A power piece

2/2014

International

Top truck engine D38

A power piece

man magazine

2/2014

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content 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 Tel.: +49. 89. 1580-1175, [email protected], www.man.eu publishing company Burda Creative Group GmbH, Arabellastraße 23, 81925 Munich, Germany Tel.: +49. 89. 9250-1320, Fax: +49. 89. 9250-1680, www.burdacreative.com editors & Authors Klaus-Peter Hilger (resp.), Yasmine Sailer (dep.), Tobias Birzer, Markus Boden, Martin Kaluza, Richard Kienberger, Jenni Roth, Marcus Schick international editors Patricia Preston (resp.), Asa C. Tomash project management Marlene Freiberger, Sara Austen concept Stefan Lemle, A New Kind Art direCtor Michael Weies, A New Kind Graphics Micheline Pollach, Andrea Hüls, Alexandra Barlow Graphics editor Elke Latinovic cover image Christian Stoll productioN Burda Creative Group GmbH printing Gotteswinter und Aumaier GmbH, Joseph-Dollinger-Bogen 22, 80807 Munich, Germany reproduction permitted with reference. Any changes must be coordinated with the editors. subscription service Thomas Mahler GmbH, Postfach 50 04 65, 80974 Munich, Germany Tel.: +49. 89. 1580-3274, [email protected] Copyright ©2014 MAN and Burda Creative Group GmbH

Simply download the app for free: for Android

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

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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. 30 Turn 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

18 A power piece Powerful and efficient as never before: The new D38 enhances MAN’s engine range. 22 Heavy 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. 40 Offshore Commuting to windparks per boat: in transit with a service team 46 Professionals drive MAN Football teams around the world enjoy the travel comfort of coaches made by MAN. 48 The mileage masters Even with more than a million kilometres on the odometer, MAN trucks operate flawlessly.

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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

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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

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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.

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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

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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

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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

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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.

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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.

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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

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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”.

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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

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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.

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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.

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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+.