European Truck Factory GmbH

MT-240 MINING TRUCK Technical description

ETF presents Mining haulage for the 21st century

Hydrokinetic Drive & Retarding System

The truck is equipped with 4 MTU / Mercedes OM 502 V8 engines. Each of the 4 engines is attached to a rear mounted pump drive gearbox supporting four variable displacement hydraulic pumps powering one axle line. Each axle line comprises two independent wheel groups supporting two drive wheels. Each individual wheel group incorporates twin variable displacement drive motors powering a planetary reduction gearbox with independent oil circulation cooling and microfiltration. This uniquely configured, electronically managed transmission system provides the greatest possible versatility in terms of performance and retarding capability, offering a defining combination of high operational performance and low overall energy cost.

All-Wheel-Steering
All wheel steering operating with a clearance turning circle of 29 m / 95, 1 ft. Full-hydraulic steering system controlled by a steer-by-wire function, featuring real time automatic all wheel alignment. ETF trucks are also equipped with a special variable speed steering system, at very low speeds, such as when spotting around the loading or dumping area requires just two turns from lock to lock.

Axle configuration (20x16x20)

The MT-240 has 5 axle lines, 10 wheel groups and twenty wheels, all steered and 16 driven, technically described as a 20x16x20 axle configuration. Each axle-line consists of two independent wheel groups that osculate 10 degrees each way, combined this with the long 950 mm suspension travel provides greatly improved wheel/road contact, high stability and excellent off-road capabilities.

Suspension System
The MT-240 truck features a unique hydro-pneumatic load compensating suspension system offering uncompromising ride characteristics irrespective of payload. The extra long wheel travel protects the main frame from heavy surface irregularities as well as loading impacts, while also offering stability against roll-over during tipping. Another feature of full compensating suspension is vastly improved stability while negotiating curves, resulting in higher permissible haul speeds and shorter trip times. Suspension Frequency (empty 0,37 Hz) (laden 0,47 Hz).

Efficient Tire Management

Twenty 24.00 R35 tyres mounted on five axle lines support the vehicles GVW. During empty haulage one axle line, two wheel groups are lifted automatically, saving fuel and tyres. The MT-240 mining truck is equipped with a Central Tyre Inflation System. This keeps the exact tyre pressure under real-time conditions. In case of a flat tyre the offending axle is immediately and automatically lifted preventing total-loss of the tyre and possible damage to the suspension. Overall this inherent design fault increases core temperature and risk of failure while contributing to as much as 47 % increased tyre wear. In direct comparison all 20 wheels on the ETF truck are independently controlled, irrespective of direction or steering angle, each following a geometrically correct pathway across the road surface. Tyre changed within 15 minutes! ETF developed a fast tyre-change system. Any wheel whatever its location on the truck, inner or outer can be exchanged within 15 minutes using the powered tyre changer, maintaining the vehicles high technical availability.
Empty haulage Damaged tyre

Scrubbing/abrasion When conventional two axle trucks turn into a curve; the rear dual tyres act very much like two, very wide tyres with both inner and outer edges fighting to follow different circumferences or pathways or on the road surface. This result is called scrubbing/abrasion of the tyre surfaces as the inner is forced to turn at a different speed than the outer on the same side. Irrespective of whether the truck is mechanically controlled by a differential or by angle sensors for electric drive, in real mine site conditions all rear tyres are affected by the same rapid, uneven tyre wear.

Competition (max. 15,6% scrub)

ETF (max. 4,2% scrub)

ETF powered tyre changer in action

High Technical Availability and Utilization

Stop-ages resulting from safety related issues like very wet tropical weather conditions have a considerable negative impact on machine utilization and availability. MT-240 trucks multi wheel drive, all wheel steer capability; provides continuous operation even under conditions that would prevent conventional two wheel drive trucks from operating. There is also additional time and cost savings due to hot-seat shift change. Operators dont have to carry out any shift change checks; fluids top ups are completed automatically saving an average of at least 20 minutes per shift, or 4% more usage. 95 % Technical Availability is guaranteed including lost time for any tyre changes!

Operators Cab
The ergonomically designed high visibility cab provides a clean unobstructed and above all quiet operating environment to less than 80 dB, enabling the driver to concentrate more on safe driving and less on distracting controls, greatly reducing stress and fatigue. The ETF Hydrokinetic drive system is controlled with a simple forward, neutral and reverse function. The cabin is equipped with a modern micro-filtered climate controlled heating, ventilation and air-conditioning system (HVAC), ensuring perfect temperatures under extreme ambient temperature. The truck is fully FOPS and ROPS certificated. Seating comprises of three full sized air vented and suspended seats, one high level centre operator position with two additional seats one either side. All seating is equipped with orange safety belts. Resulting from the cab positioning in the centre of the deck area together with the elevated location of the centre seat, visibility is unequalled through large expanses of windows, both front and sides. No other truck in its class offers better visibility without visual aids. The trainer sitting next to the driver maintains control at all times using separate demountable dual controls, steering wheel and brake control. Access to the cab is by a hydraulically operated stairway on both sides with automatic LED step lighting.

Main Frame
Design: Unique trapezoidal section monorail frame braced with 6 rectangular section cross members with internal stiffeners carries the load. The monorail and axle support system has ten points on which the load is transferred to the wheel groups. In this way forces into the frame are better equalised and distributed across its entire length. Dual pass welding inside and out together with 100% ultrasonic inspection to AWS D 1.1, ensures strength and in-service durability. This exclusive frame construction in combination with independent long suspension travel drastically reduces frame fatigue over the life cycle of the machine. All ETF truck frames are developed using computer aided design, finite element analysis and 3-D modelling.

Material: St 690 is a high strength steel with good fatigue properties and welding ability and suitable for use in minus 40 to plus 60 degrees Celsius.

External Lighting
Clearly its vital that a true 24/7 / 365 day mining operation maintains full machine utilization even under extreme climatic conditions and therefore demands the very best in vehicle lighting. In order to achieve this ETF engineers equipped the truck with six Xenon front lamps, four fixed and two steering-activated directional lamps illuminating directly into curves in the road. At the rear, high intensity multiple LED marker/brake and directional indicators ensure the vehicle is seen from a distance, even in poor visibility conditions. When reversing at night where external lighting can be limited, twin reversing lamps combined with two additional side body lamps supporting the two mirror cams, provide almost daylight visibility. All lamps are equipped with sequential washing facilities in order to provide clear vision at all times. No other mining truck comes equipped as standard with this array of safety illumination.

Operators field of view

ISO 5006 compliant ISO 5006 specifies a static test method for determining and evaluating the operators visibility on a rectangular 1 m boundary close around the machine at 1, 5 m high. The ETF truck fully complies with ISO 5006. Currently no other mining truck complies with this safety standard. ISO 5006: 2006 applies to earth-moving machines for operation on work sites. Cameras Despite offering the best possible forward (image 2) and side visibility of any truck in its weight class, safety remains paramount to ETF, so a number of high visibility camera systems are included on each truck. Two rear facing high vision cameras replace conventional side mirrors, each mirror cam is connected to cab displays, mounted either side of the cab providing the best possible rear view visibility. In addition, there is one camera displaying forward vision (image 1) from the extreme left of the truck in line with the outer drive wheel, enabling drivers to quickly become accustomed to the centre mounted cab position after operating a truck with conventional left side cab arrangement. By providing a clear unobstructed view of the shoulder berm at all times, greatly assists in maintaining safe operating clearance between on-coming trucks. When reversing to the crusher or dump area this monitor switches to the view from the rear camera and when used in combination with both mirror cameras, provides the best and safest possible wide angle rear view vision. All truck mounted cameras are equipped with sequential washing facilities in order to provide clear vision at all times.

Safety features
ETF Trucks are standard equipped with: ABS brakes, Electronic Traction Control, Electronic Stability Control, Collision Warning, Optical Safety, Sleep Deterrent systems and a dual component factory fitted fire suppression system. All these features are unique in the industry. It should be noted that developments in safety related equipment are a systematic process and while many safety technologies are incorporated into ETF trucks which do not come as standard on competitors vehicles, ETF remains committed to increasing the range and scope of its industry leading safety and performance equipment. Additional systems are being developed, including alcohol breath diagnostic testing prior to vehicle operation and seat belt locking inter action with machine start control, are available upon request.

Natural forward visibility

Views from cameras; 1) Left side mirror cam 2) Right side mirror cam

3) Forward camera 4) Reverse camera

On-board weighing system

ETF trucks are standard equipped with an on-board weighing system with external displays using large LCD panels on both sides of the truck; enabling shovel/loader operators to optimise the load by adjusting bucket capacity accordingly. This system is not stand alone but fully integrated into the trucks operational systems determining engine power and suspension settings. ETF designed its trucks with the eyes of the technician who has to work on it. In practice this means that every component and system has been studied carefully in order to ensure there is a fast and reliable way to repair or maintain it. A general rule is that when a repair needs to be carried out that might take longer than 20 minutes, the item will be exchanged. Therefore the complete engine can be replaced in just 15 minutes. A tyre change is also completed within 15 minutes! Even an entire wheel group is removed and replaced in just 60 minutes. Trucks are quickly back in production: main sub components can then be repaired in the workshop without any lost production. ETF calls this the Formula One Pit Stop approach. ETF guarantees a Technical Availability of 95 % including time for tyre changes.

Container Delivery
In order to reduce cost of transportation all ETF trucks and associated equipment are always delivered in standard ISO containers for assembly at the mine site. This efficient logistical solution avoids problems normally associated with the transportation of large haul trucks, such as road width and bridge carrying capacities. Assembling time for each truck is approx. 1.5 weeks without the necessity to use cranes.

Weight
Operating Weight: 192 metric tons / 211 short tons Payload Capacity: 218 metric tons / 240 short tons Maximum GVW: 410 metric tons / 451 short tons - Combined power rating: 1920 kW/2574 HP The truck is equipped with four (4) MTU / Mercedes OM 502 V8, each rated at 480 kW/643 HP 2800 Nm/ 2065 lb/ft 15.93 litres Off Highway EU Stage 3a with Tier 4 Interim 350 kW 12 volt, 1150 CCA 28 volt, 80 A Donaldson

- Torque: - Displacement: - Emission standard: - Engine brake power: - Batteries (2): - Alternator: - Air cleaners: Synchronized electric starting

All engines operate independently; each is mounted in a removable Power Pack Unit that includes: Full cooling system, batteries, air cleaner pump-drives and hydraulic pumps.

Braking Systems
- Service: - Parking: - ABS: - Retarding: On all wheels 650 mm / 25. 6 O.D disc supporting three (3) callipers. On all wheels, capable holding laden truck on an incline of 15 percent. Anti lock braking (ABS) is standard on all wheels. Full Dynamic Retarding provided on all powered wheels.

All Braking systems exceed the requirements of SAE/ISO 3450.

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Dump Body Capacity (Standard Rock)

2:1 Heaped: Struck: Construction material: 120 m/ 161 yd 52 m / 70 yd Hardox 450

Body Hoist System

Dump angle: Dump cycle: Dump pressure: Dump cylinders: 50 degrees 15 seconds (raise loaded) 15 seconds (power down) 330 bar / 4786 psia one stage, double acting, stroke 2460 mm / 96,85 in

ETF Trucks are capable of changing from rock to a coal body within 15 minutes. Note: Various body capacities are available to suit any material density and application.

Dimensions MT-240 Mining Truck

1. Overall width 2. Overal height 3. Overall length 4a. Ground clearance (front) 4b. Ground clearance 5. Swingarm ground clearance 6. Wheel base

7600 mm 6914 mm 21395 mm 1380 mm 1857 mm 406 mm 12250 mm

24ft 2ft 70ft 4ft 6ft 1ft 40ft

11ln 8ln 2ln 6ln 1ln 4ln 2ln

7. Centerline bogie width 8. Centerline tyre width 9. Width betweet inner wheel 10. Body floor height 11. Loading height - empty 12. Overall height - body raised 13. Dump clearance

4700 mm 1600 mm 2700 mm 3300 mm 5635 mm 16193 mm 2110 mm

15ft 5ft 8ft 10ft 18ft 53ft 6ft

5ln 3l 10ln 10ln 6ln 2ln 11ln

14. Average body length 15. Platform height 16. Driversi eyes height 17. First axle to front 19. Tuming radius inner wheels 20. Tuming radius outer wheels

12500 mm 2550 m 4200 m 5595 mm 3480 mm 11480 mm

41ft 8ft 13ft 18ft 47ft 11ft 37ft

0ln 4ln 9ln 4ln 7ln 5ln 8ln

18. Tuming radius - between walls 14500 mm

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Axle configuration (20x16x20)

The MT-240 has 5 axle lines, 10 wheel groups and twenty wheels, all steered and 16 driven, technically described as a 20x16x20 axle configuration. Each axle-line consists of two independent wheel groups that osculate 10 degrees each way, combined this with the long 950 mm suspension travel provides greatly improved wheel/road contact, high stability and excellent off-road capabilities.

Suspension System
The MT-240 truck features a unique hydro-pneumatic load compensating suspension system offering uncompromising ride characteristics irrespective of payload. The extra long wheel travel protects the main frame from heavy surface irregularities as well as loading impacts, while also offering stability against roll-over during tipping. Another feature of full compensating suspension is vastly improved stability while negotiating curves, resulting in higher permissible haul speeds and shorter trip times. Suspension Frequency (empty 0, 37 Hz) (laden 0, 47 Hz).

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European Truck Factory GmbH Grafschafter TechnologieZentrum, Enschedestr . 14, 48529 Nordhorn, Germany

Tel: +49 5921 879 136 Web: www.etftrucks.eu Fax: +49 5921 879 150 E-mail: info@etftrucks.eu