Technology 

MAN construction vehicles – over rough country

Maximum transportation performance during multi-shift operations, extremely heavy loads, adaptability to rough terrain and high exposure to dust - construction vehicles have to stand up to the most demanding conditions. For more than 75 years, MAN has been supplying construction trucks, including models with all-wheel drive, and can offer extensive expertise in this field.

Three silver MAN trucks at a stone pit

Conditions are often much harder on building sites than on normal roads, making the demands on construction vehicles extremely high. Customers expect robust trucks with a long service life, equipped with powerful and efficient engines that also deliver cost-effective and outstanding driving performance in all-wheel mode. Other important features include high loading capacity, flexible superstructures, as well as a wide range of special chassis and various drive options. With the TGS series MAN Truck & Bus meets all these wishes and technical requirements for all-wheel-drive vehicles. Another challenge is complying with Euro 6 emission standards. Since January 1, 2014, the limits for nitrogen oxides and particulate matter have been drastically reduced. In order to meet these limits, the engine technology, exhaust aftertreatment and entire vehicle electronics in MAN´s construction vehicles have been completely reconfigured and integrated into the vehicle platforms, along with the tried and tested common rail diesel engines.

Whell loader loading sand on a silver MAN truck
75 years of expertise in all-wheel drive – about half of Europe´s all-wheel-drive trucks are currently made by MAN.

Easy going on difficult terrain

All-wheel drive plays an important role in the construction industry. It gives vehicles the necessary muscle to cover the most difficult terrain (propulsion), as well as ensuring optimal power distribution across all the wheels (traction). MAN can look back on more than 75 years of experience in the design and construction of trucks with all-wheel drive.

There are few commercial vehicle manufacturers other than MAN offering both optional and permanent all-wheel-drive systems. The advantage of the optional version lies in the versatility of the vehicles, which can be driven equally well either on or off the road. Another plus is the possibility of using only the rear-axle drive on hard surfaces. This reduces wear and tear on the tires and makes steering the vehicle easier.

Maximum traction

The four-axle TGS 96S 8x8 model is generally used to drive across rough terrain, for instance in the case of erecting overhead power lines, mineral prospecting, exploratory drilling, measuring seismic activity or transporting timber along steep, muddy tracks. It offers maximum traction and excellent stability - even over longer distances with frequently changing adhesion conditions. “Although this stately truck with a maximum allowable gross weight of 41 tons has a permit to use public roads, this is generally needed only to reach its destination," explains Rolf Schmidt-Robin, Senior Manager for Truck Project Management at MAN Truck & Bus AG, Munich.

All-wheel drive also provides many highly-rated facilities in TGS models equipped with two or three axles. These “smaller brothers” of the 8x8 trucks work under the most diverse conditions on construction sites, for municipal services, including winter road maintenance and road sweeping, but also for emergency services, such as Germany’s Federal Agency for Technical Relief and fire departments.

Meeting Euro 6 standards

In order to cater for the wide range of possible uses for construction vehicles and also comply with Euro 6 emission standards, all finished truck chassis must be able to freely accommodate superstructures made by different manufacturers, many of which are quite complex. For this reason, no vehicle components may protrude beyond the upper edge of the frame. Another obstacle is that, compared with Euro 5, the ultra-efficient exhaust aftertreatment system requires larger housing for the exhaust silencer. MAN has collected information from customers and is familiar with their needs. The additional components needed have therefore been designed in such a way that a minimum amount of payload is lost and the curb weight of the truck remains as low as possible. By focusing consistently on lightweight design and integrating several functions into a single component, MAN’s engineers have succeeded in combining full functionality and driving performance on rough terrain with enhanced environmental compatibility.

Technical components in detail:

1. The Steel Bumper

was also adapted to the vehicle design. An integrated footstep assists the driver when climbing up to change the windshield wipers. The bumper comes in a three-part design in all production series models to minimize repair costs in the case of component replacement.

2. Stucture

The three-dircetional dumper truck is just one variant of a versatile construction vehilce range. In order to not curtail the flexibility of superstructure options, no vehicle components may protrude beyond the upper edge of the frame.

3. A Metal Protection Grille

shields the headlights, giving a long service life. This ensures that this essential fuction remains operational even in the toughest conditons.

4. Steps

Elastic foot boards can cope with the most challenging terrain and impact from rock falls. They give way rather than being bent out of shape permanently

5. AdBlue Tank

Urea (AdBlue) is used in the exhaust aftertreatment to reduce nitric oxides. The combined exhaust aftertreatment system ensures low fuel consumption and minimized utilization of AdBlue.

6. Exhaust Aftertreatment

When compared to the Euro 5 standard, Euro 6 requires a reduction of nitric oxide emisssions from its previous level of 2g/kWh to 0.4g/kWh. The TGS series achieves this goal with a combination of cooled exhaust gas recirculation (CEGR) and an SCR (select catalytic reduction) catalytic converter.

1. Euro 6 Engines

Central components of the engine design are the Common Rail fuel injection, the cooled and regulated exhaust gas recirculation, the two-phase turbocharging and the exhaust aftertreatment. This combination ensures compliance with pollutant limits while reducing diesel consumption and CO² emmisions.

2. The Main Gear Unit

transmits the 440-hp engine output of the TGS 96S 8x8 to the transfer gear box, which was specifically developed and manufactured by MAN.

3. The Permanent All-Wheel Drive

of the TGS 96S 8x8 offers maximum traction and a high degree of handling stability in varying conditions traction. The transfer cases for power distribution were developed by MAN.

4. Differential Gearbox

The differential gearboxes - the gear unit for front axle 1 is shown here - ensure complete rpm balancing between the individual wheels without any loss of power, so balancing out the different wheel paths when the vehicle takes curves.

5. Differential Gearbox

for front axle 2

6. Transfer Gearbox

In permanent all-wheel drive, this is responsible for constantly transferring the engine output to all wheels in just the right ratio.

7. Differential Gearbox

for rear axle 1

8. Differential Gearbox

for rear axle 2

Blue: Drive for transfer gearbox
Green: Drive for front axles
Yellow: Drive for rear axles

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