2/2014. International. Top truck engine D38. A power piece

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1 International Top truck engine D38 A power piece

2 Explore much more of on your tablet. digitally content International 04 Artwork on wheels Robert Mahrle is proud of his individually designed MAN truck. for Android Simply download the app for free: for ios The best of MAN s world Which Innovations is MAN going to present at the 2014 IAA? What is the focus of MAN developers while exploring the urban traffic patterns of the future? And how is an old engine transformed into a new one? This second issue of MANmagazine offers answers to all these and many more interesting questions. It reflects the world of MAN: a world shaped by technology with fascinating topics drawn from the realm of trucks and buses, all the way to the turbines and engines that are deployed in ships or power plants. We wish you an enjoyable read while discovering the following pages. Or simply download the digital tablet version. It is free and available as an app for ios and Android. masthead MAN magazine is published three times a year in 16 languages. published by MAN Corporate Communications Andreas Lampersbach, Ungererstraße 69, Munich, Germany editor in chief Florian Wöst Editor Joachim Kelz Tel.: , magazin@man.eu, publishing company Burda Creative Group GmbH, Arabellastraße 23, Munich, Germany Tel.: , Fax: , 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, Munich, Germany reproduction permitted with reference. Any changes must be coordinated with the editors. subscription service Thomas Mahler GmbH, Postfach , Munich, Germany Tel.: , Thomas.Mahler-ext@man.eu Copyright 2014 MAN and Burda Creative Group GmbH Photos: APPLE INC. Pr 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 Jungle trials Volksbuses built by MAN Latin America shuttle Brazilian children to school. 08 Four hearts for a dream boat The Viking Star is fitted with four clean engines from MAN Diesel & Turbo. 10 Red-hot responders The history of MAN fire engines 12 News Current events in MAN s world 16 Navigating the world of MAN At the IAA commercial vehicles show, MAN makes an emotional brand appearance. 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. 26 Looking out for the future ahead 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. 36 Trucks are us 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

3 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 The founder of the company, Heinrich Büssing, is depicted on the 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 the MAN vehicle? I started back in 2005, with 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. One of a kind: The original TGA was transformed to adopt the look of a TGX truck. MAN fan: Robert Mahrle is a passionately committed truck driver. Photos: Michael Hudler 04 05

4 Jungle Mobile education: The yellow Volksbus picks up children in rural districts of Brazil and gets them safely to school. trials Pedro is 12 years old, and lives on the periphery of Mata de São João in Brazil s federal state of Bahia. Not too long ago it would have been impossible for him to attend school every day, as there are no public transport services in his suburb. Since 2007, however, a yellow Volksbus has been negotiating the unsurfaced gravel roads in the outlying districts of Mata de São João. Every morning, it takes Pedro and other children to school, and brings them back home in the evening. Known as Caminho da Escola ( road to school ), the initiative was launched by the Brazilian government and aims to get children from rural districts to school with the assistance of a modern bus fleet. These buses therefore contribute to regular school attendance. MAN Latin America developed two Volksbus models for the programme, with powerful suspension springs and reduced overhang at the front and rear, features that are particularly suitable for coping with the difficult roads. The school buses feature extra-large doors, emergency windows, comfortable seats with safety belts and a built-in speed limit, as the safety of young passengers is always a top priority. Today, more than 14,000 Volksbus vehicles are servicing various regions of Brazil under the auspices of the Caminho da Escola project. MAN Latin America provides the majority of the buses, thus promoting the country s educational development. Without these buses, Pedro and thousands of other schoolchildren would never be able to manage the long and hazardous trip to school. Photo: Fernando Vivas/MAN Latin America pr 06 07

5 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 oxide emissions all over the world. Made to measure: In the ship s engine room, mechanics install the first of four MAN engines. Photos: Fincantieri/MAN, Viking Star PR 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

6 Red-hot responders 1985 With the cab-over-engine configuration, MAN opened a new chapter in the history of firefighting vehicles in 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. 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 ultramodern 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 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 In partnership with Swiss manufacturer Saurer, MAN began offering the first fire engines as cardan or chain cars in In addition to a crew of ten men, the vehicle provided room for ladders, a pump, hoses and an array of other extinguishing equipment Photos: MAN, Ziegler 2013 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 >

7 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. German football champion FC Bayern München celebrated its 24th championship title in style, with a triumphal procession through the centre of Munich. Converted into an open-top, an MAN TGX with the champions on board took off from MAN s head office in Munich to proceed through streets thronged with fans to Munich s city hall. In addition, 400 MAN employees also planned a special surprise and assembled before departure to applaud their heroes. 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 Wittlich. The engineers made sure that the truck would be sturdy enough to withstand the jigs of joy executed by the team. MAN has been a partner of FC Bayern München since 2008 and provides the official team bus. For the coming season, the contract has been extended for another three years, lasting until Championship celebration: The FC Bayern parade through the city centre of Munich commenced at MAN s head office. Jubilant crowds await the stars of Bayern: Thousands of fans celebrated victory and championship title of the Bundesliga team. The look of celebration: FC Bayern players present the championship shield. Photos: Lennart Preiss/MAN (3), Alstom pr, MAN Alstom orders another 200 rail engines the French rail-vehicle maker Alstom has ordered 200 MAN engines for the diesel electric drive of its Régiolis railcar. In a first serial order, Alstom had already received 500 engines for the regional train of its French rail operator SNCF. Deliveries of the railcars began in April Each vehicle is fitted with four or six MAN engines, each with an output of 338 kilowatts or 460 hp. The efficient six-cylinder in-line engine stands out for its compact and weight-saving design. As a result, the complete drive package consisting of the diesel engine and generator, cooling system, air filter, exhaust system, and electrical and electronic components, can be accommodated on the roof. Improved accessibility simplifies servicing, and the consistently low floors of the interior increase passenger comfort. Alstom is operating the first large fleet of low-floor vehicles with a roof engine design in Europe. MAN delivers buses to Siberia the russian transport company either two or three axles, the MAN Lion s Neotrans uses long-distance coaches of Regio buses offer room for up to 63 pasthe MAN Lion s Regio type to carry employees of Russia s largest coal producer, Common Rail diesel engine with 310 hp. sengers and are powered by an MAN D20 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 by a well-known industrial company like SUEK as a transport services provider has further substantiated our decision to choose MAN, said Sergey Verzhbitsky, Managing Director Neotrans, on the occasion of vehicle delivery. Featuring For miners: MAN Lion s Regio buses 12 13

8 Pioneer: the freighter Petunia Seaways already meets the strict emission standards of Tier III. Ecological pioneer: Stockholm owns the world s largest fleet of MAN hybrid buses. freighter Petunia Seaways with an SCR system, therefore complying with Tier III limits: Ready for Tier III Nitric oxides in the exhaust have been 283 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 emergency vehicles diesel engines issued by the International EGR system for a container ship of the The German disaster management agency Maritime Organisation (IMO), goes into Maersk Line. MAN Diesel & Turbo is also relies on special all-wheel vehicles from MAN. The Federal Ministry of the Interior is effect. MAN Diesel & Turbo already owns the meeting the challenge of Tier III with dualfuel putting 164 MAN TGMs with double crew engines, for example, which can be pow- cabs for human decontamination purposes expertise and the technology such as into service. In addition, there are 119 hoseexhaust gas recirculation (EGR) and selective ered by clean-combusting gas as well as with laying vehicles, which can transport long catalytic reduction (SCR) to comply with the strict rules for nitric oxide emissions. MAN Diesel & Turbo has already fitted the Danish heavy oil. MAN considers emission regulations an innovative inspiration in the development of maritime technologies. hose lines for major fire-fighting operations or after flooding. The first emergency vehicles have already been delivered to disaster management authorities in Bonn. Vienna relies on MAN 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 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 from ZF. Two additional MAN buses will be used on routes with narrow or winding streets. Decisive factors for Dr. Richard were the price-benefit ratio and low fuel consumption of the MAN buses. Handover: Managing Director Dr Ludwig Richard (left) and Technical Director Johann Strasser (right) take delivery of the buses from Peter Blaha of MAN (centre). MAN is market leader in Russia Tow-away duties: In Moscow, the new MAN TGLs will keep the streets clear. 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 one can tow away a vehicle weighing up to five metric tons. Photos: Petunia Seaways pr, MAN (3), gettyimages 181 buses for Stockholm 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 CO 2 emissions by up to 30%. Another advantage of the hybrid 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. The world s best MAN workshop The MAN Service Quality Award was awarded to the staff of the Auto Hrvatska PSC Slavonski Brod service centre in Croatia, which was recognised as the Best MAN Workshop 2013/2014. Places two and three went to the 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 in the contest required that participants demonstrated their practical and theoretical skills in automotive technology, customer management and commercial practice in several rounds and over the course of an entire year. The 21 best workshop staff were invited to the First place: The Auto Hrvatska PSC Slavonski Brod service centre is the Best MAN Workshop 2013/2014. finals in Berlin. MAN has bestowed the Service Quality Award on the best service team since In total, 60% of all MAN workshops worldwide had entered the contest this year a record high. Working in ferocious heat 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 axles and designed as all-wheel vehicles, they are particularly suitable for use in heavy traction operations. In western Turkmenistan, they are deployed for building roads while developing sites for oil and gas production. The vehicles are equipped for extreme weather conditions, as summer temperatures in Turkmenistan can reach around 60 C. Robust dumper: Featuring two powered rear axles, the MAN TGS WW truck is especially suitable for deployment as a heavy-duty traction vehicle. MAN began delivery of the offroad vehicles in May The local importing company manages the servicing of the fleet in Turkmenistan. The rapid access to workshop services and a supply of spare parts in this remote region played a decisive part in the decision of Turkmen Oil and Gas Construction to choose MAN

9 Navigating 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. MAN world premiere Different versions of the new high-end model are presented right next to the main stage: three MAN TGX D38 vehicles. 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 at the 2014 IAA, Hall 12 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. From 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, transport 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 elaborate 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 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 by the Skyliner, Cityliner and Jetliner models. At the centre of the trade exhibit is a display 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. Stage On a stage with LED background projection, IAA visitors can experience shows, presentations and lectures. 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. MAN Truck, Traction Whether utilised for the transport of heavy loads or on construction sites, MAN vehicles for traction transport will master every challenge. 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 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. NEOPLAN NEOPLAN s Skyliner, Cityliner and Jetliner models combine comfort and efficiency in premium-class travel coaches. MAN Latin America Represented by Constellationclass trucks and a Volksbus, MAN Latin America is also part of MAN s presence. Driving the Future SEPTEMBER 25 OCTOBER 02, 2014 HANNOVER 16 17

10 A power piece 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. That engine of mine is still making considerable progress. When Rudolf Diesel contemplated his masterpiece made possible by MAN back in 1895, his invention was barely three years old. He could not have known that his statement would still ring true in the 21st century. And its lasting validity will be proven once again, when MAN Truck & Bus presents its highlights at the IAA Commercial Vehicles show in Hanover and displays its engine competence to the automotive trade audience. On centre stage is the new MAN D38, a six-cylinder engine with 15.2-litre cubic capacity and three performance options: 520 hp, 560 hp or 640 hp. While the highly innovative Euro 6 engine is designed for long-distance transport, traction and heavy loads, it still weighs in at 160 kilograms less than its predecessor, the D28-V8. Working under project director Norbert Schatz, a core team of about 70 specialists had spent roughly five and a half years developing the new D38 engine. We wanted a robust, reliable and highly efficient unit, which would meet even the most challenging of transport tasks in the range of 500 hp or more, says Schatz, when outlining the project. The 53-yearold certified engineer is particularly intrigued by the fabulous opportunity of starting the development of a totally new engine on a blank slate and continuing with design and simulation, right through to the first prototypes and up to serial production. The successors of rudolf diesel bundle drive technologies and progress together in the MAN engine competence centres, which develop high-performance systems such as diesel and natural gas engines with a performance range of 150 up to 1,800 hp. They are not just intended for MAN s commercial vehicles, but also for road and rail vehicles, yachts and work boats, power aggregates, or combined heat and power plants, as well as construction and agricultural machinery. A basic engine for many applications serves as the foundation. It is the starting point for developing the MAN engine series with fourand six-cylinder engines for road vehicles as well as its eight- and 12-cylinder engines for agricultural machinery, trains, yachts, work boats, and its diesel and gas units for power 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 18 19

11 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 engine 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 serves 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. 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 predecessor, 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). Optional extras include the Lane Guard System (LGS), Adaptive Cruise Control (ACC) and the efficient cruise GPS cruise control system. 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. 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. 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. Design elements The MAN TGX D38 high-end model is painted in a soft silver on the mirror caps and radiator grille. 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. 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. Adaptive Cruise Control (ACC) Adaptive Cruise Control automatically maintains a proper safety distance from the vehicle ahead. 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 ideal choice of materials. It involves optimising 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 > 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 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

12 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. 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. Photos: Richard Kienberger 22 23

13 Intermediate stop: Michael Sipho takes a break from his journey for a brief visit to his sisters in the town of Pongola kilometres 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. Namibia South Africa Rustenburg 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. Winding through the east of South Africa, this is National Highway 2, at a spot somewhere between Empangeni and Pongola. After a few hundred metres of densely planted woodland, a few huts come into view at a crossroads. A telegraph wire attached to an askew wooden mast spans the wide and well-constructed road, a family sits together under the shade of a tree. Michael Sipho brings his MAN to a halt in the lay-by, and turns on the hazard lights. Two girls in brightly coloured dresses stand in the grass alongside the road they were expecting him. These are my sisters, says Michael. The young driver has been working as a trucker for three years and supports his parents and siblings, who live here in a small village in the east of the country. It s a good job, says the 29-year-old, who switched to a different employer just a few months ago. He now works for the Chrome Carriers transport company and steers a new MAN truck that he praises enthusiastically: As far as I m concerned, MAN is number one! For decades, South Africa has been recognised as the economic development engine of an entire continent. In the booming mining industry, Chrome Carriers a subsidiary of the Reinhardt Transport Group (RTG) evolved into the largest private logistics part- ner of mining enterprises. The company s depot sits in the port of Richards Bay, in the province of KwaZulu-Natal. Its 284 drivers transport chromium ore from the mines in the north of the country to Richards Bay, to be shipped to destinations all over the world. On the way back, the specialised side dumper trucks fill up with coal or other bulk goods needed to process the metal. For Michael Sipho and his colleagues, every new trip always starts at the Richards Bay depot, where both tanks of the tractor-trailer unit are filled up, and the residue of chrome ore is flushed out of the dumper bodies. Whenever necessary, a mechanic carries out minor servicing and repairs on the trucks. new drivers such as Michael Sipho receive thorough training by Chrome Carriers before they go on tour independently. One training course is conducted in the mines, where rigorous safety requirements are in force. Even more important, however, is training the drivers how to handle their vehicles safely and economically. RTG has a modern fleet of almost 500 units. Following thorough practical tests, the Chrome Carriers division partially renewed its fleet in 2012 and added 140 MAN TGS trucks. Our decision to place that order with MAN was based on the fact that the vehicles suffered absolutely no technical defects after more than 200,000 kilometres of continuous operation. Other factors determining our choice of supplier were the low fuel consumption rates of the trucks, the excellent cost-benefit ratio, driving comfort, as well as MAN s maintenance service and warranty policies, explains Derick Reinhardt, CEO of RTG. The vehicles operate in South Africa under challenging conditions, often using tandem semitrailers, for example. These so-called interlinks of the seven-axle vehicles are designed for a high payload of 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 Photos: Richard Kienberger MAN, which covers servicing and maintenance, as well as extended guarantee provisions. After three years and up to 700,000 kilometres of mileage, the trucks are traded in for new vehicles. The first leg of Michael Sipho s tour takes him from Richards Bay into the outlying areas of the mining town Piet Retief. The road winds past national parks and water reservoirs, crosses pastureland, towns and villages, marks the border with Swaziland and occasionally turns into a mountain pass. The journey is a difficult one for the fully loaded trucks, not least due to the sharp inclines. Richards Bay is at sea level, while Piet Retief lies at an altitude of 1,250 metres in the highlands of Mpumalanga Province. (Mpumalanga is Bantu for the place where the sun rises.) The short stop at his family s village is the only break during Michael s journey before reaching his destination. After five hours of driving he arrives in Piet Retief a town where the roads and houses look very different from the tidy boulevards of Richards Bay. Coal dust covers the rough and muddy ground, and an approaching storm front only serves to darken the car park next to the mines even more. The access roads to the mine are the only offroad stretches on these trips, yet they are not always as short as here in Piet Retief. Michael first trundles over the weigh station before positioning his sevenaxle vehicle alongside one of the big coal heaps. A wheeled loader shovels the coal into the dumper holders, which fill up in just a few minutes. As it leaves, the truck is weighed once more. Have a good trip! says an employee of the mining company, and hands Michael the documents. It will be nearly another 500 kilometres before he reaches his next destination a chrome mine near Rustenburg, west of Pretoria. Here he will swap his coal for chrome, sleep for a few hours and then head east again back to Richards Bay, where his cargo will be carried over the oceans to places all over the world. Find more information about MAN South Africa at > 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 24 25

14 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 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. O. nce the signal turns green, we are on our way. Yet just 100 metres further on, the next traffic light already awaits. And this time, it is a red one. Klaus-Dieter Habedank is quite relaxed as he sits behind the wheel. His truck approaches the signal at a speed of 40 kilometres per hour. The signal then changes to green. Since Habedank s truck receives information from traffic lights, the vehicle can calculate the speed likely to catch the green wave. What a great driving experience, says Habedank, a professional truck driver since Moving so easily through an urban setting is certainly not a commonplace experience for him especially considering that he is not even depressing the accelerator. Then the tour comes to an end. A white screen appears where Habedank had just faced the road and its traffic a moment ago. His driver s seat actually sits on the premises of MAN s research department in Munich. The green Photos: Sorin Morar wave and communications between truck and traffic lights are visions for the future brought to life by a deceptively real simulation. Researching urban transport of tomorrow, making it safe, efficient and especially a continuously moving flow has become an important undertaking and research project called UR:BAN for MAN and its coopera - tion 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 26 27

15 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. Karlheinz Dörner, head of the Engineering Research Electronics division at MAN Researcher in motion: Karlheinz Dörner likes cycling from his office to the test track. and designed to run for four years, the research project has received significant support from Germany s Federal Ministry for Economic Affairs and Energy. This year is the halfway mark, and the first result rendered by MAN developers are quite impressive. The team of developers from the Engineering Research Electronics department at MAN s facilities in Munich is led by Karlheinz Dörner. An electronics engineer and control technology expert, he joined MAN back in He first worked in advance development and then became a department head responsible for driver-assistance systems and electronics thus bringing a wealth of experience to the UR:BAN project. We are simultaneously working on the sub-areas Networked Traffic System, Cognitive Assistance and Human Factors in Traffic. The principal focus of our research is always on the driver. That includes the delay and green wave assistant, for instance, which professional truck driver and study participant Klaus-Dieter Habedank has just been testing in a prototype version. The developers put one of the most important topics for commercial vehicles on their agenda: Looking at results: Walter Schwertberger (right) and Michael Reule (left) examine the images of the Bird View camera in the test bus. reducing fuel consumption. This includes the avoidance of unnecessary stops and starts, by integrating the prognosis for switching times and stopping points at traffic lights. Andreas Zimmermann, responsible for one of the UR:BAN sub-projects, describes it as a complex process: We induce traffic lights to communicate with the vehicle via mobile phone or WLAN. Based on that data exchange, our control equipment calculates the driving strategy best suited to take optimised advantage of the green wave, summarises the electronics engineer. At some point, this strategy should result in real savings, considering that frequent stop-and-start driving in urban traffic often defeats the high efficiency rate of modern commercial vehicles. A study on the efficiency of commercial vehicles issued by the German Association of the Automotive Industry (VDA) confirms that just two stops per kilometre will triple the fuel consumption of a fully loaded 40-metric-ton vehicle. Both the simulator and a field-trials track in Düsseldorf provide significant insights for the project. Receiving feedback from drivers is just as important for the researchers as it is for the drivers themselves. I greatly enjoy Photos: Sorin Morar working with the researchers and developers from MAN and the university, says Klaus- Dieter Habedank. I find that despite all the cabling, driving in the simulator seems almost real. Therefore, I can judge rather effectively which new systems are designed to make life easier for the driver, or where they might be optimised. Situation-sensitive driver support is also at the centre of the UR:BAN Cognitive Assistance sub-project. Through integrated camera systems, the driver should be enabled to view the entire immediate vicinity of the vehicle on a monitor when necessary. Here, the researchers are using municipal buses as an example for investigating different types of display. In their working environment, bus drivers find themselves facing special challenges, explains project director Walter Schwertberger. These primarily include bus stops, pedestrian and cyclist crossings, narrowing of roads, oncoming traffic and lane changes. Seeking to provide a more comprehensive view, the researchers are looking into rendering the immediate surroundings from a virtual bird s eye perspective. To this end, they work with a so-called Bird View system, Bird s-eye perspective: The monitor offers drivers a comprehensive view of the vehicle s immediate vicinity, from above and in 3D. which was installed in a city bus. Six cameras attached along the length of the vehicle deliver images for 360-degree detection, which are computer-processed to yield an overall image of the vehicle and its immediate surroundings. Much fundamental work is needed before such an idea can evolve into an application ready for serial production. Where are the best camera positions, which perspective is needed to get a realistic image of an obstacle? How can dynamic angle changes that occur in articulated buses, for instance, be reflected accurately? In this phase of the project, we are primarily dealing with many questions, states Karlheinz Dörner. While looking for answers, his team is supported by MAN experts and its project partners at the University of Applied Sciences. Provided that the project appears promising, research results can first enter advanced and later serial development. The researchers are well aware that technology is only as effective as its utilisation in real life. Despite all the possibilities of intelligent automation as it pertains to driving operations, human behaviour still plays a key role. As a doctoral candidate at Munich s 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 view, driver feedback is essential: Nobody knows better than these professionals what information they need while on the road, 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 > 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 > Find a video interview with Eberhard Hipp on the app

16 Spa treatment for machinery: Old engines (left) are salvaged by MAN in Nuremberg and conditioned into fully functional replacement engines (right). Turn old into new Photos: Vuk Latinovic 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

17 1 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. 3 Glancing over the piece numbered , we can t help but notice its rather lamentable condition: dirty, scratched and with traces of rust. Until just recently, the part had faithfully performed its duty in an MAN truck, until its host after having delivered more than a million kilometres over a decade had been overcome by crankshaft demise. So on to the scrap heap? Perhaps in times gone by. Today, all parts with remaining functionality are refurbished and prepared for a new lease on life. Technical developments and further advancements are taken into account during the process of adaptation, which is referred to as remanufacturing. So part number 6089 a used cooling-water pump is scheduled to undergo this process. Following the rejuvenation cure, the new ecoline number 9089 will find itself fully functional and installed in a replacement engine. While waiting for remanufacturing to begin, the cooling water pump is housed in a workshop facility that is situated on the huge grounds of the Engine Competence Centre of MAN Truck & Bus in Nuremberg. With an area covering 350,000 square metres, the site could accommodate 50 football fields. E1 is written in large letters over the gates. Inside the hall, parts such as our water pump are subjected to a thorough cleansing. They are first taken apart, then cleaned in a wash system, sand-blasted and repainted with some parts being subject to rejection. After cleaning, you can tell what is still re-usable, explains Georg Kugler, 61, Head of Hot Testing and Replacement Parts at MAN in Nuremberg. We closely inspect the parts for wear and tear as well as material fatigue. For Kugler, maximum quality is the sole benchmark. In 2013, his team turned out 780 engines, with 11,325 other spare parts sent over to MAN s stock depot in Dachau, near Munich. Replacement parts are subject to the same guarantees as new parts, so quality standards are extremely stringent. After processing, the replacement parts are stored away or shipped to where they are needed. All the refurbished parts required for replacement engines remain in Nuremberg, where they are directly installed in the engines. One example is the assembly line for the types D20/D26: Working in two shifts, 260 employees can assemble up to 22 engines an hour. Softly humming conveyor belts carry the new and replacement engines to the workstation, lined up like a string of pearls. The atmosphere is as clean as the light-grey floor, with the sense of concentration at different manufacturing stations almost tangible. With practice and skill, the technicians assemble everything the way it ought to be. How to tell the difference between new units and a replacement engine? Only through the part number, says Peter Tscharntke, Section Head Segment 2, as this assembly line is called. When a replacement engine has reached the end of the line, it must still surmount one last hurdle: functional testing. During hot tests, the engine will run for half an hour on the test bed under different stress levels. working at man in munich, Stefan Ott is Project Director and responsible for the new MAN Genuine Parts ecoline product series. As far as he is concerned, the future began three years ago when the spare parts business was elevated to Top Ten status in the MAN Group s corporate objectives. Re-using and refurbishing previously used parts saves resources and cuts down on energy usage, he says. And Parts are closely inspected for wear and tear as well as material fatigue. Georg Kugler, Head of Hot Testing and Replacement Parts, MAN Nuremberg Photos: Vuk Latinovic 2 4 because fewer new parts need to be produced, emissions are also reduced. Customers such as Deutsche Bahn and municipal transport companies specifically demand this kind of thing. This is the ecological aspect in the ecoline series. Thus, ecoline also facilitates MAN s Corporate Responsibility strategy and greatly contributes to protecting the environment while supporting sustainable mobility. The focus is on vehicles that are four years old or older, which generally account for 70% to 80% of a vehicle fleet. This is where MAN s ecoline approach first takes hold, as there are many good arguments for customers in favour of this seasoned material : A replacement part from MAN has the same quality as a new one, it is manufactured to the same specifications as the original component, and MAN offers the identical warranties. And all this comes at a rate of up to 50% less than the cost of a new part. Shorter downtime, with replacement rather than repairs, is another advantage of the ecoline approach. Primarily, however, installing original MAN parts 780 engines In 2013, 616 truck engines and 164 bus engines were refurbished at MAN s plant in Nuremberg 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