 2014.
ons on board took off from MAN’s head office
Each vehicle is fitted with four or six MAN engines, each with an output of 338 kilowatts or
in Munich to proceed through streets
460 hp. The efficient six-cylinder in-line engine stands out for its compact and weight-saving
thronged with fans to Munich’s city hall. In
design. As a result, the complete drive package – consisting of the diesel engine and generator,
addition, 400 MAN employees also planned a
cooling system, air filter, exhaust system, and electrical and electronic components, can be
special surprise and assembled before depar-
accommodated on the roof. Improved accessibility simplifies servicing, and the consistently
ture to applaud their heroes.
low floors of the interior increase passenger comfort. Alstom is operating the first large fleet of
Photos: Lennart Preiss/MAN (3), Alstom pr, MAN
The spacious TGX platform was large
enough to accommodate the entire team of
players together with their trainer, Pep
Guardiola, as well as other dignitaries. The
converted open-top truck offered the public
an unobstructed view of the Bavarian football
stars, allowing for unfettered cheering of
fans. “After this fantastic season, the team
certainly deserved to properly celebrate their
accomplishment. Thus, I am glad that we
could organise this parade together with our
partners,” said Karl-Heinz Rummenigge,
Chairman of FC Bayern München. On the
­occasion of FC Bayern’s triple victory a year
ago, the championship vehicle had been converted at MAN’s Truck Modification Centre in
MAN delivers buses to Siberia
the russian transport company
Regio buses offer room for up to 63 pas-­
the MAN Lion’s Regio type to carry em-
sengers and are powered by an MAN D20
ployees of Russia’s largest coal producer,
­Common Rail diesel engine with 310 hp.
Siberian Coal Energy Company (SUEK), to
coal mines in the west Siberian town
Kemerovo and its vicinity. “Quality, safety and reliability are core values of our
company, and the MAN buses set standards in all of these areas. Being selected
truck would be sturdy enough to withstand
by a well-known industrial company like
the jigs of joy executed by the team.
SUEK as a transport services provider has
München since 2008 and provides the official
team bus. For the coming season, the contract
has been extended for another three years,
lasting until 2016.
Jubilant crowds await
the stars of Bayern:
Thousands of fans
celebrated victory and
championship title
of the Bundesliga team.
either two or three axles, the MAN Lion’s
Neotrans uses long-distance coaches of
Wittlich. The engineers made sure that the
MAN has been a partner of FC Bayern
12
Championship
celebration: The
FC Bayern parade
through the city
centre of Munich
commenced at
MAN’s head office.
low-floor vehicles with a roof engine design in Europe.
further substantiated our decision to
choose MAN,” said Sergey Verzhbitsky,
The look of celebration:
FC Bayern players present
the championship shield.
Managing Director Neotrans, on the
occasion of vehicle delivery. Featuring
For miners: MAN Lion’s Regio buses
13
man magazine
2/2014
Pioneer: the freighter Petunia
Seaways already meets the strict
emission standards of Tier III.
Ready for Tier III
freighter Petunia Seaways with an SCR sys-
as of 1 January 2016, “Tier III”, the next
reduced by more than 80%. Back in 2012, the
level of emission regulations for marine
company had received its first order for an
diesel engines issued by the International
EGR system for a container ship of the
Maritime Organisation (IMO), goes into
Maersk Line. MAN Diesel & Turbo is also
effect. MAN Diesel & Turbo already owns the
meeting the challenge of Tier III with dual-
expertise and the technology – such as
fuel engines, for example, which can be pow-
­exhaust gas recirculation (EGR) and selective
ered by clean-combusting gas as well as with
catalytic reduction (SCR) – to comply with the
heavy oil. MAN considers emission regula-
strict rules for nitric oxide emissions. MAN
tions an innovative inspiration in the
Diesel & Turbo has already fitted the Danish
development of maritime technologies.
tem, therefore complying with Tier III limits:
Nitric oxides in the exhaust have been
Ecological pioneer: Stockholm
owns the world’s largest
fleet of MAN hybrid buses.
Working in
ferocious heat
283
Turkmen Oil and Gas Construction has
ordered 61 all-terrain MAN TGS vehicles, becoming a first-time customer of MAN trucks.
The heavy dumper trucks feature 360 hp
engines and a permissible overall weight
of 33 metric tons. With two power-driven rear
emergency vehicles
axles and designed as all-wheel vehicles, they
The German disaster management agency
relies on special all-wheel vehicles from
MAN. The Federal Ministry of the Interior is
putting 164 MAN TGMs with double crew
cabs for human decontamination purposes
into service. In addition, there are 119 hoselaying vehicles, which can transport long
hose lines for major fire-fighting operations
or after flooding. The first emergency vehicles have already been delivered to disaster
management authorities in Bonn.
tion operations. In western Turkmenistan,
are particularly suitable for use in heavy tracthey are deployed for building roads while
developing sites for oil and gas production.
The vehicles are equipped for extreme weath-
181 buses for Stockholm
er conditions, as summer temperatures in
Turkmenistan can reach around 60°C.
Keolis Sverige AB is enlarging its Stockholm fleet with the addition of 181 MAN Lion’s City
municipal buses. The order from the Swedish transport company comprises 52 hybrid buses,
127 articulated buses with CNG (compressed natural gas) and diesel drive, as well as two MAN
Lion’s City M vehicles. All vehicles meet Euro 6 requirements, the strictest exhaust standards
to date, and are a very ecological means of transport. The MAN Lion’s City Hybrid, for example,
reduces diesel consumption and CO2 emissions by up to 30%. Another advantage of the hybrid
Vienna relies on MAN
buses is reduced noise. When leaving the bus stop, the bus relies entirely on the electrical drive,
while the diesel engine kicks in a few hundred metres later. With its 52 new additions, Stockholm now owns the largest fleet of MAN hybrid buses in the world.
Dr. Richard, a transport company based in
Austria, took delivery of 64 MAN Lion’s City municipal buses in Euro 6 version for its Vienna lines.
The low-floor buses offer room for 87 passengers
The world’s best MAN workshop
and are equipped with wheelchair accommodation, air conditioning and a passenger information
system. The drive is provided by a 320 hp engine
and a six-gear automated transmission system
The MAN Service Quality Award was
from ZF. Two additional MAN buses will be used on
awarded to the staff of the Auto Hrvatska PSC
Slavonski Brod service centre in Croatia, which
routes with narrow or winding streets. Decisive
and low fuel consumption of the MAN buses.
Tow-away duties: In Moscow, the new
MAN TGLs will keep the streets clear.
MAN is market leader in Russia
For the fourth time in succession, MAN has become market leader in Russia among
truck manufacturers from the EU. According to statistics from the Russian institute
Evitos-Inform, MAN achieved a top market share of around 22% in the year 2013, with
6,435 out of the total of 29,300 newly licensed trucks over six metric tons. Municipal
vehicles and special vehicles make up a large proportion of this market share. In
Moscow, 260 new MAN TGL tow-away vehicles went into service in February. With a
loading crane that can be extended to a length of 10 metres and a sliding platform, each
Handover: Managing Director Dr Ludwig
Richard (left) and Technical Director Johann Strasser (right)
take delivery of the buses from Peter Blaha of MAN (centre).
14
one can tow away a vehicle weighing up to five metric tons.
was recognised as the “Best MAN Workshop
Robust dumper: Featuring two powered rear axles, the
MAN TGS WW truck is especially suitable for deployment
as a heavy-duty traction vehicle.
2013/2014”. Places two and three went to the
Photos: Petunia Seaways pr, MAN (3), gettyimages
factors for Dr. Richard were the price-benefit ratio
MAN service centre in Bavaria’s Rosenheim
and MAN’s partner workshop Andreas Tröger
GmbH, based in Saalfeld, Thuringia. The winners came out on top after competing against
800 teams from all over the world. Taking part
MAN began deliver y of the of froad
First place: The Auto Hrvatska PSC Slavonski Brod
service centre is the “Best MAN Workshop 2013/2014”.
in the contest required that participants dem-
­vehicles in May 2014. The local importing
company manages the servicing of the fleet
in Turkmenistan. The rapid access to work-
onstrated their practical and theoretical skills
finals in Berlin. MAN has bestowed the Service
shop services and a supply of spare parts in
in automotive technology, customer manage-
Quality Award on the best service team since
this remote region played a decisive part
ment and commercial practice in several
2008. In total, 60% of all MAN workshops
in the decision of Turkmen Oil and Gas
rounds and over the course of an entire year.
worldwide had entered the contest this year –
­Construction to choose MAN.
The 21 best workshop staff were invited to the
a record high.
15
man magazine
2/2014
Navigating
MAN at the 2014 IAA, Hall 12
MAN world premiere
Different versions of the new
high-end model are presented
right next to the main stage:
three MAN TGX D38 vehicles.
the world of MAN
The 2014 IAA Commercial Vehicles trade fair is the highlight of the year.
MAN Truck & Bus will present its complete range of vehicles
and brands in Hanover, including the new top truck model TGX D38.
F
Engines
Visitors interested in technical
aspects can inspect the latest
MAN engines with state-of-theart Euro 6 technology, as well
as other Euro 5 engines.
MAN Truck, Distribution
Designed for distribution purposes,
vehicles of the TGS, TGM and TGL
series are the ideal solution for
transport and logistics in urban areas
and regional traffic.
Innovations
In this area, MAN exhibits
innovations and novelties
from the truck sector.
rom 25 September to 2 October, the
international world of commercial
vehicles will meet once again at
the 2014 IAA Commercial Vehicles
trade fair in Hanover. At this leading exhibition for mobility, trans-
port and logistics, MAN Truck & Bus offers an
innovative presentation spread over an area of
nearly 10,000 square metres.
Visitors to the IAA will find the full model
range from the brand world of MAN Truck &
Bus displayed in Hall 12. The MAN exhibit was
redesigned and is now easily recognisable
even from a distance due to a white brand
line. The different brands and segments are
clearly arranged in separate areas, transporting customers to distinct worlds with elabo-
Stage
On a stage with LED
background projection,
IAA visitors can
experience shows,
presentations and
lectures.
MAN Latin America
Represented by Constellationclass trucks and a Volksbus,
MAN Latin America is also part
of MAN’s presence.
rate settings that highlight the strengths and
versatile uses of MAN vehicles.
In addition to three vehicles of the highend TGX D38 model, show attendees can
­survey a total of 11 truck models, including the
MAN Truck, Long-Distance Transport
MAN’s TGX and TGX EfficientLine
series offer powerful traction units for
the long haul. A TGL tarpaulin-sided
vehicle is also on display.
NEOPLAN
NEOPLAN’s Skyliner,
Cityliner and Jetliner models
combine comfort and
efficiency in premium-class
travel coaches.
MAN TGS WW especially designed for the export market. The area dedicated to buses features an MAN Lion’s Coach and three variants
of the MAN Lion’s City – namely a CNG natural
gas, a hybrid and a Euro 6 diesel version. The
travel coach brand NEOPLAN is represented
MAN Truck, Traction
Whether utilised for the transport of
heavy loads or on construction sites,
MAN vehicles for traction transport
will master every challenge.
Driving the Future
by the Skyliner, Cityliner and Jetliner models.
showcasing the range of MAN engines. MAN
Latin America will also attend the event in
Hanover, accompanied by two trucks of the
Constellation class and a VW Volksbus. Alongside the products, visitors can also obtain information on the services offered by MAN.
16
MAN Bus
The bus sector presents the
MAN Lion’s City in natural gas, hybrid
and Euro 6 variants for urban and
short-distance transport, as well as
the MAN Lion’s Coach for tourist and
long-distance travel.
Illustration: MAN
At the centre of the trade exhibit is a display
Service
At the centre of the IAA show stand,
customers can receive tailored
information about the services offered
by MAN – including MAN Solutions,
Modification and the Customer Centres.
SEPTEMBER 25 – OCTOBER 02, 2014
HANNOVER
17
A power piece
man magazine
2/2014
For more than a century, expertise and innovational
strength have been at the core of MAN’s engine
development – with key technologies paving the way
for high-performance machines. The new D38
combines commanding performance and utmost
efficiency with low operating costs.
T
hat engine of mine is still
Schatz, when outlining the project. The 53-year-
making considerable pro-
old certified engineer is particularly intrigued
gress.” When Rudolf Diesel
by “the fabulous opportunity of starting the
contemplated his master-
development of a totally new ­engine on a
piece – made possible by MAN – back in 1895,
blank slate and continuing with design and
his invention was barely three years old. He
simulation, right through to the first proto-
could not have known that his statement
types and up to serial production”.
18
lasting validity will be proven once again,
The successors of rudolf diesel bun-
when MAN Truck & Bus presents its highlights
dle drive technologies and progress together
at the IAA Commercial Vehicles show in Hano-
in the MAN engine competence centres,
ver and displays its engine competence to the
which develop high-performance systems
automotive trade audience. On centre stage is
such as diesel and natural gas engines with a
the new MAN D38, a six-cylinder engine with
performance range of 150 up to 1,800 hp. They
15.2-litre cubic capacity and three performance
are not just intended for MAN’s commercial
options: 520 hp, 560 hp or 640 hp. While the
vehicles, but also for road and rail vehicles,
highly innovative Euro 6 engine is designed
yachts and work boats, power aggregates, or
for long-distance transport, traction and heavy
combined heat and power plants, as well as
loads, it still weighs in at 160 kilograms less
construction and agricultural machinery.
than its predecessor, the D28-V8.
A “basic engine for many applications” serves
Working under project director Norbert
as the foundation. “It is the starting point for
Schatz, a core team of about 70 specialists had
­developing the MAN engine series with four-
spent roughly five and a half years developing
and s­ ix-cylinder engines for road vehicles – as
the new D38 engine. “We wanted a robust,
well as its eight- and 12-cylinder engines for
­reliable and highly efficient unit, which would
agricultural machinery, trains, yachts, work
meet even the most challenging of transport
boats, and its diesel and gas units for power
tasks in the range of 500 hp or more,” says
generation – and launching them on the
Function and design: The cylinder head
of the new D38 engine features highly
rigid materials, a new cooling system and
innovative valve controls (shown).
Photo: Christian Stoll
would still ring true in the 21st century. And its
19
man magazine
­market with as many identical components as
possible,” says Walter Gotre, Head of Engine
Performance & Emissions at MAN. “The more
engine components can be utilised in different ­e ngine designs, the better. After all, it
benefits efficient development and assembly,
as well as facilitating servicing and the replacement of worn parts later on.”
The common rail injection used by
all diesel engines built by MAN Truck & Bus
hereby ser ves as the uniting factor. It
involves injecting the fuel at a pressure of up
to 1,800 bar – or even up 2,500 bar in the new
D38 – into the individual cylinders at precisely defined times, which results in atomisation. “The engine electronics are constantly
aware of all the relevant data, such as engine’s
rotational speed, load and temperature,”
­explains Gotre. This allows for calculating the
ideal injection time and exact quantity of
­injection fuel for each cylinder and any kind
of driving situation. As the injection system
doses the fuel precisely in adjusting to the
­engine load, the engine receives only the fuel
it needs and can burn soot-free.
Looking for innovations, the developers
also generally focus on the operating costs as
a vital parameter for the vehicle’s economic
viability. “We define the performance in
terms of low consumption and optimised
torque generation even at low speeds,” says
Norbert Schatz, when describing the task of
the developers. Here, the interaction of components is always geared towards a vehicle
service life of up to 1.5 million kilometres.
2/2014
Design elements
The MAN TGX D38 high-end
model is painted in a soft silver on
the mirror caps and radiator grille.
The new MAN TGX D38
The top model of MAN’s trucks for longdistance transport, traction and heavy loads
has a completely new drive train with numerous
technical innovations. The vehicle’s main
feature is the D38 six-cylinder engine with a
15.2-litre cubic capacity that ensures efficiency
and optimum performance. With a choice of
520 hp or 560 hp, or even up to 640 hp as
a heavy-duty tractor version, the D38 offers
utmost traction power for all requirements –
without intending to break any hp records.
The engine is 160 kg lighter than its pred­
ecessor, with MAN’s new TipMatic 2 gear
system resulting in even greater efficiency.
The ultra-modern, fully automated shift system
supports GPS-controlled shifting, with three
new functions: “Speed Shifting”, “EfficientRoll”
and “Idle Speed Driving” (see illustration). The
long rear axle provides additional running
smoothness and low rotational speeds. Due
to all these factors – including the new fuel
injection system – the D38 is exceptionally
economical. Full braking control, even at maximum load levels, is provided by the Intarder 3
with its higher braking torque, and the EVB
­engine brake with an increased braking performance of 340 kilowatts and even 600 kilowatts
for heavy-duty vehicles with EVB Turbo. All
standard versions of the TGX D38 incorporate
the Emergency Braking Assistant (EBA).
­O ptional extras include the Lane Guard System
(LGS), Adaptive Cruise Control (ACC) and the
“efficient cruise” GPS cruise control system.
Efficient Cruise GPS
Due to stored maps and the truck’s GPS position,
the cruise control system recognises gradient changes
in the road ahead. As a result the lorry can
“think ahead” and so optimise fuel consumption.
Lane Guard System (LGS)
The latest generation of LGS
recognises road markings with
extreme precision – offering
even more safety and comfort.
Turbocharging
Two-phase turbocharging ensures
that the engine is ideally supplied
with combustion air across a wide
speed range. The MAN D38
already reaches its full torque at
930 revolutions per minute.
Emergency Brake
Assist (EBA)
The Emergency Brake
Assist or EBA automatically
activates emergency
braking should the driver
be at risk to collide with
a stationary obstacle
or moving object in front.
Rear axle
With its exceptionally high gear ratio,
the rear axle exploits the torque of
the high-end MAN model and saves
fuel while still running smoothly.
Adaptive Cruise
Control (ACC)
Adaptive Cruise Control
automatically maintains
a proper safety distance
from the vehicle ahead.
The TGX D38 is suitable for all transport tasks,
especially heavy loads. Whether employed for
hauling timber in Scandinavia, long-distance
transport on the motorway or shipping exceptionally heavy goods up to 250 tonnes:
The MAN TGX D38 offers reliability, maximum
efficiency and low operating costs at all times.
Since the D38 has become significantly
lighter, efficiency will increase even further
for vehicle owners. “We wanted to offer operators the option of carrying a greater payload,”
say Schatz. This was achieved through an
ing the existing materials, combined with
­targeted geometrical design wherever necessary.” So what would Rudolf Diesel have
thought of it? Perhaps he might repeat his
original comment: “That engine of mine is
still making considerable progress.”
Find more information on the MAN TGX
D38 at the 2014 IAA at > www.man.eu
20
MAN TipMatic 2
The “Speed Shifting” function accelerates the shifting
process for gears 10, 11 and 12 – thus saving fuel
when negotiating gradients, as it retains more
momentum. The “EfficientRoll” function optimises fuel
consumption on descending gradients, and “Idle
Speed Driving” enables the MAN vehicle to accelerate
from stop directly to idle speed.
Illustration: MAN
­ideal choice of materials. “It involves optimis-
Retarder system
MAN’s Exhaust Valve Brake (EVB)
and Turbo EVB ensure maximum
braking performance. This amounts to
340 kilowatts, or even 600 kilowatts
for heavy-duty vehicles.
Common rail system
With a pressure of 2,500 bar, the
common rail system provides even
finer atomisation and therefore
maximises combustion efficiency.
High tech in the cylinder head
The new cooling system directs the cooling liquid in
the cylinder head directly from above to the points
most exposed to thermal stress, thus reducing wear
and tear. For the first time in a diesel truck engine,
MAN has utilised hardly deformable convex valves that
increase the service lives of valve and valve seat ring.
21
man magazine
2/2014
Heavy
metal
Filled up: A driver signs
the fuel receipt and accepts
his vehicle for the next trip.
Heavy haulage: Michael Sipho’s truck is
loaded up at the Piet Retief coal mine.
Photos: Richard Kienberger
Chromium ore from the mines of South Africa is in high
demand by the metal industry worldwide. MAN trucks carry
metric tons of the raw material from the country’s north
over a steep mountain pass to the port of Richards Bay. On tour
with the South African logistics company Chrome Carriers.
22
23
man magazine
2/2014
Intermediate stop: Michael Sipho takes
a break from his journey for a brief visit to
his sisters in the town of Pongola.
W
inding through the east
ner of mining enterprises. The company’s
of South Africa, this is
­depot sits in the port of Richards Bay, in the
National Highway 2, at a
province of KwaZulu-Natal. Its 284 drivers
spot somewhere between
transport chromium ore from the mines in
Empangeni and Pongola.
the north of the country to Richards Bay, to be
After a few hundred me-
shipped to destinations all over the world. On
tres of densely planted woodland, a few huts
the way back, the specialised side dumper
come into view at a crossroads. A telegraph
trucks fill up with coal or other bulk goods
wire attached to an askew wooden mast spans
needed to process the metal. For Michael
the wide and well-constructed road, a family
Sipho and his colleagues, every new trip
sits together under the shade of a tree.
­always starts at the Richards Bay depot, where
kilometres
Michael Sipho brings his MAN to a halt in the
both tanks of the tractor-trailer unit are filled
lay-by, and turns on the hazard lights. Two
up, and the residue of chrome ore is flushed
The journey from Richards Bay to
Rustenburg and back is a challenge:
Altitude differences of 1,250 metres and
a varied terrain are stressful for both
drivers and engines.
girls in brightly coloured dresses stand in the
out of the dumper bodies. Whenever neces-
grass alongside the road – they were expecting
sary, a mechanic carries out minor servicing
him. “These are my sisters,” says Michael. The
and repairs on the trucks.
Namibia
Rustenburg
South Africa
Piet
Retief
Richards
Bay
Double pack: While the twin tyre set is designed to
cope with tough operating conditions in South Africa and
the high payload, a tyre might still occasionally fail.
young driver has been working as a trucker for
three years and supports his parents and sib-
new drivers such as Michael Sipho re-
lings, who live here in a small village in the
ceive thorough training by Chrome Carriers
east of the country. “It’s a good job,” says the
before they go on tour independently. One
29-year-old, who switched to a different em-
training course is conducted in the mines,
ployer just a few months ago. He now works
where rigorous safety requirements are in
for the Chrome Carriers transport company
force. Even more important, however, is train-
and steers a new MAN truck that he praises en-
ing the drivers how to handle their vehicles
thusiastically: “As far as I’m concerned, MAN is
safely and economically. RTG has a modern
MAN, which covers servicing and mainte-
Coal dust covers the rough and muddy
number one!”
fleet of almost 500 units. Following thorough
nance, as well as extended guarantee provi-
ground, and an approaching storm front only
For decades, South Africa has been recog-
practical tests, the Chrome Carriers division
sions. After three years and up to 700,000 kil-
serves to darken the car park next to the
nised as the economic development engine of
partially renewed its fleet in 2012 and added
ometres of mileage, the trucks are traded in
mines even more. The access roads to the
an entire continent. In the booming mining
140 MAN TGS trucks. “Our decision to place
for new vehicles.
mine are the only offroad stretches on these
industry, Chrome Carriers – a subsidiary of
that order with MAN was based on the fact
the Reinhardt Transport Group (RTG) –
that the vehicles suffered absolutely no tech-
The first leg of Michael Sipho’s tour
in Piet Retief. Michael first trundles over the
evolved into the largest private logistics part-
nical defects after more than 200,000 kilo-
takes him from Richards Bay into the outly-
weigh station before positioning his seven-
metres of continuous operation. Other ­factors
ing areas of the mining town Piet Retief. The
axle vehicle alongside one of the big coal
determining our choice of supplier were the
road winds past national parks and water res-
heaps. A wheeled loader shovels the coal into
low fuel consumption rates of the trucks, the
ervoirs, crosses pastureland, towns and vil-
the dumper holders, which fill up in just a few
excellent cost-benefit ratio, driving comfort,
lages, marks the border with Swaziland and
minutes. As it leaves, the truck is weighed
as well as MAN’s maintenance service and
occasionally turns into a mountain pass. The
once more. “Have a good trip!” says an em-
warranty policies,” explains Derick Reinhardt,
journey is a difficult one for the fully loaded
ployee of the mining company, and hands
CEO of RTG. The vehicles operate in South
trucks, not least due to the sharp inclines.
Michael the documents. It will be nearly an-
­A frica under challenging conditions, often
Richards Bay is at sea level, while Piet Retief
other 500 kilometres before he reaches his
using tandem semitrailers, for example.
lies at an altitude of 1,250 metres in the high-
next destination – a chrome mine near
These so-called interlinks of the seven-axle
lands of Mpumalanga Province. (Mpumalanga
Rustenburg, west of Pretoria. Here he will
vehicles are designed for a high payload of
is Bantu for “the place where the sun rises”.)
swap his coal for chrome, sleep for a few hours
The short stop at his family’s village is the
and then head east again – back to Richards
only break during Michael’s journey before
Bay, where his cargo will be carried over the
reaching his destination. After five hours of
oceans to places all over the world.
34 metric tons. Operating conditions are further exacerbated by the demanding topography of the country, which is why precise servicing by the close network of MAN service
points is indispensable. Chrome Carriers has
concluded a full maintenance contract with
24
trips, yet they are not always as short as here
Photos: Richard Kienberger
1 500
driving he arrives in Piet Retief – a town
where the roads and houses look very different from the tidy boulevards of Richards Bay.
Find more information about MAN South
Africa at > www.man-south-africa.co.za/truck
Flexible transporter: The MAN TGS vehicles
of Chrome Carriers have been specially fitted with
side-dumping bodies.
“As far as I’m
concerned, MAN
is number one!”
Michael Sipho, truck driver with Chrome Carriers
25
man magazine
2/2014
Almost reality: In the simulator, study
participants experience how assistance
systems like the “green wave assistant”
could facilitate driving in the future.
Test situation: Sonja Stockert of the Munich University
of Applied Sciences fits the test person with special glasses
to record his viewing direction.
Looking out for the
future ah ead
26
O
nce the signal turns green, we
great driving experience,” says Habedank, a
wave and communications between truck and
are on our way. Yet just 100 me-
professional truck driver since 1971. Moving so
traffic lights are visions for the future –
tres further on, the next traffic
easily through an urban setting is certainly
brought to life by a deceptively real simulation.
light already awaits. And this time, it is a red
not a commonplace experience for him – es-
one. Klaus-Dieter Habedank is quite relaxed as
pecially considering that he is not even de-
he sits behind the wheel. His truck approaches
pressing the accelerator.
the signal at a speed of 40 kilometres per hour.
Then the tour comes to an end. A white
The signal then changes to green. Since
screen appears where Habedank had just faced
Habedank’s truck receives information from
the road and its traffic a moment ago. His driv-
traffic lights, the vehicle can calculate the
er’s seat actually sits on the premises of MAN’s
speed likely to catch the “green wave.” “What a
research department in Munich. The green
Researching urban transport of tomorrow, making it safe, efficient and especially
Photos: Sorin Morar
Within the framework of
the UR:BAN project, MAN
developers are working to
make city driving safer and
more efficient. Essential
elements are innovative
driver assistance and traffic
management systems for
trucks and buses.
.
a continuously moving flow has become an
important undertaking and research project
called “UR:BAN” for MAN and its coopera­tion with 31 companies, universities, research
institutions and metro areas. Launched in 2012
The German Federal
Ministry for Economic
Affairs and Energy is
a significant supporter
of the UR:BAN project.
“We induce traffic
lights to communicate
with vehicles.”
Andreas Zimmermann, expert on human-machine interface
27
man magazine
31
partners
A total of 31 companies, universities,
cities and research institutes are
cooperating in the UR:BAN project.
“The focus of our
research is always
on the driver.”
2/2014
and designed to run for four years, the re-
reducing fuel consumption. This includes the
working with the researchers and developers
which was installed in a city bus. Six cameras
search project has received significant support
avoidance of unnecessary stops and starts, by
from MAN and the university,” says Klaus-
attached along the length of the vehicle
from Germany’s Federal Ministry for Econom-
integrating the prognosis for switching times
Dieter Habedank. “I find that despite all the
deliver images for 360-degree detection,
ic Affairs and Energy. This year is the halfway
and stopping points at traffic lights. Andreas
cabling, driving in the simulator seems
which are computer-processed to yield an
mark, and the first result rendered by MAN de-
Zimmermann, responsible for one of the
almost real. Therefore, I can judge rather ef-
overall image of the vehicle and its immedi-
velopers are quite impressive.
UR:BAN sub-projects, describes it as a com-
fectively which new systems are designed to
ate surroundings.
plex process: “We induce traffic lights to com-
make life easier for the driver, or where they
might be optimised.”
Much fundamental work is needed before
The team of developers from the Engi-
municate with the vehicle via mobile phone
neering Research Electronics department at
or WLAN. Based on that data exchange, our
Situation-sensitive driver support is also
such an idea can evolve into an application
ready for serial production. “Where are the
MAN’s facilities in Munich is led by Karlheinz
control equipment calculates the driving
at the centre of the UR:BAN “Cognitive Assis-
best camera positions, which perspective is
Dörner. An electronics engineer and control
strategy best suited to take optimised advan-
tance” sub-project. Through integrated cam-
needed to get a realistic image of an obstacle?
technology expert, he joined MAN back in
tage of the green wave,” summarises the elec-
era systems, the driver should be enabled to
How can dynamic angle changes that occur in
1998. He first worked in advance development
tronics engineer. At some point, this strategy
view the entire immediate vicinity of the ve-
articulated buses, for instance, be reflected
and then became a department head respon-
should result in real savings, considering that
hicle on a monitor when necessary. Here, the
accurately? In this phase of the project, we are
sible for driver-assistance systems and elec-
frequent stop-and-start driving in urban traf-
researchers are using municipal buses as an
primarily dealing with many questions,”
tronics – thus bringing a wealth of experience
fic often defeats the high efficiency rate of
example for investigating different types of
states Karlheinz Dörner. While looking for an-
to the UR:BAN project. “We are simultaneous-
modern commercial vehicles. A study on the
display. “In their working environment, bus
swers, his team is supported by MAN experts
ly working on the sub-areas ‘Networked Traffic
efficiency of commercial vehicles issued by
drivers find themselves facing special chal-
and its project partners at the University of
System’, ‘Cognitive Assistance’ and ‘Human
the German Association of the Automotive In-
lenges,” explains project director Walter
Applied Sciences. Provided that the project
Factors in Traffic’. The principal focus of our
dustry (VDA) confirms that just two stops per
Schwertberger. “These primarily include bus
appears promising, research results can first
research is always on the driver.” That includes
kilometre will triple the fuel consumption of
stops, pedestrian and cyclist crossings, nar-
enter advanced and later serial development.
the “delay and green wave assistant”, for in-
a fully loaded 40-metric-ton vehicle.
rowing of roads, oncoming traffic and lane
stance, which professional truck driver and
Both the simulator and a field-trials track
changes.” Seeking to provide a more compre-
The researchers are well aware that
study participant Klaus-Dieter Habedank has
in Düsseldorf provide significant insights for
hensive view, the researchers are looking into
technology is only as effective as its utilisa-
just been testing in a prototype version. The
the project. Receiving feedback from drivers
rendering the immediate surroundings from
tion in real life. Despite all the possibilities of
developers put one of the most important top-
is just as important for the researchers as it is
a virtual bird’s eye perspective. To this end,
intelligent automation as it pertains to driv-
ics for commercial vehicles on their agenda:
for the drivers themselves. “I greatly enjoy
they work with a so-called Bird View system,
ing operations, human behaviour still plays a
key role. As a doctoral candidate at Munich’s
Bird’s-eye perspective: The monitor offers
drivers a comprehensive view of the vehicle’s
immediate vicinity, from above and in 3D.
Karlheinz Dörner, head of the Engineering Research
Electronics division at MAN
University of Applied Sciences, Sonja Stockert
is part of the UR:BAN “Human Factors in Traffic” sub-project. Here the media IT specialist
is focusing on the interaction of humans and
machines, to bring about a relaxed, efficient
and safe tour through urban traffic for the
driver. One of the 33 test drivers is Harald
Rauschmayr. In his part-time job as a transfer
driver for trucks, the 53-year-old civil servant
has regularly participated in the simulator
tests for the last four years: “It’s a great feeling to contribute my experiences as a truck
driver to the development of new vehicle
technology.” From Sonja Stockert’s point of
“Milestones for
urban traffic”
Eberhard Hipp, Head of Research
at MAN, on innovations for urban
traffic in the future
How can driver-assistance systems increase the efficiency and safety of
commercial vehicles in urban traffic?
We focus on networking the information not available to the driver, such as
the switching rhythms of traffic lights
or the most-current traffic disruptions.
As assistance systems process information like this in real time, they can
respond more presciently than the
driver, warn of critical situations, or
even intervene automatically.
How significant are the UR:BAN
project results for MAN customers?
It is our goal to use innovative systems
and new technologies to analyse the
increasingly complex traffic conditions
surrounding the vehicle. On this basis,
we hope to develop practical, consumption-optimised driving strategies
and support drivers as best we can.
That is our contribution to more efficiency and safety in road traffic.
The entire interview is posted at
> www.man.eu/discovermanurban
view, driver feedback is essential: “Nobody
knows better than these professionals what
information they need while on the road,”
Researcher in motion:
Karlheinz Dörner
likes cycling from his
office to the test track.
28
Looking at results: Walter Schwertberger (right)
and Michael Reule (left) examine the images of
the Bird View camera in the test bus.
Photos: Sorin Morar
she explains. Thus, research retains a practical orientation – for the benefit of those who
will be applying the results.
Find more information on the UR:BAN
project at > www.urban-online.org/en
Find a video interview
with Eberhard Hipp on
the app.
29
man magazine
2/2014
Spa treatment for machinery:
Old engines (left) are salvaged
by MAN in Nuremberg and
conditioned into fully functional
replacement engines (right).
Turn
old
Photos: Vuk Latinovic
into
new
30
An MAN replacement part offers the same quality as a new one, and with it
comes the same MAN guarantee. At the Nuremberg plant, previously used parts are
processed according to strict quality criteria. The outcome of this rejuvenation
process is a top-quality original part that protects the environment and cuts costs.
31
man magazine
2/2014
1
G
The remanufacturing process: 1 Employees at
the Nuremberg plant sort disassembled parts
before the first cleaning. 2 Dirt and grease are
removed from the individual parts, both
through a wash system and by hand. 3 Before
being processed by the sand-blaster, traces of
rust are still clearly visible. 4 An MAN employee
determines the exact measurements of specific
pre-used components.
lancing over the piece num-
benchmark. In 2013, his team turned out 780
bered 51.06500-6089, we
engines, with 11,325 other spare parts sent
can’t help but notice its
over to MAN’s stock depot in Dachau, near
rather lamentable condi-
Munich. Replacement parts are subject to the
tion: dirty, scratched and
same guarantees as new parts, so quality
with traces of rust. Until just recently, the part
3
standards are extremely stringent.
had faithfully performed its duty in an MAN
After processing, the replacement parts
truck, until its host – after having delivered
are stored away or shipped to where they are
more than a million kilometres over a decade
needed. All the refurbished parts required for
– had been overcome by crankshaft demise. So
replacement engines remain in Nuremberg,
on to the scrap heap? Perhaps in times gone by.
where they are directly installed in the
Today, all parts with remaining functionality
­engines. One example is the assembly line
are refurbished and prepared for a new lease
for the types D20/D26: Working in two shifts,
on life. Technical developments and further
260 employees can assemble up to 22 engines
advancements are taken into account during
an hour. Softly humming conveyor belts carry
the process of adaptation, which is referred to
the new and replacement engines to the work-
as remanufacturing. So part number 6089 – a
station, lined up like a string of pearls. The
used cooling-water pump – is scheduled to un-
­atmosphere is as clean as the light-grey floor,
dergo this process. Following the rejuvenation
with the sense of concentration at different
cure, the new ecoline number 9089 will find
manufacturing stations almost tangible. With
itself fully functional and installed in a replace-
practice and skill, the technicians assemble
ment engine.
everything the way it ought to be. How to tell
2
780
“Parts are closely
inspected for wear
and tear as well as
material fatigue.”
engines
While waiting for remanufacturing to be-
the difference between new units and a
gin, the cooling water pump is housed in a
­replacement engine? “Only through the part
workshop facility that is situated on the huge
number,” says Peter Tscharntke, Section Head
grounds of the Engine Competence Centre of
Segment 2, as this assembly line is called.
MAN Truck & Bus in Nuremberg. With an area
When a replacement engine has reached the
covering 350,000 square metres, the site
end of the line, it must still surmount one last
could accommodate 50 football fields. “E1” is
hurdle: functional testing. During hot tests,
written in large letters over the gates. Inside
the engine will run for half an hour on the test
­because fewer new parts need to be produced,
­ecoline a­ pproach first takes hold, as there are
the hall, parts such as our ­w ater pump are
bed under different stress levels.
emissions are also reduced. Customers such
many good arguments for customers in
as Deutsche Bahn and municipal transport
­favour of this “seasoned material”: A replace-
4
Georg Kugler, Head of Hot Testing and Replacement
Parts, MAN Nuremberg
subjected to a thorough cleansing. They are
32
In 2013, 616 truck engines and 164 bus
engines were refurbished at MAN’s plant
in Nuremberg.
working at man in munich, Stefan Ott is
companies specifically demand this kind of
ment part from MAN has the same quality as
tem, sand-blasted and ­repainted – with some
Project Director and responsible for the new
thing.” This is the “ecological” aspect in the
a new one, it is manufactured to the same
parts being subject to rejection. “After clean-
MAN Genuine Parts ecoline product series. As
ecoline series. Thus, ecoline also facilitates
specifications as the original component, and
ing, you can tell what is still re-usable,”
far as he is concerned, the future began three
MAN’s Corporate Responsibility strategy and
MAN offers the identical warranties. And all
explains Georg Kugler, 61, Head of Hot Testing
years ago when the spare parts business was
greatly contributes to protecting the environ-
this comes at a rate of up to 50% less than the
and Replacement Parts at MAN in Nurem-
elevated to Top Ten status in the MAN Group’s
ment while supporting sustainable mobility.
cost of a new part. Shorter downtime, with
berg. “We closely ­i nspect the parts for wear
corporate objectives. “Re-using and refurbish-
The focus is on vehicles that are four years old
­replacement rather than repairs, is another
and tear as well as ­
m aterial fatigue.”
ing previously used parts saves resources and
or older, which generally account for 70% to
advantage of the ecoline approach. Primarily,
For Kugler, maximum quality is the sole
cuts down on energy usage,” he says. “And
80% of a vehicle fleet. This is where MAN’s
however, installing original MAN parts
Photos: Vuk Latinovic
first taken apart, then cleaned in a wash sys-
1800
replacement
parts
Currently, around 1,800 replacement
parts can be ordered from MAN.
This portfolio will be extended to more
than 3,000 part numbers by 2016.
33
man magazine
adds value to the vehicle. Thus, ecoline
in Germany, the programme became available
also ­denotes the concept of “economical”.
in 17 European countries. The plan is a continu-
There are several good reasons why custom-
ous expansion to cover the remaining top 50
ers make a conscious decision to choose
global markets.
“MAN Genuine Parts ecoline”.
“MAN Genuine Parts ecoline” is just a
small part of the overall portfolio of MAN’s
“Conditioning
used parts saves
resources and
cuts energy usage.”
Stefan Ott, Project Manager,
“MAN Genuine Parts ecoline”
at MAN, every replacement part in-
original component business. All original
cludes a deposit system: When a customer
parts are made to MAN’s stringent quality
purchases an ecoline cooling water pump
guidelines – that is, according to state-of-the-
from the MAN workshop, for example, a
art technology standards. In addition, they
markup of 10% to 15% is added to the purchas-
come with a worldwide 12-month-guarantee
ing price. Upon returning the used original
policy. In order to reduce downtime as far as
part, the deposit is returned. The used compo-
possible when a breakdown occurs, MAN’s
nent is sent to Salzgitter in Lower Saxony, the
service centres usually have on average 8,000
central returns plant for anything recyclable,
original parts in stock – even for older models
and is then passed on to the expert techni-
and special vehicles. In all, 95% of all original
cians for further processing. Anything to do
parts are delivered to repair shops overnight.
with engines ends up in Nuremberg.
Find additional photos
of engine reconditioning in
Nuremberg on the app.
MAN retains a total of 200,000 original
“MAN Genuine Parts ecoline” is a major
components for its customers, stored in sev-
project, which demands a vast amount of
eral central warehouses around the world.
­logistical backup. There are plans to expand
Currently, MAN can offer about 1,800 num-
the scope of its portfolio in coming years, with
bers as replacement parts, while another 1,200
a growing number of participating countries.
should be added by 2016. Naturally, ecoline
In 2013, the overall turnover of ecoline parts
number 51.06500-9089 will also remain in the
amounted to €140 million. “ecoline is one of
portfolio range.
GENERATION 3.
DRIVEN BY YOUR NEEDS.
our most important topics,” confirms Frantz
Perre, Head of After Sales at MAN Truck & Bus
France. Ever since the process was introduced
– 1.9 l /
100 km
*
See the entire upcycling process in pictures at
> www.man.eu/discovermanecoline
The pro in
fuel efficiency:
Conti EcoPlus
› Excellent fuel efficiency
› High mileage performance
› Premium retreadability
Equal treatment: During
final assembly, engines of
all ages are tested with
strict quality guidelines.
34
Ready for dispatch: Both the new and reconditioned engines sit at MAN’s
Nuremberg plant, waiting for their assignment.
Photos: Vuk Latinovic
Conti EcoPlus HS3
Sep. 25 to Oct. 2, 2014
Hall 17, Booth A06/B11
Conti EcoPlus HD3
Conti EcoPlus HT3
* Applies to the following products HS3 315/70 R 22.5, HD3 315/70 R 22.5 and
HT3 385/55 R 22.5 in the Conti-EcoPlus range compared with each of their predecessors.
www.continental-truck-tires.com
man magazine
2/2014
Trucks
are us
Plant tours, shop talks
and 170 trucks available for
testing: Organised under
the motto “Meet the world
of efficiency”, the MAN
Trucknology Days in Munich
offer drivers, fans and
­customers a diverse and
wide-ranging programme
of events.
36
varied programme has attracted drivers, fans,
customers and MAN employees to the Truck
Forum building and the test track.
One highlight for the public: the special
line-up of fire engines. The body manufacturHands-on trucks: Visitors to
Trucknology Days were
able to experience MAN vehicles
up close and personal.
ers present their vehicles based on an MAN
chassis in the Euro 5 and regionally still
­approved version, and for the first time in the
new Euro 6 design. While many visitors are
unable to resist an excursion on the extension ladder and its lofty views of the periphery, the men of Hohenpeissenberg’s volunteer
fire brigade are mainly interested in vehicle
details: “We want to take a look at what the
different body manufacturers have to offer.”
Naturally a test drive is also on the agenda.
oni Estermann is impressed.
After all, there are 36 vehicles waiting to be
The Managing Director of
tried out under the supervision of MAN
the Swiss agricultural distribu-
ProfiDrive trainers on the circuit course here,
tor Kühlhaus Gunzwil AG has
on country roads or on the motorway.
just returned from a guided
While the Bavarian firefighters are mov-
tour through MAN’s Munich
ing onto the test track, Jack Penders is
plant. “It is quite remarkable
­i nspecting the vehicles displayed in front of
to see how little of the production here is done
the Truck Forum. These include MAN trucks
by robots,” he says. As an MAN customer,
built for practically all branches of industry.
­Estermann has come all the way from Switzer-
Penders, who is Dutch, works at MAN’s service
land to observe production first hand and try
centre in Venlo, Netherlands. “I am here to
out the new Euro 6 vehicles. He is one of 6,000
learn about new models and services, which
visitors who have come to Munich for the
enables me to better answer many customer
Truck­nology Days event. Test drives, shop talk
questions.” Sandra and Paul Schuler are less
with experts, 170 trucks on display, guided
interested in product information but rather
plant tours – over the course of two days, the
in the adventure of it all. Paul, 3, is blissfully
“To me, MAN
means 20 years of
great experiences.”
Toni Estermann, Managing Director of
Kühlhaus Gunzwil AG
Photos: Richard Kienberger
T
My turn today: Different generations
took to the truck wheels.
37
man magazine
“Events like the
Trucknology Days
truly reflect the
quality of MAN.”
Roberto Ruiz, proprietor of Transportes R. Ruiz e Hijos
Trucks to the horizon: The
test terrain is studded with vehicles
for a close-up view or a test drive.
reflect the quality you get from MAN,” he says.
One of his highlights: He got to drive a Euro 6
truck for the first time on the test track. “The
truck moves great, just like a Euro 5 vehicle,”
comments Ruiz. Off the circuit, the MAN
trucks also demonstrate their capabilities on
the gravelly off-road track. Close-by, a special
agriculture and forestry exhibit displays tractor-trailer units and complete vehicles that
have been modified to meet the specific requirements of the agricultural industry.
the Trucknology Days held in Munich
mark the launch of the “MAN Trucknology
RoadShow 2014”. A fleet of 65 vehicles of the
TGL, TGM, TGS and TGX classes will be tourseated behind the steering wheel. Such a
ing all over Europe. MAN sales staff will offer
­moment is precisely the kind of experience
customers the opportunity to try out these
that Trucknology Days offers its guests. MAN
vehicles for several days. For Toni Estermann,
has been organising its annual in-house exhi-
this is just another reason to emphasise the
bition since 2008 – with much success. The
MAN quality that he has believed in for a long
number of visitors noted this year – a notable
time: “I have garnered great experiences with
6,000 – has set a new record. Guests from 27
MAN for the past 20 years. The chassis are
countries travel to Munich, their homelands
light, yet still robust, and the price-perfor-
ranging from Brazil to Estonia and South Ko-
mance ratio is an excellent one.” The 2014
rea. Roberto Ruiz has come from Spain. The
Trucknology Days have only served to con-
proprietor of transport company Transportes
firm his opinion once again.
R. Ruiz e Hijos owns seven MAN trucks and
Use this QR code to
access a video about
Trucknology Days 2014.
38
has been an MAN customer for more than 15
More images of the 2014 Trucknology
years. “It is events like the Trucknology Days
Days are posted at > www.flickr.com/photos/
and the reliability of the vehicles that truly
mantruckandbus
Photos: Richard Kienberger
Heavyweight: Even the
largest vehicles could be tried
out on the test circuit.
Offs hore
man magazine
2/2014
Floating maintenance service: The
“Eden Rose” heads for the Sheringham Shoal
wind park off the coast of England.
40
Photo: Jiri Rezak
Any idle time of wind turbines on the high seas costs a
fortune. On the east coast of England, special ships
powered by 1,000-hp MAN engines carry service teams
and spare parts swiftly and reliably to their destination.
41
man magazine
2/2014
Fasten your safety belts: Once
they have roped up, service workers
climb from the ship to a cage
platform at the foot of the turbine.
P
1075
wind turbines
The first British offshore wind park
went online in 2001. Since 2008, the
UK has been offshore world champion
with 1,075 wind turbines.
3.6
gigawatts
Altogether, the 22 British wind parks
have an output of 3.6 gigawatts –
more than half of the offshore wind
energy generated worldwide.
42
be exceptionally reliable, especially since the
maran Tia Elizabeth leaves
boats cannot set out to sea in just any weather
Wells-next-the-Sea, a small tidal port on the
conditions. “This also has implications for
coast of Norfolk, a three-hour drive north of
what customers expect from the engines,”
London. The skipper takes advantage of the
explains Eugen Maier, the Area Sales Manager
morning tide, as putting out is not possible at
at MAN Engines Marine who is responsible for
ebb tide. Arranged in a zigzag pattern, buoys
the English market. “Apart from focusing on
indicate the course to the open North Sea.
fuel consumption, operators are mainly
Discernible are a few walkers on the beach and
mindful of reliability and service.”
the colourful wooden cabins so typical of the
In today’s hazy weather, the first wind
Norfolk coast. The Tia Elizabeth, however, is
turbines appear on the horizon after a one-
not carrying holidaymakers but rather half a
hour journey. The gigantic towers rise 80 me-
dozen service technicians on their way to the
tres above the water, with every rotor blade
Sheringham Shoal offshore wind park.
extending 52 metres in length. Way up above,
The Tia Elizabeth is one of three supply
red cage platforms for service technicians are
ships operated by the offshore access compa-
mounted to the engine houses. There are
ny Tidal Transit. With room for 12 passengers
88 turbines arranged in a diamond formation,
plus crew, a length of 20.3 metres and a width
each at a distance of around 500 metres from
of eight metres, the boat was built at the
the next. The Sheringham Shoal wind park is
Mercurio Plastics shipyard in Spain and is a
located about 17 kilometres from the English
typical specimen of its industry. The drive
coast and belongs to Scira Offshore Energy, a
comes from two MAN V12 engines, each with
joint venture of Statoil and Statkraft. Together,
an output of 1,019 hp. MAN manufactures
the wind turbines can produce a total output
high-speed four-stroke diesel engines in
of 317 megawatts – sufficient to supply over
Nuremberg, which are geared towards
200,000 British households with green energy.
Climbing excursion: The
technicians mount the
turbine mast to carry out
maintenance at the top.
commercial shipping. Every year, the production site builds 1,300 engines for ferries,
In the cabin below deck, Robert Pennock,
emergency service ships, tug boats and other
Ross Gordon and Kevin English sit on cush-
vessel classes.
ioned individual seats at one of the tables,
The expansion of offshore wind energy
drinking tea aboard the Tia Elizabeth. These
has resulted in a dedicated market for wind
ships are comfortable – after all, the techni-
park supply ships. Every day, Sheringham
cians should be rested when they reach their
Shoal sends as many as 36 service technicians
destination. The men work for Siemens, the
out to sea. The systems require regular main-
turbine manufacturer, and are doing a routine
tenance, as any idle time of wind turbines
check of one of the gears. A second team on
costs the operator a fortune. The turbine
board is responsible for maintaining the cable
gears are checked, the rotors examined for
winches and lifts inside the turbine masts.
cracks, the cables and lifts serviced. In
A green light comes on in the cabin, the signal
contrast with wind parks on land, however,
for transfer. The team moves forward to the
service staff can’t reach assigned job sites in
bow of the ship, with heavy waterproof bags
their own service van or car, but instead need
already waiting for them. These hold tools,
to rely on the supply vessels. And these must
spare parts and oil for the gears. Today the sea
Photos: Jiri Rezak
Powerful and effective: The 1,019-hp engines from MAN must
be exceptionally reliable to cope with their daily deployment.
ainted blue and white, the cata-
43
man magazine
pressing the bow of the ship against the plat-
GOOD BRAKING. BETTER DRIVING. INTARDER!
form to facilitate the mens’ platform transfer.
“This puts the most strain on the engines,”
says the skipper. “Even at a speed of 20 knots,
the trip out here is trivial by comparison. It’s
unusual that the engines must expel tonnes of
Good braking means better driving. Better driving means driving more economically, safely, and more environmentally friendly. The ZF-Intarder hydrodynamic hydraulic brake allows for wear-free braking without fading, relieves
the service brakes by up to 90 percent, and in doing so, reduces maintenance costs. Taking into account the vehicle’s
entire service life, the Intarder offers a considerable savings potential ensuring quick amortization. In addition, the
environment benefits from the reduced brake dust and noise emissions. Choose the ZF-Intarder for better performance
on the road. www.zf.com/intarder
water behind them, without the boat moving
forward an inch.”
man knows about these requirements.
“During the docking process, the boat is subPrecision work: The very
focused skipper Harry Getliffe
manoeuvres the “Tia Elizabeth”
through the wind park.
ject to powerful vibrations,” explains Eugen
Maier of MAN Engines Marine. “During installation, the ship’s diesel engines must be set up
with highly elastic bearings, just as the exhaust.” Even the engines find the manoeuvres
a strain: “These require almost maximum
torque,” says Maier, “and here we can refer to
previous experience. We’ve long since encountered comparable challenges in the ferry
business. Ferries can’t waste time either, and
they brake from 100 to zero or accelerate
quickly. Even docking is a similar operation.”
The engines sit in the two hulls of the catamaran. A narrow stairway leads down into the engine room, the walls are lined with an insulation layer of shiny silver. The two four-stroke
high-speed MAN diesel engines are installed
in this tightly confined space, where one person can barely squeeze past the light-grey ma-
Stand-by position: Having completed their
work on the wind turbines, the service teams
will return to the “Eden Rose”.
chine. “Such catamarans have very cramped
engine rooms,” says Maier, “but that actually
works to our advantage. The MAN engines are
Eugen Maier, Area Sales Manager,
MAN Engines Marine
More images of the trip
to Sheringham Shoal are
available in the app.
44
weight than anything else on the market.”
no problems. In heavy winds and high water,
Throughout the afternoon, radio calls are
setting over is the most precarious part of
repeatedly received from service teams who
work. Each wind turbine features access points
have finished their work on one of the tur-
on two sides. The men rope up their landing
bines. The Tia Elizabeth picks them up and
gear, step onto a ladder on the turbine mast
takes them to the next installation – similar
and climb a few metres to reach a cage plat-
to a kind of radio taxi. By evening, all the ser-
form. Each of these manoeuvres is a delicate
vice teams are back on board, and the ship
operation for skipper Harry Getliffe. Anchor-
makes its way back to Wells-next-the-Sea.
ing is out of the question, as it would damage
Back in the harbour, a minibus already waits
the cables below water. The bow is wide and
to take the teams to company headquarters
protected by heavy rubber cladding. While
in Egmere. Thus ends the mens’ 13-hour work
these manoeuvres are referred to as “bump
day. Tomorrow, they will be off again, catch-
and jump” in the industry, naturally no one
ing the late-morning tide at 10.30 am.
is supposed to do any jumping here. The service team can safely make it across at a swell
of up to two metres. Getliffe steadily keeps
Find more information on MAN’s marine
engines at > www.man-engines.com
Photos: Jiri Rezak
“The MAN engines
are exceptionally
compact and much
more lightweight.”
exceptionally compact and much more lightis calm and peaceful, so the transfer presents
man magazine
2/2014
Teamwork: While football star Sebastian Kehl
steers the new BVB coach into a parking
slot, Christian Schulz offers some useful tips.
Professionals
drive MAN
Most Bundesliga clubs and
several Champions League
teams are transported in team
coaches provided by MAN.
Transport for stars: The players of Paris Saint-Germain arrive in their
MAN team coach to make a red-carpet appearance.
46
Photos: Norbert Schmid/MAN, Jean-François Robert/PRESSE SPORTS, frenzl pr
Luxury on wheels: Features of the
new BVB coach include are a real wooden
floor and top-quality leather seats.
C
given. The most popular spots on the coach
are the two groups of four seats around a
table, where the footballers like to play cards.
MAN provides the means of transport for
the Bundesliga stars to their games. What began in 2008 with a sponsorship of FC Bayern
München underwent continuous expansion.
Hamburger SV, Borussia Mönchengladbach,
VfL Wolfsburg and Borussia Dortmund are
also partners – with another seven Bundesliga
teams also using MAN coaches. It’s a similar
picture on the international stage: Paris
Saint-Germain is an official partner, as are
onfident of victory, Sebastian
AC Milan and FC Barcelona, joined by 15 top
Kehl squeezes in behind the
league teams in Brazil, plus Brazil’s national
steering wheel. In contrast,
team, which all appreciate the amenities
21-year-old Jonas Hofmann, the
offered by MAN coaches. As Patrick Eble,
team’s young midfield talent –
Sponsoring and Events Team Leader at MAN,
seems a little bit nervous as he
comments with pride: “We are the premier
climbs into the team coach. The two Borussia
supplier worldwide for top-class sports. Our
Dortmund players competed against each oth-
partnerships make an important contribu-
er in several disciplines during a team-only
tion to the positive perception of MAN as a
duel on asphalt in the new and old team
strong brand.”
coaches. The final call was not made until the
Christian Schulz covers around 60,000
very end, when Kehl coaxed the ever popular
kilometres in his Lion’s Coach every year.
“Heja BVB” song out of the new coach by acti-
What was his finest hour? “Definitely the trip
vating a lever on the steering wheel. That was
back to the hotel from Berlin’s Olympic
the winning goal.
Stadium, after our 5-2 victory in the 2012 Cup
“Hopefully Sebastian won’t be competing
Final against Bayern München. The jubilant
for my job,” joked Christian Schulz after the
fans, the singing players – I had tears in my
fun contest, held on the occasion of officially
eyes.” Times have changed, however. Anyone
handing over the new MAN coach to Borussia
heading to Munich after the Bayern victory
Dortmund. The 43-year-old driver has safely
over Dortmund in the 2013 Champions
and comfortably chauffeured the football
League Final at the Allianz Arena was met by
stars to their matches for the last three years.
a gigantic banner on the outskirts of town,
“The predecessor was already fabulous, but
reading “Welcome to the city of the Very
what MAN has delivered this time is simply
Best!” Driving home from a match in Munich,
fantastic.” The 480-hp MAN Lion’s Coach L
Christian Schulz steers his team coach onto
represents the top class of the road – a team
the motorway in the opposite direction. As
cabin on wheels, with every comfort imagina-
long as he’s driving an MAN coach, however,
ble. Plush and flexibly adjustable leather seats
he’s certainly on the right course.
provide utter relaxation on any journey. The
three LCD monitors show movies or reports
from the day’s games. “On the drive home,
A “making of” report of the duel may be
found at > www.man.eu/discovermanbvbduel
the lads like to watch the recap of matches,”
says Schulz. The onboard SAT system renders
it possible. There is also a DVD player, a sound
system, a multimedia system and a WLAN
router. Fixtures such as a fully automated coffee machine or refrigerator naturally are a
Watch a video of
Sebastian Kehl and
Jonas Hofmann in
the BVB team coach
on the app.
47
man magazine
2/2014
The mileage masters
Racking up mileage of a million kilometres sounds
like a very long life cycle for a truck. MAN vehicles,
however, keep performing flawlessly beyond the
­million mark without a single engine replacement.
And not just on the well-maintained roads of Germany.
Robust, not rusty:
Paul Kick’s truck
receives top service.
Read more on how buses
can also surpass a
million miles in the app.
G
rass-green on top and scarlet red
below, the love of Paul Kick’s life
has no name, only a number. In
spite of its stately age, it is still
sprightly – and a millionaire. A
mileage millionaire, to be pre-
cise. That love is a 2007 TGA 19.440, Paul Kick’s
oldest MAN truck and “practically one of the
family by now.” The 40-tonnes vehicle has
been part of the haulage contractor’s fleet in
Kerpen, Germany, for seven years, shuttling
between Cologne and Berlin, on motorways,
mountain roads and local runs. The truck can
take a payload of up to 25 tonnes, and carries
everything from foodstuffs to trade fair goods
and construction materials. Naturally, other
heavy-duty vehicles can also perform this service.
Once a truck begins to age, however, it might
start losing oil, the batteries become tired, and
rust patches can develop. “My truck is as fit as
ever,” says Kick. The tractor-trailer unit has already
shouldered well over a million kilometres, with
Kick at the steering wheel for the entire distance.
Paul Kick has practically grown up in
a truck. Even as a child, he was already riding
with his father, who founded the family business. Today, he manages the company together with his brothers. Over all these years, Kick
has become a big MAN fan. Besides superior
quality and good maintenance, intelligent
driving habits are also essential in order to
extract top performance from a truck, he
says. And when it comes to servicing, it is
­impor tant to always remember the oil
change, check the brakes and examine the
wheel bearings. Due to his training as a motor
A passion for driving: Paul Kick has been at the
wheel of his truck for every mile.
48
Photos: Frank van Groen
­mechanic at MAN, Kick can perform all these
tasks himself. While there, he could already
learn about the quality of the vehicles he was
repairing. Well, actually:“We didn’t have
much to do,” he says with a wink.
Busy commuter: Paul Kick’s MAN
TGA has been carrying a range
of cargo goods between Berlin and
Cologne since 2007.
While Wolfgang Kamith doesn’t perform
the r­ epairs himself, the freight operator based
49
man magazine
Desert assignment: Trucks operating for
the fleet of Saif Bin Darwish drive roughly
100,000 off-road kilometres every year.
million kilometres
Paul Kick’s MAN TGA has already
passed the million milestone and has per­formed impeccably and without any
major repairs for years. Not surprisingly,
as MAN trucks are designed for a service
life of 1.5 million kilometres and more.
truck is still far away from the scrap yard, he
workshop at his doorstep that he has relied on
says. Even if Kamith could no longer utilize
for two decades. “They are not just interested
the vehicle for long-distance operations, he
in doing more business, but will also provide
could still sell it.
free advice,” he says. “Without these colleagues, we would have never hit the million
MAN achieves top performance – and not
mark,” A while ago, he also had the rear axle
just on Germany’s well-maintained roads,
of his 7.5-metric-ton truck repaired at the
but also in regions with lots of sand and swel-
workshop. Built in 1996, the vehicle already
tering heat. In the United Arab Emirates, for
had 950,000 kilometres on it. “But I said to
instance, 6,000 kilometres to the southeast.
myself, ‘It’s an MAN, it will be worth it.’”
The Saif Bin Darwish corporate group, a spe-
Thomas Dillitzer, Head of Sales Management
cialist in civil engineering and construction
MAN Trucks Germany, says, “A repair is al-
projects, has been relying on German trucks
ways economical, unless the cost surpasses
for 30 years. Three trucks have already passed
the value of the vehicle. Our trucks, however,
the one million mark. “We were not really
are built to run up to 1.5 million kilometres
­astonished to find that our MAN TGA models
and more.” Kamith was attached to his truck,
have so far kept going for more than a million
with its grass-green driver’s cab and generous
kilometres,” says R.D. Pepler, General Man-
sleeping berth, and didn’t want to let it go.­­
ager Plant Division at Saif Bin Darwish Civil
By now, it has logged 1,185,000 kilometres,
Engineering Contractors. From his point of
travelled through Sweden, England and Italy,
view, the principal reasons for the long
and remains fully functional.
“We would never
have hit the million
mark without
MAN’s service.”
Wolfgang Kamith, Founder and Managing Director,
Kamith Lastentaxi
50
V isit us
at the
, Stand
Hall 12
vicing provided by MAN and MAN’s special
­series is still running with its original engine
training courses. These ProfiDrive courses
from 1996, and even the heating system is
improve the drivers’ theoretical and practical
still the same. Its six-cylinder engine is so qui-
knowledge to prevent damage resulting from
et that the radio is perfectly audible even
faulty handling. The 750 vehicles of the Saif
while driving on the motorway. And so pow-
Bin Darwish fleet are used on construction
erful with its 220 hp, “that you don’t need to
sites all over the country. They total an aver-
crawl even on mountainous inclines, but
age of 200,000 kilometres a year, half of it
rather just drive normally.” Meanwhile the
off-road. Despite these tough conditions,
boss also ensures that his drivers handle the
MAN’s robust trucks have low service costs
vehicle responsibly: no high revolutions, an
and operate faultlessly, even far beyond the
early gear change, and an immediate report
million-kilometre mark. It is therefore hard-
and check-up as soon as anybody hears any
ly surprising that customers all over the
strange noises. All things considered, the
world are persuaded by this level of quality.
B14
A new power – just coming at you.
­service life of the vehicles are the regular ser-
Kamith’s MAN 8 223 from the L 2000
The premiere of the MAN TGX D38. MAN kann.
Photos: MAN
1.04
in Worms, Germany, has an authorized MAN
A new class of MAN power is approaching, enabling you to gather speed for success: with the
innovative D38 engine range in the MAN TGX a perfect merger of efficiency and power takes to
the roads. And scores top marks in performance, reliability and economy. See how efficient the
new power is. Come to the world premiere of the D38 at the IAA Commercial Vehicles 2014.
www.mantruckandbus.com/tg
The new KMAX range.
Drive further all year round.
The new KMAX line delivers up to 35% more mileage
compared to its predecessor and all-season capability.*
ALL-SEASON
*
Compared to RHS II and RHD II+. Tests conducted in cooperation with different European fl eets under the supervision of Goodyear on size 315/80R22.5 between July 2011 and June 2013 show that
KMAX S and KMAX D have an improvement in mileage potential of respectively up to 30 % and 35 % vs. Goodyear RHS II and RHD II+.