2/2014. International. Bus engine development at MAN. Powerful performance
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1 International Bus engine development at MAN Powerful performance
2 man magazine Explore much more of on your tablet. digitally Content International 04 A man to the rescue Hendrik Schöler drives a line bus that becomes a rescue vehicle in emergencies. masthead MAN magazine is published three times a year in 16 languages. 06 Jungle trials Volksbuses built by MAN Latin America shuttle Brazilian children to school. for Android Simply download the app for free: for ios 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 MAN 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 18 cover story For more than a century, expertise and innovational strength have been at the core of MAN s engine development. For city buses, there are different drive solutions for every need 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 news in MAN s world 16 Navigating the world of MAN At the IAA commercial vehicles show, MAN makes an emotional brand appearance. 18 Powerful performance Be it diesel, natural gas or hybrid: MAN offers the right bus engines for every demand. 22 Professionals drive MAN Football teams around the world enjoy the travel comfort of coaches made by MAN. 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. 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. Photos: APPLE INC. Pr Town & country bus Sightseeing coach companies around the world rely on MAN chassis. 40 Offshore Commuting to windparks per boat: in transit with a service team 46 Heavy metal MAN trucks master tough challenges in South Africa. 48 The mileage masters Even with more than a million kilometres on the odometer, MAN buses operate flawlessly
3 my man A man to the rescue For the past 19 years, Hendrik Schöler, 41, has worked as a bus driver at Verkehrsbetriebe Westfalen Süd (VWS), southern Westphalia s public transport services, in Siegen. He is one of eight drivers authorized to drive the Siegen rescue bus a regular bus transformed into an evacuation vehicle in case of an emergency. How is the emergency bus utilised? As a regular line bus, it mostly services urban transport. Whenever there is an alarm, all passengers must disembark and are picked up by a substitute bus. We then proceed on to the emergency site with sirens wailing and blue light flashing. The fire brigade needs the bus for when many people require evacuation or are injured. Including standing room, we can move up to 150 passengers. Have you already been deployed? Yes, indeed, that was very exciting! There was an accident involving the regional express train on the rail line from Siegen to Cologne. When the request came from the control centre, I immediately drove to the site. Luckily, only three persons were slightly injured. So I took 30 evacuated passengers to Siegen. Does the bus have any special features? Inside, the MAN Lion s City articulated bus has special mountings for stretchers and carries emergency medical equipment in addition to the blue light, the siren and a red-andwhite paint job like that of a fire engine. What is the passengers impression? In urban traffic, our emergency bus is a real attraction. I repeatedly notice people snapping pictures. Kids are also totally thrilled to catch an emergency bus to school sometimes. Versatile adaptation: In emergencies, the regular line bus turns into a rescue vehicle. Photo: Tillmann Franzen 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 Powerful performance Photos: Hokolo 3D, MAN (3) 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 powerful and highly efficient machines. As for buses and coaches, MAN offers the right drive system for every demand ranging from diesel to hybrid technology and also natural gas. Focus on gas: Buses with natural gas drives benefit the environment. In addition, the required infrastructure is also growing. The images show the MAN Lion s City C LE CNG (left) and its drive, the E2876 recumbent underfloor rear-mounted engine (above). T hat 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 displays its century-old engine competence to an expert audience at the IAA in Hanover, the world s largest and most important trade show for commercial vehicles. Before appearing at trade fairs and eventually entering the market, the successors of Rudolf Diesel bundle drive technologies and progress at MAN s Engine Competence Centres in Nuremberg, Germany, and Steyr, Austria. They develop diesel and gas engines with a performance range of 150 to 1,800 hp, which are intended for either MAN s commercial vehicles or are fitted in road and rail vehicles, yachts and work boats, power generators or combined heat and power plants, as well as construction equipment and agricultural machinery. The foundation is a basic engine for many applications for each designated utilisation. It is the starting point for developing the MAN engine series with four- and 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 successfully launched on the - 95 % Co2 emissions Vehicles with a biogas drive can lower CO 2 emissions by up to 95 percent as compared with buses powered by diesel. market with as many identical components as possible, says Walter Gotre, who works at MAN s Nuremberg Engine Competence Centre as Head of Engine Performance & Emissions. For the 59-year-old engineer, research and development are not an end unto themselves. The central focus of development is the benefit to our customers, which signifies the highest expectations in terms of economy and reliability, says Gotre. The common rail injection used by all diesel engines built by MAN Truck & Bus is one of the shared factors. It involves injecting the fuel at a pressure of up to 2,500 bar into the individual cylinders at precisely defined times to achieve atomisation. In all the new Euro 6 engine series, SCR (Selective Catalytic Reduction) technology is used for exhaust treatment, in combination with exhaust gas recycling that is steplessly regulated. This combination results in highly efficient engines with low fuel consumption. The latest hybrid technology also helps to economise. City traffic entails quite a lot of stopping and starting manoeuvres and offers ideal conditions for utilising braking power, explains Thomas Achenbach, Head of Hybrid Engines in Nuremberg. In MAN s lowfloor Lion s City bus, an optimised D08 diesel engine therefore drives a high-performance generator, which supplies the needed power to the two electrical engines. In addition, the electrical engines are connected to the high
11 Fuel saver: As the MAN Lion s City Hybrid (above) saves up to 30% diesel and CO 2, it contributes to environmental conservation in many urban areas today. In the bus, the standing D0836 diesel unit (centre) drives the generator for the two electrical engines (below). established as well. This also includes the natural gas drive, which will be used alongside hybrid or, respectively, electrical drives, explains Herbert Knorr of MAN s Alternative Fuels research department. MAN has been accumulating experience with gas drives for 40 years, and is the world s market leader for CNG, or compressed natural gas, technology. Herbert Knorr s development team in Nuremberg has put a 310-hp natural gas turbo engine in a Euro 6 version for municipal buses on the road, which in some cases falls significantly below the stringent Euro 6 regulations for exhaust emissions. Knorr sees further potential for the future in another reduction of fuel consumption by natural gas engines by recycling the cooled exhaust, for example, which could make the mixture of natural gas, air and waste gas considerably more knock-proof and therefore more economical. Another option that we might try to implement would be to blow the natural gas directly into the combustion chamber at high pressure. The ignition of the natural gas is not triggered by a spark plug, but results from the slight quantity of diesel fuel which is injected along with it. Due to the high compression ratio, this method could achieve fuel consumption similar to that of a diesel engine, predicts Knorr. Due to the variety of its drives, MAN offers the right solution for every requirement. Alternative and innovative drive systems, such as diesel-electric hybrid drives and natural gas engines, will have a sustainable impact on the future of local transport. The wide range of MAN s engine portfolio has the right product to suit every customer. 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. More information about MAN buses and coaches at the IAA may be found at > % Diesel and CO 2 By utilising braking power, hybrid buses like the Lion s City Hybrid can cut fuel consumption by as much as 30 percent. performance capacitors of the electrical storage system s 12 ultracap modules. When operating in the inner cities, our engines must be designed to handle at least two million starting-and-stopping cycles, explains Achenbach. For us in development, this means high demands on the mechanical systems, the bearings and the oil supply. Everything must be tailored to these specific requirements, while still remaining affordable in the end. As a result, fuel and CO 2 savings in the hybrid engine drive amount to as much as 30%compared with conventional buses. yet combustion engines using other fuels also have future potential. MAN s researchers in Nuremberg continue to work on running diesel engines on BTL (Biomass To Liquid) fuels. Sourced from a basis of biological substances, these synthetic fuels burn very cleanly, and experts actually consider them The central focus of development is the benefit to our customers. Walter Gotre, Head of Engine Performance & Emissions at MAN to be the fuel of the future. Today, municipal bus companies that can rely on an existing infrastructure for a steady supply of natural gas are already frequently turning to natural gas engines as an environmentally friendly, economical and sustainable alternative. The diesel engine will not remain the only drive of commercial vehicles in future. Depending on each application and basic parameters, other drives will become Photos: Hokolo 3D, MAN (3) Maximum efficiency: With a length of 18 metres, the MAN Lion s City G bus offers a very high passenger capacity. The articulated bus is powered by a recumbent D2066 diesel engine (above)
12 Professionals drive MAN Most of Germany s Bundesliga clubs and several Champions League teams travel on team coaches made by MAN. Why do the football stars appreciate their rides? Here is an array of good reasons. Teamwork: While football star Sebastian Kehl manoeuvres the new BVB coach into a parking slot, Christian Schulz offers some useful tips. Photos: Norbert Schmid/MAN, frenzl pr W earing the demeanour of serene nonchalance, Sebastian Kehl squeezes in behind the steering wheel. The 34-year-old team captain of Borussia Dortmund sounds confident: My experience should make the difference. In contrast, 21-year-old Jonas Hofmann, the team s young midfield star, appears a little nervous as he climbs into the team coach. In a team-only duel on asphalt, the two Borussia Dortmund players competed against each other in the new and old team coaches. As Sebastian Kehl won the toss, he got to enjoy the new coach. After they had competed in the disciplines of slalom and reverse parking, the score stood at a 2-2 draw thus calling for extra time and the challenge to imitate a rallying cry on the horn. Jonas Hofmann summoned all his rhythmic talent and actually coaxed a recognizable Let s Go! from the coach. And Sebastian Kehl? He grinned at least as widely as if just having scored a winning goal, tapped lightly on a lever attached to the steering wheel and the resulting fanfare resounded with the Heja BVB evergreen melody. Hopefully Sebastian won t be competing for my job, joked Christian Schulz after the Luxury on wheels: Features of the new BVB coach include a real wooden floor and top-quality leather seats. fun contest, held on the occasion of officially handing over a new MAN coach to Borussia Dortmund. The 43-year-old driver has chauffeured the football stars to their matches for the last three years and shuttling a rather valuable cargo for that matter: The market value of Dortmund s professional team has been estimated at around 300 million. Yet it is not the only reason why Schulz is so distinctly aware of his responsibilities. It s my job to get the team to their destination safely and in the We are the premier supplier worldwide for top-class sports. Patrick Eble, Team Leader for Sponsoring and Events at MAN 22 23
13 Transport for stars: The players of Paris Saint-Germain arrive in their MAN team coach to make a red-carpet appearance kilometres Germany s Champions League teams such as Borussia Dortmund and Bayern München cover thousands of kilometres every year in their team coaches all across Germany and Europe. Luxury decor: In its interior, the team coach of Paris Saint-Germain also gleams in club colours. Watch a video of Sebastian Kehl and Jonas Hofmann in the BVB team coach on the app. most comfortable way possible, he says. The Dortmund native loves his new workstation: The predecessor was already fabulous, but what MAN has delivered this time around is fantastic. The 480-hp MAN Lion s Coach L represents the top class of the road a team cabin on wheels, with every comfort imaginable. Plush and flexibly adjustable leather seats provide utter relaxation on any journey. The three LCD monitors show movies or reports from the day s games. On the drive home, 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 capable of video presentations and a WLAN router. Fixtures such as a fully automated coffee machine or refrigerator are a 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. Naturally a fervent BVB fan, the driver finds it somewhat disconcerting that some of his passengers have turned to the hearty Bavarian game of Schafkopf. Even Marcel Schmelzer plays it, and he s from East Germany! Has it escaped the notice of trainer Jürgen Klopp and sport director Michael Zorc, who occupy seats 2 and 3 in the front row, that serious cultural infiltration is in full swing behind their backs? MAN provides the means of transport to the Bundesliga stars. What began in 2008 with a sponsorship of FC Bayern München underwent continuous expansion. Hamburger SV, Borussia Mönchengladbach, VfL Wolfsburg and Borussia Dortmund were the next clubs to rely on MAN with another seven Bundesliga teams also relying on MAN coaches. It s a similar picture on the international stage: Paris Saint-Germain is an official partner, as are AC Milan and FC Barcelona, joined by 15 top-league teams in Brazil, plus Brazil s national team, which all appreciate the amenities offered by MAN vehicles. As Patrick Eble, Sponsoring and Events Team Leader at MAN, comments with some pride: We are the premier supplier worldwide for top-class sports. Our partnerships make an important contribution to the positive perception of MAN as a strong brand. The MAN Lion s Coaches serving the Champions League teams travel roughly 60,000 kilometres per year in Germany and Europe. And they are publicity on wheels for both the team and for MAN. For instance, while Borussia driver Christian Schulz was driving to a group match against FC Shakhtar Donetsk, in the heart of the Ukraine, a local radio station stopped him and asked for an interview. And what does he recall as his finest hour? Definitely the trip back to the hotel from Berlin s Olympic Stadium, after our 5-2 victory in the 2012 Cup Final against Bayern München. The jubilant fans, the singing players I had tears in my eyes. Times have changed, however. Anyone heading to Munich after the Bayern victory over Dortmund in the 2013 Champions League Final at the Allianz Arena was met by a gigantic banner on the outskirts of town, reading, Welcome to the city of the Very Best! Driving home from a match in Munich, Christian Schulz steers his team coach onto the motorway in the opposite direction. As long as he s driving an MAN coach, however, he s certainly on the right course. A making of report on the BVB duel is available at > Photos: pr, Jean-François Robert/PRESSE SPORTS 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
18 Conditioning used parts saves resources and cuts energy usage. Stefan Ott, Project Manager, MAN Genuine Parts ecoline Find additional photos of engine reconditioning in Nuremberg on the app. adds value to the vehicle. Thus, ecoline also denotes the concept of economical. There are several good reasons why customers make a conscious decision to choose MAN Genuine Parts ecoline. at MAN, every replacement part includes a deposit system: When a customer purchases an ecoline cooling water pump from the MAN workshop, for example, a markup of 10% to 15% is added to the purchasing price. Upon returning the used original part, the deposit is returned. The used component is sent to Salzgitter in Lower Saxony, the central returns plant for anything recyclable, and is then passed on to the expert technicians for further processing. Anything to do with engines ends up in Nuremberg. MAN Genuine Parts ecoline is a major project, which demands a vast amount of logistical backup. There are plans to expand the scope of its portfolio in coming years, with a growing number of participating countries. In 2013, the overall turnover of ecoline parts amounted to 140 million. ecoline is one of our most important topics, confirms Frantz Perre, Head of After Sales at MAN Truck & Bus France. Ever since the process was introduced in Germany, the programme became available in 17 European countries. The plan is a continuous expansion to cover the remaining top 50 global markets. MAN Genuine Parts ecoline is just a small part of the overall portfolio of MAN s original component business. All original parts are made to MAN s stringent quality guidelines that is, according to state-of-theart technology standards. In addition, they come with a worldwide 12-month-guarantee policy. In order to reduce downtime as far as possible when a breakdown occurs, MAN s service centres usually have on average 8,000 original parts in stock even for older models and special vehicles. In all, 95% of all original parts are delivered to repair shops overnight. MAN retains a total of 200,000 original components for its customers, stored in several central warehouses around the world. Currently, MAN can offer about 1,800 numbers as replacement parts, while another 1,200 should be added by Naturally, ecoline number will also remain in the portfolio range. See the entire upcycling process in pictures at > You re responsible for your passengers. We help keep them safe. If you re in the business of transporting the most valuable cargo of all, then your top priorities are safety and comfort. Just as they are for the people portfolio from Continental, our latest Generation 3 tires, which have been specifically designed for coaches. Our innovative tire technologies mean better performance for you, your passengers and your business. Conti Coach HA3 Conti CityPlus HA3 Equal treatment: During final assembly, engines of all ages are tested with strict quality guidelines. Ready for dispatch: Both the new and reconditioned engines sit at MAN s Nuremberg plant, waiting for their assignment. Photos: Vuk Latinovic Sep. 25 to Oct. 2, 2014 Hall 17, Booth A06/B11 For more information visit 34
19 Town & country bus In city centres we are reliant upon minimal emissions and quiet engines. Wolfgang Willms, owner of Willms Reisen International sound: The audio system describes the city s tourist attractions in 12 different languages. Double-decker tourist buses are a common sight not just in large cities like London or Paris. A growing number of smaller towns are investing in the colourful eye-catchers, looking for reliable carriers and environmentally friendly engines. Sunday outing: Renate and Theo van Groen are enjoying the sights in Düsseldorf. O. riginally, 65-year-old Renate van Groen had wanted to sit on the lower deck to avoid having her hair mussed up by the wind. The fine views from above and the warm spring sun appearing just in time for setting off for a Düsseldorf sightseeing tour eventually did change her mind. Renate and her husband, Theo, received the tour as a gift from their son and think it marvellous that a city such as Düsseldorf, with a population of just 600,000, boasts its own sightseeing bus company. The city offers so many smaller attractions that we never knew about before, says Theo van Groen, who actually resides in Düsseldorf with his wife. Whereas, in the past, sightseeing doubledeckers prowled only the meccas of tourism such as London, Rome, Paris or Berlin in recent years a growing number of smaller cities have set up their own lines. The jazzy vehicles are eye-catchers and therefore quite popular with city marketing experts. Its brightly painted bodywork is merely one successful attribute of the double-decker. Just as important is the invisible chassis that carries the superstructure and is responsible for safety, comfort and fuel consumption. That is why sightseeing operators all over the world trust in MAN quality. The MAN A22 chassis forms the core of the Düsseldorf City Tour bus. In selecting the chassis, we value driving comfort, low and easy accessibility, easy maintenance and reliability, explains Wolfgang Willms of Willms Reisen, a tour operator. Because of inner-city environmental zones, we are also reliant upon minimal emissions, low fuel consumption and quiet engines. The Euro 6 chassis from MAN, which forms the basis for Willms buses, meets these requirements: We own 23 MAN double-deckers, and are very satisfied. Customer service in particular is excellent, says Willms. In order to offer passengers a maximum level of comfort during the tour, the buses can be equipped with numerous refinements ranging from an on-board 23 double-deckers The Willms Reisen company operates a fleet of 23 double-deckers overall, five of which run on the Düsseldorf city tours. Photos: Frank van Groen Clean mobility: The Willms Reisen sightseeing bus is based on a Euro 6 chassis from MAN
20 Enjoyable prospects: The bus not only makes sightseeing comfortable, it also offers passengers fabulous views from the upper deck. kitchen to detachable roof structures, spacious toilets, powerful air conditioning and even audio systems broadcasting in 12 different languages. Mounting the bodywork onto the basic chassis is a task for the body manufacturers, who receive support from MAN engineers elements, user-friendly displays and an ergonomic design of steering wheel and seat, make touring more pleasant for the driver. On request, MAN can equip workstations with a multifunctional steering wheel which enables a driver to control a wide range of functions at the touch of a button, without taking his or her hands off the wheel. In selecting the chassis, we value both comfort and reliability. Wolfgang Willms, owner of Willms Reisen during the construction phase. Every body While the driver manoeuvres his double- manufacturer receives a 350-page document decker through Düsseldorf, passengers seat- setting the guidelines for correct assembly. A ed on the sunny upper deck admire the Rhine regular exchange of design drawings ensures River banks, the Kö Bridge, Burgplatz and the that the lofty superstructure will not impair ultra-modern architecture of the Media Port. vehicle stability. Much attention is also paid to ensure that chassis and bodywork dovetail perfectly. Hence, the bodybuilders working Wolfgang Willms has reason to celebrate the tour s popularity: Today, the upper deck is completely full. And for good reason: A dou- Taking pride in just a with MAN can accommodate almost any cus- ble-decker simply offers the best kind of tomer preferences in terms of configuration. Many operators wish to offer their passen- sightseeing tour, as you get such a fabulous view from upstairs, says Willms. Further- Double? Who else but MAN. gers something extraordinary. We do our more, you would never get to experience so best to find the ideal solution for any ideas many sights in such a short time. suggested by our customers, while simultaneously adhering to mandatory safety standards, says Alexandre Lecompte, Head of Sales at the Spanish body maker UNVI. As drivers often find it a challenge to thread their way through narrow city streets with an oversized vehicle, it is even more important to make their workplace as comfortable as possible. The MAN A22 chassis is just one example: coherently arranged operating The MAN chassis forms the basis for the safety, comfort and efficiency of the sightseeing buses. Photos: Frank van Groen, MAN Even without a repeat of last year s Triple, we are proud to have carried FC Bayern Munich and Borussia Dortmund to all this season s games, and delighted to be doing the same next season. We are already working on ways to make their journey through the excitement and drama that lies ahead even more comfortable. By providing them with the world-class MAN Lion s Coach Supreme, we ensure that in between matches all the players need to do is lean back and dream of a rematch at Wembley. Visit our website to see what the inside of a top-tier team bus looks like: Engineering the Future since
21 Offs man magazine hore 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. Floating maintenance service: The Eden Rose heads for the Sheringham Shoal wind park off the coast of England. Photo: Jiri Rezak 40 41
22 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. Powerful and effective: The 1,019-hp engines from MAN must be exceptionally reliable to cope with their daily deployment wind turbines The first British offshore wind park went online in 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. P ainted blue and white, the catamaran Tia Elizabeth leaves Wells-next-the-Sea, a small tidal port on the coast of Norfolk, a three-hour drive north of London. The skipper takes advantage of the morning tide, as putting out is not possible at ebb tide. Arranged in a zigzag pattern, buoys indicate the course to the open North Sea. Discernible are a few walkers on the beach and the colourful wooden cabins so typical of the Norfolk coast. The Tia Elizabeth, however, is not carrying holidaymakers but rather half a dozen service technicians on their way to the Sheringham Shoal offshore wind park. The Tia Elizabeth is one of three supply ships operated by the offshore access company Tidal Transit. With room for 12 passengers plus crew, a length of 20.3 metres and a width of eight metres, the boat was built at the Mercurio Plastics shipyard in Spain and is a typical specimen of its industry. The drive comes from two MAN V12 engines, each with an output of 1,019 hp. MAN manufactures high-speed four-stroke diesel engines in Nuremberg, which are geared towards commercial shipping. Every year, the production site builds 1,300 engines for ferries, emergency service ships, tug boats and other vessel classes. The expansion of offshore wind energy has resulted in a dedicated market for wind park supply ships. Every day, Sheringham Shoal sends as many as 36 service technicians out to sea. The systems require regular maintenance, as any idle time of wind turbines costs the operator a fortune. The turbine gears are checked, the rotors examined for cracks, the cables and lifts serviced. In contrast with wind parks on land, however, service staff can t reach assigned job sites in their own service van or car, but instead need to rely on the supply vessels. And these must be exceptionally reliable, especially since the boats cannot set out to sea in just any weather conditions. This also has implications for what customers expect from the engines, explains Eugen Maier, the Area Sales Manager at MAN Engines Marine who is responsible for the English market. Apart from focusing on fuel consumption, operators are mainly mindful of reliability and service. In today s hazy weather, the first wind turbines appear on the horizon after a onehour journey. The gigantic towers rise 80 metres above the water, with every rotor blade extending 52 metres in length. Way up above, red cage platforms for service technicians are mounted to the engine houses. There are 88 turbines arranged in a diamond formation, each at a distance of around 500 metres from the next. The Sheringham Shoal wind park is located about 17 kilometres from the English coast and belongs to Scira Offshore Energy, a joint venture of Statoil and Statkraft. Together, the wind turbines can produce a total output of 317 megawatts sufficient to supply over 200,000 British households with green energy. In the cabin below deck, Robert Pennock, Ross Gordon and Kevin English sit on cushioned individual seats at one of the tables, drinking tea aboard the Tia Elizabeth. These ships are comfortable after all, the technicians should be rested when they reach their destination. The men work for Siemens, the turbine manufacturer, and are doing a routine check of one of the gears. A second team on board is responsible for maintaining the cable winches and lifts inside the turbine masts. A green light comes on in the cabin, the signal for transfer. The team moves forward to the bow of the ship, with heavy waterproof bags already waiting for them. These hold tools, spare parts and oil for the gears. Today the sea Photos: Jiri Rezak Climbing excursion: The technicians mount the turbine mast to carry out maintenance at the top
23 pressing the bow of the ship against the platform 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 water behind them, without the boat moving forward an inch. man knows about these requirements. During the docking process, the boat is sub- Stand-by position: Having completed their work on the wind turbines, the service teams will return to the Eden Rose. The MAN engines are exceptionally compact and much more lightweight. Eugen Maier, Area Sales Manager, MAN Engines Marine More images of the trip to Sheringham Shoal are available in the app. Precision work: The very focused skipper Harry Getliffe manoeuvres the Tia Elizabeth through the wind park. is calm and peaceful, so the transfer presents no problems. In heavy winds and high water, setting over is the most precarious part of work. Each wind turbine features access points on two sides. The men rope up their landing gear, step onto a ladder on the turbine mast and climb a few metres to reach a cage platform. Each of these manoeuvres is a delicate operation for skipper Harry Getliffe. Anchoring is out of the question, as it would damage the cables below water. The bow is wide and protected by heavy rubber cladding. While these manoeuvres are referred to as bump and jump in the industry, naturally no one 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 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 machine. Such catamarans have very cramped engine rooms, says Maier, but that actually works to our advantage. The MAN engines are exceptionally compact and much more lightweight than anything else on the market. Throughout the afternoon, radio calls are repeatedly received from service teams who have finished their work on one of the turbines. The Tia Elizabeth picks them up and takes them to the next installation similar to a kind of radio taxi. By evening, all the service teams are back on board, and the ship makes its way back to Wells-next-the-Sea. Back in the harbour, a minibus already waits to take the teams to company headquarters in Egmere. Thus ends the mens 13-hour work day. Tomorrow, they will be off again, catching the late-morning tide at am. Find more information on MAN s marine engines at > Photos: Jiri Rezak Mia wants to drive her bus across the country and on water. Driving on water might be difficult. In cities and on journey we are already doing a good job. The ZF-EcoLife automatic transmission makes no compromises. Whether flat countryside or mountains: The intelligent drive program TopoDyn Life adjusts the shift characteristics to the route profile and reduces fuel consumption and CO 2 emissions. The changes between all six gears are hardly noticeable and the high gear spread means that the engine speed is low even at 80 km/h. The retarder also offers no-compromise performance. It is actuated smoothly and depending on topography. The dual cooling concept with an integrated oil cooler and an attached retarder oil cooler can resist high temperatures. For a long, excellent drive. ZF-EcoLife. The universal genius. 44
24 Filled up and ready to go: A driver signs his fuel receipt, and accepts his vehicle for the next trip. Black gold: Chrome ore from South Africa is a raw material much in demand. Heavy haulage: Michael Sipho s truck is loaded up at the Piet Retief coal mine. Stopover: During his tour, Michael Sipho takes a break to pay a brief visit to his sisters near Pongola. Heavy metal Chrome 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. Winding through the east of South Africa, this is National Highway 2, 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 partner of mining enterprises. The company s depot sits in the port of Richards Bay, in the province of KwaZulu-Natal. Its 284 drivers transport Photos: Richard Kienberger 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 chrome ore from the mines in the north of the country to Richards Bay, where the mineral is then shipped to destinations all over the world. On the way back, the trucks fill up with coal or other bulk material needed to process the ore. 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 very much 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, the excellent cost-benefit ratio, driving comfort, as well as MAN s maintenance service and warranty policies, explains Derick Reinhardt, CEO of RTG. As they are subjected to a high 34-metric-ton payload and the somewhat demanding South African topography, the vehicles operate under challenging conditions which is why the so-called full maintenance contract provides for precise servicing at MAN s network of service centres. 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. The short stop at his family s home remains the only break during Michael s journey before reaching his destination. After five hours of driving he arrives in Piet Retief a town where 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 mines 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 seven-axle 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 his documents. It will be nearly another 500 kilometres before he reaches his next destination a chrome mine located near Rustenburg, west of Pretoria. Once arrived, he will swap his coal for chrome ore, 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
25 The mileage masters Read more on how trucks can also surpass a million miles in the app. While clocking up a million kilometres is actually not uncommon for coaches, few will manage a mileage of three million. MAN quality makes it possible on almost every continent and in nearly any climate zone. Coach captain: Driven by İbrahim Güler for SEÇ, this NEOPLAN already has already racked up over two million kilometres. Photos: Ivor Prickett Fond farewells: A coach departs the bus station in Gaziantep for its 1,350-kilometre journey to Cannakale. NEOPLAN offers a longer service life than other brands. Settar Konukoğlu, Managing Director of SEÇ Driving a bus or coach is such a highly prestigious profession in Turkey that the man behind the wheel is not referred to merely as a driver, but rather goes by the title of captain. This large country situated between Europe and Asia has a patchy rail network and an insufficient aviation infrastructure which means that coaches still are the most important means of transport in Turkey. To ensure the high quality of coach travel, Turkish operators primarily rely on dependable engineering skills from Germany. Based in Gaziantep in southern Turkey, SEÇ is a transport business that supplies coaches to companies all over the country. Its fleet includes more than 50 NEOPLAN models. The name alone stands for the first-class image of MAN, explains Settar Konukoğlu, Managing Director of SEÇ. Passengers love NEOPLAN coaches because they are so comfortable. Another significant competitive advantage, he says, is NEOPLAN s lifetime service. In this case, a lifetime can be a long while, as Konukoğlu knows from experience. Six of his coaches have already passed the two million mark, the mosttravelled coach has done 2.6 million kilometres. And it will certainly manage another million! predicts Konukoğlu. He is also aware, however, of the important human factor, assigning no more than two drivers to a coach. After a while, the drivers will treat it as their own. The municipal transport authorities in Szczecinek, in Poland s West Pomeranian lake district, also realized how much of difference this could make for the life cycle of a bus. They always strive to use the identical driver for the same bus usually an MAN model. The city took the first MAN buses into service in 1997 and went on to replace the old Polish Jelzc and Autosan brands. It was almost a technological revolution. Many of the locals also thought so and often purchased several tickets at once 48 49
26 Efficient. Durable. Comfortable. The New Goodyear Coach Line. Mexico: Antonio Sierra Flores, a driver for Enlaces Terrestres Nacionales, covers 25,000 kilometres every month. Poland: MAN s green and white buses have been a familiar sight in Szczecinek since million kilometres Five NEOPLAN coaches operated by the Turkish company SEÇ have already exceeded the two million mark. The record-holder has logged 2.6 million kilometres without major repairs. Solid vehicle maintenance is essential, and I often do my own. Helmut Schwayer, coach operator in Kronburg just to remain on board for a while longer. In 2011, Szczecinek purchased six new Lion s City buses. Today, the roaring lion on the green and white buses has long become part of the town s landscape, as the cost-benefit ratio is simply unbeatable. The buses are ecological, quiet and, most importantly, efficient. Two of the buses put into service in 1997 have already passed the one-million mark which reflects not only the technological quality, but also the high level of service: MAN never failed to support the municipal mechanics. Despite the complex drive technology of low-entry buses, MAN s customer service staff always finds a solution, even for the trickiest problem. Helmut Schwayer, on the other hand, does most of his own maintenance. The independent coach operator from Kronburg, Germany, knows his vehicle s every nut and bolt. He immediately hears and sees any detail out of place. Not surprising, as he has taken his MAN double-decker hither all over for the last 12 years, from Lisbon to St. Petersburg, from Norway s North Cape to Sicily. So far, he has racked up 1,050,000 kilometres at the wheel with no end in sight. The MAN is Schwayer s only coach. Apart from the red ski rack, it is completely white and huge: 26 metric maximum permissible weight, a length of 12 metres and four metres high. This travel coach has had to deal with all kinds of adverse conditions: the North Cape s salted roads, potholes in Morocco, loose gravel in the Czech Republic. How was he still able to accrue over a million kilometres? Operate your coach carefully and treat it well, sums up Schwayer. The same is true in distant Mexico, where the vehicles of Enlaces Terrestres Nacionales (ETN), a leading Mexican passenger coach company, cover about 25,000 kilometres every month. Thus, they are never idle and cold, practically remaining in an ideal operating state at all times. In addition, climate conditions in Mexico are very coach-friendly, as Mexico lacks the sub-zero temperatures likely to induce wear and tear on the engine when it does a cold start. That is one reason why our vehicles perform so well, says Alexander Wolf, Head of After Sales at MAN Truck & Bus Mexico. For nine years now, ETN s MAN coaches have been travelling the roads of Mexico, with 34,000 trips and 450,000 passengers every month. The greater part of the fleet comprises MAN vehicles with an average of two million on the odometer already. That s a notable record, says Gustavo Ascencio, Managing Director of ETN. He is very mindful of having his top-quality coaches serviced on a regular basis which is not exactly common practice in Mexico, where many companies try to lower their servicing costs by using cheap oil and sub-standard filters. MAN still insists on its standards, however, knows Wolf: Once our customer services encountered a complaint about a vehicle with noises coming from the rear axle. It turned out that the customer had already done 700,000 kilometres without an oil change which is regularly due every 180,000 kilometres. And yet the coach had never broken down. Most certainly not just thanks to the favourable Mexican climate that MAN vehicle would probably have lasted just as long in any other country in the world. Photos: private The new Goodyear Marathon Coach and UltraGrip Coach Made to enhance your fleet efficiency*, Goodyear offers you coach tires featuring TravelMax Technology. Asymmetric design, Silefex tread compound, waffle blades it all stands for reduced rolling resistance, improved fuel efficiency, longer lasting performance and low running noise for more comfort. In addition, it offers you mobility in all weather conditions. Learn more at goodyear.eu/truck 50 * Performances compared to Goodyear s previous recommended fi tment for coaches (Marathon LHS II, UltraGrip WTD). MADE TO FEEL GOOD.
27 Economical Across the Line. The DIWA efficiency package for your citybuses: with the new DIWA.6 automatic transmission plus topography-dependent gear shifting program SensoTop you ensure lower fuel consumption and higher driving comfort. In combination with the telemetric system DIWA SmartNet you are in control of your maintenance costs and increase your availability. Get to your destination more economically and comfortably with the DIWA efficiency package. Give us a call on voith.com
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