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A power piece
Top truck engine D38
International
02
MAN MAGAZINE
WHICH INNOVATIONS is MAN going to pre-
sent at the 2014 IAA? What is the focus of MAN
developers while exploring the urban trafic
patterns of the future? And how is an old en-
gine transformed into a new one? This second
issue of MANmagazine offers answers to all
these and many more interesting questions. It
relects the world of MAN: a world shaped by
technology withfascinating topics drawnfrom
the realmof trucks andbuses, all the waytothe
turbines andengines that are deployedinships
or power plants.
We wish you an enjoyable read while dis-
covering the following pages. Or simply down-
load the digital tablet version. It is free and
available as an app for iOS and Android.
FOR iOS FOR ANDROID
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The best of MANs world
MASTHEAD
MAN MAGAZINE is published three times a year
in 16 languages.
PUBLISHED BY MAN Corporate Communications
Andreas Lampersbach,
Ungererstrae 69, 80805 Munich, Germany
EDITOR IN CHIEF Florian Wst
EDITOR Joachim Kelz
Tel.: +49. 89. 1580-1175, magazin@man.eu,
www.man.eu
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EDITORS & AUTHORS Klaus-Peter Hilger (resp.),
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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 Hls,
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COVER IMAGE Christian Stoll
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03
COVER STORY
For more than a century, expertise and innovative strength have
been at the core of MANs engine development. The new D38 engine
combines commanding performance with utmost efficiency.
18
2/2014
04 Artwork on wheels
Robert Mahrle is proud of his individually
designed MANtruck.
06 Jungle trials
Volksbuses built by MANLatin America shuttle
Brazilian children to school.
08 Four hearts for a dream boat
The Viking Star is itted with four clean engines
fromMANDiesel & Turbo.
10 Red-hot responders
The history of MANire engines
12 News
Current events in MANs world
16 Navigating the world of MAN
At the IAA commercial vehicles show, MAN
makes an emotional brand appearance.
18 A power piece
Powerful and eficient as never before:
The new D38 enhances MANs engine range.
22 Heavy metal
MANtrucks master tough challenges
in South Africa.
26 Looking out for the future ahead
Within the UR:BANproject, MANdevelopers
explore ideas for the trafic of the future.
30 Turn old into new
In Nuremberg, MANupgrades pre-used MAN
units into premiumGenuine Parts ecoline.
36 Trucks are us
During the Trucknology Days, visitors enjoyed
a hands-on experience of 170 trucks.
40 Offshore
Commuting to windparks per boat: in transit
with a service team
46 Professionals drive MAN
Football teams around the world enjoy the
travel comfort of coaches made by MAN.
48 The mileage masters
Even with more than a million kilometres on
the odometer, MANtrucks operate lawlessly.
26
40
CONTENT
30
International
04
MAN MAGAZINE
MY MAN
Robert Mahrle, aged 29, is a fervently dedi-
cated driver of MANtrucks. This passion is also
reflected by his own MAN TGA, which he has
configured in a rather singular way.
Mr Mahrle, what are these images on
your truck? They are historical motifs from
MANs past or, more specifically, that of the
old truck manufacturer Bssing, which MAN
acquired back in1971. The founder of the com-
pany, Heinrich Bssing, is depicted on the
right, next to his factory, and on the left is the
first Bssing truck and the famous trademark
logo, the MANlion.
Did you design the truck all on your
own? I came up with the airbrush design my-
self. MAN shared the original imagery of the
motifs with me. The actual realisation was
then done by a friend of mine, who is an air-
brush artist.
Where did youget the idea for these his-
toric images? I ama fourth-generation truck
driver its a family tradition going back to
my great-grandfather. Even as a child I was
already enthusiastic about trucks, especially
the ones made by MAN. Naturally, Ive also
always been interested in the history of cars
in general.
What other changes have you made to
the MANvehicle? I started back in 2005, with
just a few navigation lights. Then I added
a custom-made stainless steel sunshade, a
protective grille on the windscreen and the
chromium wheel rims. And the entire TGX-
style front, of course. Over time, this truck
has become quite unique.
on wheels
Artwork
One of a kind: The original TGA was transformed
to adopt the look of a TGX truck.
MAN fan: Robert Mahrle
is a passionately
committed truck driver.
2/2014
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Historic reflections: The
airbrush motif on the drivers side
depicts the first truck made by
Bssing as well as the MAN lion.
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MAN MAGAZINE
Jungle
trials
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
dificult 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 than14,000Volksbus 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 countrys edu-
cational development. Without these buses,
Pedro and thousands of other schoolchildren
would never be able to manage the long and
hazardous trip to school.
PEDRO IS 12 YEARS OLD, and lives on the
periphery of Mata de So Joo in Brazils fed-
eral state of Bahia. Not too long ago it would
have beenimpossible for himto attend school
every day, as there are no public transport
services in his suburb. Since 2007, however, a
yellow Volksbus has been negotiating the un-
surfaced gravel roads in the outlying districts
of Mata de So Joo. 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 chil-
dren from rural districts to school with the
assistance of a modern bus leet. These buses
therefore contribute to regular school attend-
ance. MAN Latin America developed two
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Mobile education: The yellow Volksbus
picks up children in rural districts of
Brazil and gets them safely to school.
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Made to measure: In the ships
engine room, mechanics install
the first of four MAN engines.
MAN MAGAZINE 2/2014
09
WITH A LENGTH OF 230 METRES, 29 metres
in width and offering room for 944 passen-
gers, the Viking Star the latest additionto the
leet of Viking Ocean Cruises is actually one
of the smaller super-luxury vessels. The luxu-
ry liner is powered by four 32/44CR engines
fromMANDiesel &Turbo. At the Italian ship-
yard 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 puriication systems to remove sulphur
oxides supplies a total of eight engines for
the Viking Star and a sister ship. By combining
the ultra-eficient MAN engines with the ex-
haust gas puriicationsystem, the newluxury
cruisers can most economically meet the
increasingly stringent regulations for sulphur
oxide emissions all over the world.
for a dream boat
Up in the air: Lifted by a
crane, the engine is hoisted
on board the cruise liner.
Visionary future: From 2015
onward, the Viking Star will be
cruising the global oceans.
Four
Watch a video about the
spectacular engine installation
via crane on the app. P
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MAN MAGAZINE
10
responders
Red-hot
In case of emergency,
MAN technology steps right
up to the plate: For 99 years,
MAN has remained a reliable
partner of ire brigades.
Since 1915, the expertise
and know-how in this ield
has evolved continuously
right up to todays ultra-
modern ireighting vehicles
with Euro 6 compliance.
1915
1937
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As a result of the strategic Fast Plan,
a measure aimed at reducing the number of
automobile types, MAN was no longer
permitted to build anything other than heavy
trucks as of 1938. Fire brigades, however,
required primarily lighter vehicles. Thus, MAN
did not succeed in solidly repositioning itself
in the firefighting sector until the late 1950s.
In partnership with Swiss manufacturer
Saurer, MAN began offering the first
fire engines as cardan or chain cars in
1915. In addition to a crew of ten men,
the vehicle provided room for ladders, a
pump, hoses and an array of other
extinguishing equipment.
2/2014
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1937
In the 1960s, MAN provided two-wheel- and
all-wheel- drive vehicles to fire departments
with the bonnet generation, including power-
ful 150-hp engines. Emergency teams could
therefore move out without delay.
2013
1985
Today there are real multitalents
among firefighting vehicles, such as
rescue vehicles and airfield fire en-
gines. 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.
1960
With the cab-over-engine
configuration, MAN opened a
new chapter in the history of
firefighting vehicles in 1985.
The new medium-weight
series earned MAN an
excellent reputation. These
emergency vehicles often
remain in service for
decades, responding to
alarms on a daily basis.
Find more on the history of MAN fire engines at
> www.man.eu/discovermanfirefighting
12
MAN MAGAZINE
Record-breakers deserve
a suitable victory vehicle.
FC Bayern Mnchen chose
a converted MAN TGX.
Jubilant crowds await
the stars of Bayern:
Thousands of fans
celebrated victory and
championship title
of the Bundesliga team.
GERMAN FOOTBALL CHAMPION FC Bayern
Mnchen 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 champi-
ons on board took off fromMANs head office
in Munich to proceed through streets
thronged with fans to Munichs city hall. In
addition, 400 MANemployees also planned a
special surprise and assembled before depar-
ture 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
anunobstructed viewof the Bavarianfootball
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 Mnchen. On the
occasion of FC Bayerns triple victory a year
ago, the championship vehicle had been con-
verted at MANs 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
Mnchen since 2008 and provides the official
teambus. For the coming season, the contract
has been extended for another three years,
lasting until 2016.
Masterful merriment
in an MAN Truck
Championship
celebration: The
FC Bayern parade
through the city
centre of Munich
commenced at
MANs head office.
2/2014
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THE FRENCH RAIL-VEHICLE maker Alstomhas ordered 200MANengines for the diesel electric
drive of its Rgiolis railcar. In a irst serial order, Alstomhad already received 500 engines for
the regional train of its French rail operator SNCF. Deliveries of the railcars began in April 2014.
Each vehicle is itted with four or six MANengines, each with an output of 338 kilowatts or
460 hp. The eficient 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 ilter, exhaust system, and electrical and electronic components, can be
accommodated on the roof. Improved accessibility simpliies servicing, and the consistently
lowloors of the interior increase passenger comfort. Alstomis operating the irst large leet of
low-loor vehicles with a roof engine design in Europe.
The look of celebration:
FC Bayern players present
the championship shield.
Alstom orders another 200 rail engines
Saving space: With their compact
dimensions and low weight, the MAN engines
can be accommodated on the railcar roof.
THE RUSSIAN TRANSPORT COMPANY
Neotrans uses long-distance coaches of
the MAN Lions Regio type to carry em-
ployees of Russias largest coal producer,
Siberian Coal Energy Company (SUEK), to
coal mines in the west Siberian town
Kemerovo and its vicinity. Quality, safe-
ty and reliability are core values of our
company, and the MAN buses set stand-
ards in all of these areas. Being selected
by a well-known industrial company like
SUEKas 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
either two or three axles, the MAN Lions
Regio buses offer room for up to 63 pas-
sengers and are powered by an MAN D20
Common Rail diesel engine with 310 hp.
MAN delivers buses to Siberia
For miners: MAN Lions Regio buses
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14
MAN MAGAZINE
AS OF 1 JANUARY 2016, Tier III, the next
level of emission regulations for marine
diesel engines issued by the International
Maritime Organisation (IMO), goes into
effect. MANDiesel &Turbo already owns the
expertise and the technology such as
exhaust gas recirculation(EGR) and selective
catalytic reduction(SCR) tocomply withthe
strict rules for nitric oxide emissions. MAN
Diesel &Turbo has already itted the Danish
Ready for Tier III
283
EMERGENCY VEHICLES
Vienna relies on MAN
Handover: Managing Director Dr Ludwig
Richard (left) and Technical Director Johann Strasser (right)
take delivery of the buses from Peter Blaha of MAN (centre).
FOR THE FOURTH TIME insuccession, MANhas become market leader inRussia 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 ive metric tons.
MAN is market leader in Russia
Tow-away duties: In Moscow, the new
MAN TGLs will keep the streets clear.
Pioneer: the freighter Petunia
Seaways already meets the strict
emission standards of Tier III.
The German disaster management agency
relies on special all-wheel vehicles from
MAN. The Federal Ministry of the Interior is
putting 164 MAN TGMs with double crew
cabs for human decontamination purposes
into service. In addition, there are 119 hose-
laying vehicles, which can transport long
hose lines for major fire-fighting operations
or after flooding. The first emergency vehi-
cles have already been delivered to disaster
management authorities in Bonn.
DR. RICHARD, A TRANSPORT COMPANY based in
Austria, took delivery of 64 MAN Lions City mu-
nicipal buses inEuro 6 versionfor its Vienna lines.
The low-loor buses offer roomfor 87 passengers
and are equipped with wheelchair accommoda-
tion, air conditioning anda passenger information
system. The drive is provided by a 320 hp engine
and a six-gear automated transmission system
fromZF. Twoadditional MANbuses will be usedon
routes with narrow or winding streets. Decisive
factors for Dr. Richard were the price-beneit ratio
and lowfuel consumption of the MANbuses.
freighter Petunia Seaways with an SCR sys-
tem, therefore complying withTier III limits:
Nitric oxides in the exhaust have been
reduced by more than80%. Back in2012, the
company had received its irst order for an
EGR system for a container ship of the
Maersk Line. MAN Diesel & Turbo is also
meeting the challenge of Tier III with dual-
fuel engines, for example, whichcanbe pow-
ered by clean-combusting gas as well as with
heavy oil. MAN considers emission regula-
tions an innovative inspiration in the
development of maritime technologies.
2/2014
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KEOLIS SVERIGE AB is enlarging its Stockholmleet with the addition of 181 MANLions 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
Lions City Mvehicles. All vehicles meet Euro 6 requirements, the strictest exhaust standards
to date, and are a very ecological means of transport. The MANLions City Hybrid, for example,
reduces diesel consumption and CO2 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, Stock-
holmnow owns the largest leet of MANhybrid buses in the world.
181 buses for Stockholm
TURKMEN OIL and Gas Construction has
ordered 61 all-terrain MAN TGS vehicles, be-
coming a irst-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 trac-
tion operations. In western Turkmenistan,
they are deployed for building roads while
developing sites for oil and gas production.
The vehicles are equipped for extreme weath-
er conditions, as summer temperatures in
Turkmenistan can reach around 60C.
MAN began delivery of the of froad
vehicles in May 2014. The local importing
company manages the servicing of the leet
in Turkmenistan. The rapid access to work-
shop 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.
THE MAN SERVICE QUALITY AWARD was
awarded to the staff of the Auto Hrvatska PSC
Slavonski Brodservice centre inCroatia, which
was recognised as the Best MAN Workshop
2013/2014. Places two and three went to the
MAN service centre in Bavarias Rosenheim
and MANs partner workshop Andreas Trger
GmbH, based in Saalfeld, Thuringia. The win-
ners came out on top after competing against
800teams fromall over the world. Taking part
inthe contest required that participants dem-
onstrated their practical and theoretical skills
inautomotive technology, customer manage-
ment and commercial practice in several
rounds and over the course of an entire year.
The 21 best workshop staff were invited to the
Working in
ferocious heat
The worlds best MAN workshop
Ecological pioneer: Stockholm
owns the worlds largest
fleet of MAN hybrid buses.
First place: The Auto Hrvatska PSC Slavonski Brod
service centre is the Best MAN Workshop 2013/2014.
inals inBerlin. MANhas bestowedthe Service
Quality Award on the best service teamsince
2008. In total, 60% of all MAN workshops
worldwide had entered the contest this year
a record high. P
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Robust dumper: Featuring two powered rear axles, the
MAN TGS WW truck is especially suitable for deployment
as a heavy-duty traction vehicle.
MAN MAGAZINE
16
F
rom25 September to2 October, the
international world of commercial
vehicles will meet once again at
the 2014 IAA Commercial Vehicles
trade fair in Hanover. At this lead-
ing exhibition for mobility, trans-
port and logistics, MAN Truck & Bus offers an
innovative presentationspread over anarea of
nearly 10,000 square metres.
Visitors to the IAAwill ind the full model
range from the brand world of MAN Truck &
Bus displayed in Hall 12. The MANexhibit 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, transport-
ing customers to distinct worlds with elabo-
rate settings that highlight the strengths and
versatile uses of MANvehicles.
In addition to three vehicles of the high-
end TGX D38 model, show attendees can
survey a total of 11 truck models, including the
MAN TGS WWespecially designed for the ex-
port market. The area dedicated to buses fea-
tures an MANLions Coach and three variants
of the MANLions City namely a CNGnatural
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 VWVolksbus. Along-
side the products, visitors can also obtain in-
formation on the services offered by MAN.
MAN Bus
The bus sector presents the
MAN Lions City in natural gas, hybrid
and Euro 6 variants for urban and
short-distance transport, as well as
the MAN Lions Coach for tourist and
long-distance travel.
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 Truck, Long-Distance Transport
MANs TGX and TGX EfficientLine
series offer powerful traction units for
the long haul. A TGL tarpaulin-sided
vehicle is also on display.
Stage
On a stage with LED
background projection,
IAA visitors can
experience shows,
presentations and
lectures.
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.
Navigating
the world of MAN
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NEOPLAN
NEOPLANs Skyliner,
Cityliner and Jetliner models
combine comfort and
efficiency in premium-class
travel coaches.
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.
MAN Latin America
Represented by Constellation-
class trucks and a Volksbus,
MAN Latin America is also part
of MANs presence.
Engines
Visitors interested in technical
aspects can inspect the latest
MAN engines with state-of-the-
art Euro 6 technology, as well
as other Euro 5 engines.
MAN world premiere
Different versions of the new
high-end model are presented
right next to the main stage:
three MAN TGX D38 vehicles.
Innovations
In this area, MAN exhibits
innovations and novelties
from the truck sector.
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.
MAN AT THE 2014 IAA, HALL 12
Driving the Future
SEPTEMBER 25 OCTOBER 02, 2014
HANNOVER
MAN MAGAZINE
18
T



hat engine of mine is still
making considerable pro-
gress. When Rudolf Diesel
contemplated his master-
piece 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 MANTruck &Bus presents its highlights
at the IAACommercial Vehicles showinHano-
ver and displays its engine competence to the
automotive trade audience. On centre stage is
the new MAN D38, a six-cylinder engine with
15.2-litre cubic capacity and three performance
options: 520 hp, 560 hp or 640 hp. While the
highly innovative Euro 6 engine is designed
for long-distance transport, tractionand heavy
loads, it still weighs in at 160 kilograms less
than its predecessor, the D28-V8.
Working under project director Norbert
Schatz, a core teamof about 70 specialists had
spent roughly five and a half years developing
the new D38 engine. We wanted a robust,
reliable and highly efficient unit, whichwould
meet even the most challenging of transport
tasks in the range of 500 hp or more, says
Schatz, whenoutliningthe project. The 53-year-
old certified engineer is particularly intrigued
by the fabulous opportunity of starting the
development of a totally new engine on a
blank slate and continuing with design and
simulation, right through to the first proto-
types and up to serial production.
THE SUCCESSORS OF RUDOLF DIESEL bun-
dle drive technologies and progress together
in the MAN engine competence centres,
which develop high-performance systems
such as diesel and natural gas engines with a
performance range of 150up to 1,800hp. They
are not just intended for MANs commercial
vehicles, but also for road and rail vehicles,
yachts and work boats, power aggregates, or
combined heat and power plants, as well as
construction and agricultural machinery.
Abasic engine for many applications serves
as the foundation. 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 launching them on the
A power piece
For more than a century, expertise and innovational
strength have been at the core of MANs engine
development with key technologies paving the way
for high-performance machines. The new D38
combines commanding performance and utmost
efficiency with low operating costs.
Function and design: The cylinder head
of the new D38 engine features highly
rigid materials, a new cooling system and
innovative valve controls (shown).
2/2014
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A power piece
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MAN MAGAZINE
Turbocharging
Two-phase turbocharging ensures
that the engine is ideally supplied
with combustion air across a wide
speed range. The MAN D38
already reaches its full torque at
930 revolutions per minute.
Rear axle
With its exceptionally high gear ratio,
the rear axle exploits the torque of
the high-end MAN model and saves
fuel while still running smoothly.
MAN TipMatic 2
The Speed Shifting function accelerates the shifting
process for gears 10, 11 and 12 thus saving fuel
when negotiating gradients, as it retains more
momentum. The EfficientRoll function optimises fuel
consumption on descending gradients, and Idle
Speed Driving enables the MAN vehicle to accelerate
from stop directly to idle speed.
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market withas many identical components as
possible, says Walter Gotre, Head of Engine
Performance &Emissions at MAN. The more
engine components can be utilised in differ-
ent engine designs, the better. After all, it
beneits eficient development and assembly,
as well as facilitating servicing and the re-
placement of worn parts later on.
The common rail injection used by
all diesel engines built by MANTruck&Bus
hereby serves as the uniting factor. It
involves injecting the fuel at a pressure of up
to 1,800 bar or even up 2,500 bar in the new
D38 into the individual cylinders at precise-
ly deined times, which results in atomisa-
tion. The engine electronics are constantly
aware of all the relevant data, such as engines
rotational speed, load and temperature,
explains Gotre. This allows for calculating the
ideal injection time and exact quantity of
injection fuel for each cylinder and any kind
of driving situation. As the injection system
doses the fuel precisely in adjusting to the
engine load, the engine receives only the fuel
it needs and can burn soot-free.
Looking for innovations, the developers
also generally focus on the operating costs as
a vital parameter for the vehicles economic
viability. We deine the performance in
terms of low consumption and optimised
torque generation even at low speeds, says
Norbert Schatz, when describing the task of
the developers. Here, the interaction of com-
ponents is always geared towards a vehicle
service life of up to 1.5 million kilometres.
SINCE THE D38 has become signiicantly
lighter, eficiency will increase even further
for vehicle owners. We wanted to offer opera-
tors the option of carrying a greater payload,
say Schatz. This was achieved through an
ideal choice of materials. It involves optimis-
ing the existing materials, combined with
targeted geometrical design wherever neces-
sary. So what would Rudolf Diesel have
thought of it? Perhaps he might repeat his
original comment: That engine of mine is
still making considerable progress.
Find more information on the MAN TGX
D38 at the 2014 IAA at > www.man.eu
The top model of MANs trucks for long-
distance transport, traction and heavy loads
has a completely new drive train with numerous
technical innovations. The vehicles main
feature is the D38 six-cylinder engine with a
15.2-litre cubic capacity that ensures efficiency
and optimum performance. With a choice of
520 hp or 560 hp, or even up to 640 hp as
a heavy-duty tractor version, the D38 offers
utmost traction power for all requirements
without intending to break any hp records.

The engine is 160 kg lighter than its pred-
ecessor, with MANs new TipMatic 2 gear
system resulting in even greater efficiency.
The ultra-modern, fully automated shift system
supports GPS-controlled shifting, with three
new functions: Speed Shifting, EfficientRoll
and Idle Speed Driving (see illustration). The
long rear axle provides additional running
smoothness and low rotational speeds. Due
to all these factors including the new fuel
injection system the D38 is exceptionally
economical. Full braking control, even at maxi-
mum load levels, is provided by the Intarder 3
with its higher braking torque, and the EVB
engine brake with an increased braking perfor-
mance of 340 kilowatts and even 600 kilowatts
for heavy-duty vehicles with EVB Turbo. All
standard versions of the TGX D38 incorporate
the Emergency Braking Assistant (EBA).
Optional extras include the Lane Guard System
(LGS), Adaptive Cruise Control (ACC) and the
efficient cruise GPS cruise control system.

The TGX D38 is suitable for all transport tasks,
especially heavy loads. Whether employed for
hauling timber in Scandinavia, long-distance
transport on the motorway or shipping excep-
tionally heavy goods up to 250 tonnes:
The MAN TGX D38 offers reliability, maximum
efficiency and low operating costs at all times.
The new MAN TGX D38
21
2/2014
Retarder system
MANs Exhaust Valve Brake (EVB)
and Turbo EVB ensure maximum
braking performance. This amounts to
340 kilowatts, or even 600 kilowatts
for heavy-duty vehicles.
Design elements
The MAN TGX D38 high-end
model is painted in a soft silver on
the mirror caps and radiator grille.
Efficient Cruise GPS
Due to stored maps and the trucks GPS position,
the cruise control system recognises gradient changes
in the road ahead. As a result the lorry can
think ahead and so optimise fuel consumption.
Lane Guard System (LGS)
The latest generation of LGS
recognises road markings with
extreme precision offering
even more safety and comfort.
Common rail system
With a pressure of 2,500 bar, the
common rail system provides even
finer atomisation and therefore
maximises combustion efficiency.
Emergency Brake
Assist (EBA)
The Emergency Brake
Assist or EBA automatically
activates emergency
braking should the driver
be at risk to collide with
a stationary obstacle
or moving object in front.
Adaptive Cruise
Control (ACC)
Adaptive Cruise Control
automatically maintains
a proper safety distance
from the vehicle ahead.
High tech in the cylinder head
The new cooling system directs the cooling liquid in
the cylinder head directly from above to the points
most exposed to thermal stress, thus reducing wear
and tear. For the first time in a diesel truck engine,
MAN has utilised hardly deformable convex valves that
increase the service lives of valve and valve seat ring.
MAN MAGAZINE
Filled up: A driver signs
the fuel receipt and accepts
his vehicle for the next trip.
Heavy haulage: Michael Siphos truck is
loaded up at the Piet Retief coal mine.
22
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Chromium ore from the mines of South Africa is in high
demand by the metal industry worldwide. MAN trucks carry
metric tons of the raw material from the countrys north
over a steep mountain pass to the port of Richards Bay. On tour
with the South African logistics company Chrome Carriers.
metal
Heavy
MAN MAGAZINE
24
ner of mining enterprises. The companys
depot sits in the port of Richards Bay, in the
province of KwaZulu-Natal. Its 284 drivers
transport chromium ore from the mines in
the northof the country to Richards Bay, to be
shipped to destinations all over the world. On
the way back, the specialised side dumper
trucks ill up with coal or other bulk goods
needed to process the metal. For Michael
Sipho and his colleagues, every new trip
always starts at the Richards Bay depot, where
both tanks of the tractor-trailer unit are illed
up, and the residue of chrome ore is lushed
out of the dumper bodies. Whenever neces-
sary, a mechanic carries out minor servicing
and repairs on the trucks.
NEW DRIVERS such as Michael Sipho re-
ceive thorough training by Chrome Carriers
before they go on tour independently. One
training course is conducted in the mines,
where rigorous safety requirements are in
force. Evenmore important, however, is train-
ing the drivers how to handle their vehicles
safely and economically. RTG has a modern
leet of almost 500 units. Following thorough
practical tests, the Chrome Carriers division
partially renewed its leet in 2012 and added
140 MAN TGS trucks. Our decision to place
that order with MAN was based on the fact
that the vehicles suffered absolutely no tech-
nical defects after more than 200,000 kilo-
metres of continuous operation. Other factors
determining our choice of supplier were the
low fuel consumption rates of the trucks, the
excellent cost-beneit ratio, driving comfort,
as well as MANs maintenance service and
warranty policies, explains Derick Reinhardt,
CEO of RTG. The vehicles operate in South
Africa under challenging conditions, often
using tandem semitrailers, for example.
These so-called interlinks of the seven-axle
vehicles are designed for a high payload of
34 metric tons. Operating conditions are fur-
ther exacerbated by the demanding topogra-
phy of the country, which is why precise ser-
vicing by the close network of MAN service
points is indispensable. Chrome Carriers has
concluded a full maintenance contract with
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.
KILOMETRES
1 500
Double pack: While the twin tyre set is designed to
cope with tough operating conditions in South Africa and
the high payload, a tyre might still occasionally fail.
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Richards
Bay
Rustenburg
Piet
Retief
Namibia
South Africa
W
inding through the east
of South Africa, this is
National Highway 2, at a
spot somewhere between
Empangeni and Pongola.
After a few hundred me-
tres 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 sib-
lings, who live here in a small village in the
east of the country. Its a good job, says the
29-year-old, who switched to a different em-
ployer just a few months ago. He now works
for the Chrome Carriers transport company
and steers a newMANtruck that he praises en-
thusiastically: As far as Imconcerned, MANis
number one!
For decades, South Africa has been recog-
nised as the economic development engine of
an entire continent. In the booming mining
industry, Chrome Carriers a subsidiary of
the Reinhardt Transport Group (RTG)
evolved into the largest private logistics part-
2/2014
25
MAN, which covers servicing and mainte-
nance, as well as extended guarantee provi-
sions. After three years and up to 700,000 kil-
ometres of mileage, the trucks are traded in
for new vehicles.
THE FIRST LEG of Michael Siphos tour
takes him from Richards Bay into the outly-
ing areas of the mining town Piet Retief. The
road winds past national parks and water res-
ervoirs, crosses pastureland, towns and vil-
lages, marks the border with Swaziland and
occasionally turns into a mountain pass. The
journey is a dificult 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 high-
lands of Mpumalanga Province. (Mpumalanga
is Bantu for the place where the sun rises.)
The short stop at his familys village is the
only break during Michaels journey before
reaching his destination. After ive hours of
driving he arrives in Piet Retief a town
where the roads and houses look very differ-
ent fromthe tidy boulevards of Richards Bay.
Coal dust covers the rough and muddy
ground, and an approaching stormfront only
serves to darken the car park next to the
mines even more. The access roads to the
mine are the only offroad stretches on these
trips, yet they are not always as short as here
in Piet Retief. Michael irst 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 ill up in just a few
minutes. As it leaves, the truck is weighed
once more. Have a good trip! says an em-
ployee of the mining company, and hands
Michael the documents. It will be nearly an-
other 500 kilometres before he reaches his
next destination a chrome mine near
Rustenburg, west of Pretoria. Here he will
swap his coal for chrome, sleep for a fewhours
and then head east again back to Richards
Bay, where his cargo will be carried over the
oceans to places all over the world.
Find more information about MAN South
Africa at > www.man-south-africa.co.za/truck
As far as Im
concerned, MAN
is number one!
Michael Sipho, truck driver with Chrome Carriers
Intermediate stop: Michael Sipho takes
a break from his journey for a brief visit to
his sisters in the town of Pongola.
Flexible transporter: The MAN TGS vehicles
of Chrome Carriers have been specially fitted with
side-dumping bodies.
MAN MAGAZINE
26
O
.
nce the signal turns green, we
are on our way. Yet just 100 me-
tres further on, the next trafic
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 40kilometres per hour.
The signal then changes to green. Since
Habedanks truck receives information from
trafic lights, the vehicle can calculate the
speed likely to catch the green wave. What a
Within the framework of
the UR:BAN project, MAN
developers are working to
make city driving safer and
more eficient. Essential
elements are innovative
driver assistance and trafic
management systems for
trucks and buses.
Almost reality: In the simulator, study
participants experience how assistance
systems like the green wave assistant
could facilitate driving in the future.
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great driving experience, says Habedank, a
professional truck driver since 1971. Moving so
easily through an urban setting is certainly
not a commonplace experience for him es-
pecially considering that he is not even de-
pressing the accelerator.
Then the tour comes to an end. A white
screenappears where Habedank hadjust faced
the roadandits trafic a moment ago. His driv-
ers seat actually sits onthe premises of MANs
research department in Munich. The green
Looking out for the
future ah ead
2/2014
27
We induce traffic
lights to communicate
with vehicles.
Andreas Zimmermann, expert on human-machine interface
Test situation: Sonja Stockert of the Munich University
of Applied Sciences fits the test person with special glasses
to record his viewing direction.
wave andcommunications betweentruck and
trafic lights are visions for the future
brought tolife bya deceptivelyreal simulation.
RESEARCHING URBAN TRANSPORT of tomor-
row, making it safe, eficient and especially
a continuously moving low has become an
important undertaking and research project
called UR:BAN for MAN and its coopera -
tion with 31 companies, universities, research
institutions andmetroareas. Launchedin2012
future ah ead
The German Federal
Ministry for Economic
Affairs and Energy is
a significant supporter
of the UR:BAN project.
MAN MAGAZINE
28
and designed to run for four years, the re-
searchproject has receivedsigniicant support
fromGermanys Federal Ministry for Econom-
ic Affairs and Energy. This year is the halfway
mark, andthe irst result renderedby MANde-
velopers are quite impressive.
THE TEAM OF DEVELOPERS from the Engi-
neering Research Electronics department at
MANs facilities in Munich is led by Karlheinz
Drner. An electronics engineer and control
technology expert, he joined MAN back in
1998. He irst worked inadvance development
and then became a department head respon-
sible for driver-assistance systems and elec-
tronics thus bringing a wealth of experience
to the UR:BANproject. We are simultaneous-
ly working onthe sub-areas NetworkedTrafic
System, Cognitive Assistance and Human
Factors in Trafic. The principal focus of our
researchis always onthe driver. That includes
the delay and green wave assistant, for in-
stance, 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 top-
ics for commercial vehicles on their agenda:
The focus of our
research is always
on the driver.
Karlheinz Drner, head of the Engineering Research
Electronics division at MAN
reducing fuel consumption. This includes the
avoidance of unnecessary stops and starts, by
integrating the prognosis for switching times
and stopping points at trafic lights. Andreas
Zimmermann, responsible for one of the
UR:BAN sub-projects, describes it as a com-
plex process: We induce trafic lights to com-
municate 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 advan-
tage of the green wave, summarises the elec-
tronics engineer. At some point, this strategy
should result in real savings, considering that
frequent stop-and-start driving in urban traf-
ic often defeats the high eficiency rate of
modern commercial vehicles. A study on the
eficiency of commercial vehicles issued by
the GermanAssociationof the Automotive In-
dustry (VDA) conirms that just two stops per
kilometre will triple the fuel consumption of
a fully loaded 40-metric-ton vehicle.
Both the simulator and a ield-trials track
in Dsseldorf provide signiicant 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
A total of 31 companies, universities,
cities and research institutes are
cooperating in the UR:BAN project.
31
PARTNERS
Looking at results: Walter Schwertberger (right)
and Michael Reule (left) examine the images of
the Bird View camera in the test bus. Researcher in motion:
Karlheinz Drner
likes cycling from his
office to the test track.
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working with the researchers and developers
from MAN and the university, says Klaus-
Dieter Habedank. I ind that despite all the
cabling, driving in the simulator seems
almost real. Therefore, I can judge rather ef-
fectively 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 Assis-
tance sub-project. Through integrated cam-
era systems, the driver should be enabled to
view the entire immediate vicinity of the ve-
hicle 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 ind themselves facing special chal-
lenges, explains project director Walter
Schwertberger. These primarily include bus
stops, pedestrian and cyclist crossings, nar-
rowing of roads, oncoming trafic and lane
changes. Seeking to provide a more compre-
hensive view, the researchers are looking into
rendering the immediate surroundings from
a virtual birds eye perspective. To this end,
they work with a so-called Bird View system,
Eberhard Hipp, Head of Research
at MAN, on innovations for urban
traffic in the future
How can driver-assistance systems in-
crease the efficiency and safety of
commercial vehicles in urban traffic?
We focus on networking the informa-
tion not available to the driver, such as
the switching rhythms of traffic lights
or the most-current traffic disruptions.
As assistance systems process infor-
mation 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, con-
sumption-optimised driving strategies
and support drivers as best we can.
That is our contribution to more effi-
ciency and safety in road traffic.
The entire interview is posted at
> www.man.eu/discovermanurban
Milestones for
urban traffic
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 immedi-
ate 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?
Howcandynamic angle changes that occur in
articulated buses, for instance, be relected
accurately? In this phase of the project, we are
primarily dealing with many questions,
states Karlheinz Drner. While looking for an-
swers, his teamis supported by MANexperts
and its project partners at the University of
Applied Sciences. Provided that the project
appears promising, research results can irst
enter advanced and later serial development.
THE RESEARCHERS are well aware that
technology is only as effective as its utilisa-
tion in real life. Despite all the possibilities of
intelligent automation as it pertains to driv-
ing operations, human behaviour still plays a
key role. As a doctoral candidate at Munichs
University of Applied Sciences, Sonja Stockert
is part of the UR:BANHuman Factors in Traf-
ic sub-project. Here the media IT specialist
is focusing on the interaction of humans and
machines, to bring about a relaxed, eficient
and safe tour through urban trafic 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: Its a great feel-
ing to contribute my experiences as a truck
driver to the development of new vehicle
technology. From Sonja Stockerts 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 practi-
cal orientation for the beneit of those who
will be applying the results.
Find more information on the UR:BAN
project at > www.urban-online.org/en
Birds-eye perspective: The monitor offers
drivers a comprehensive view of the vehicles
immediate vicinity, from above and in 3D.
Find a video interview
with Eberhard Hipp on
the app.
MAN MAGAZINE
30
Turn
Spa treatment for machinery:
Old engines (left) are salvaged
by MAN in Nuremberg and
conditioned into fully functional
replacement engines (right).
old
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new
into
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.
MAN MAGAZINE
32
G


lancing over the piece num-
bered 51.06500-6089, we
cant help but notice its
rather lamentable condi-
tion: 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
onto the scrap heap? Perhaps intimes 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 un-
dergo this process. Following the rejuvenation
cure, the new ecoline number 9089 will find
itself fully functional and installed in a replace-
ment engine.
While waiting for remanufacturing to be-
gin, the cooling water pump is housed in a
workshop facility that is situated on the huge
grounds of the Engine Competence Centre of
MANTruck &Bus inNuremberg. With anarea
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 sys-
tem, sand-blasted and repainted with some
parts being subject to rejection. After clean-
ing, you can tell what is still re-usable,
explains Georg Kugler, 61, Head of Hot Testing
and Replacement Parts at MAN in Nurem-
berg. We closely inspect the parts for wear
and tear as wel l as material fatigue.
For Kugler, maximum quality is the sole
Parts are closely
inspected for wear
and tear as well as
material fatigue.
Georg Kugler, Head of Hot Testing and Replacement
Parts, MAN Nuremberg
benchmark. In 2013, his teamturned out 780
engines, with 11,325 other spare parts sent
over to MANs 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
anhour. Softly humming conveyor belts carry
the newand replacement engines to the work-
station, 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
MANGenuine 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 Tenstatus inthe MANGroups
corporate objectives. Re-using and refurbish-
ing previously used parts saves resources and
cuts down on energy usage, he says. And
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.
2/2014
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In 2013, 616 truck engines and 164 bus
engines were refurbished at MANs plant
in Nuremberg.
780
ENGINES
Currently, around 1,800 replacement
parts can be ordered from MAN.
This portfolio will be extended to more
than 3,000 part numbers by 2016.
REPLACEMENT
PARTS
1800
because fewer newparts 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
MANs Corporate Responsibility strategy and
greatly contributes to protecting the environ-
ment 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 MANs
ecoline approach first takes hold, as there are
many good arguments for customers in
favour of this seasoned material: A replace-
ment part fromMANhas 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
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Find additional photos
of engine reconditioning in
Nuremberg on the app.
Conditioning
used parts saves
resources and
cuts energy usage.
Stefan Ott, Project Manager,
MAN Genuine Parts ecoline
adds value to the vehicle. Thus, ecoline
also denotes the concept of economical.
There are several good reasons why custom-
ers make a conscious decision to choose
MANGenuine Parts ecoline.
AT MAN, EVERY REPLACEMENT PART in-
cludes 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 purchas-
ing price. Upon returning the used original
part, the deposit is returned. The used compo-
nent is sent to Salzgitter in Lower Saxony, the
central returns plant for anything recyclable,
and is then passed on to the expert techni-
cians 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, conirms Frantz
Perre, Head of After Sales at MAN Truck & Bus
France. Ever since the process was introduced
Ready for dispatch: Both the new and reconditioned engines sit at MANs
Nuremberg plant, waiting for their assignment.
Equal treatment: During
final assembly, engines of
all ages are tested with
strict quality guidelines.
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in17 Europeancountries. The planis a continu-
ous expansion to cover the remaining top 50
global markets.
MAN Genuine Parts ecoline is just a
small part of the overall portfolio of MANs
original component business. All original
parts are made to MANs stringent quality
guidelines that is, according to state-of-the-
art 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, MANs
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 sev-
eral central warehouses around the world.
Currently, MAN can offer about 1,800 num-
bers as replacement parts, while another 1,200
should be added by 2016. Naturally, ecoline
number 51.06500-9089 will also remain in the
portfolio range.
Seetheentireupcyclingprocess inpictures at
> www.man.eu/discovermanecoline
1.9 l /100 km*
Conti EcoPlus HS3 Conti EcoPlus HD3 Conti EcoPlus HT3
www.continental-truck-tires.com
GENERATION 3.
DRIVEN BY YOUR NEEDS.
Conti EcoPlus
Excellent fuel efficiency
High mileage performance
Premium retreadability
The pro in
fuel efficiency:
* Applies to the following products HS3 315/70 R 22.5, HD3 315/70 R 22.5 and
HT3 385/55 R 22.5 in the Conti-EcoPlus range compared with each of their predecessors.
Sep. 25 to Oct. 2, 2014
Hall 17, Booth A06/B11
Conti_GEN3_MAN_220x280_Truck.indd 1 13.06.14 16:14
MAN MAGAZINE
36
Plant tours, shop talks
and 170 trucks available for
testing: Organised under
the motto Meet the world
of efficiency, the MAN
Trucknology Days in Munich
offer drivers, fans and
customers a diverse and
wide-ranging programme
of events.
Trucks
are us
T
oni Estermann is impressed.
The Managing Director of
the Swiss agricultural distribu-
tor Khlhaus Gunzwil AG has
just returned from a guided
tour through MANs Munich
plant. It is quite remarkable
to see howlittle of the production here is done
by robots, he says. As an MAN customer,
Estermann has come all the way fromSwitzer-
land to observe production first hand and try
out the newEuro 6 vehicles. He is one of 6,000
visitors who have come to Munich for the
Trucknology Days event. Test drives, shop talk
with experts, 170 trucks on display, guided
plant tours over the course of two days, the
To me, MAN
means 20 years of
great experiences.
Toni Estermann, Managing Director of
Khlhaus Gunzwil AG
varied programme has attracted drivers, fans,
customers and MAN employees to the Truck
Forumbuilding and the test track.
One highlight for the public: the special
line-up of fire engines. The body manufactur-
ers present their vehicles based on an MAN
chassis in the Euro 5 and regionally still
approved version, and for the first time in the
new Euro 6 design. While many visitors are
unable to resist an excursion on the exten-
sion ladder and its lofty views of the periph-
ery, the menof Hohenpeissenbergs volunteer
fire brigade are mainly interested in vehicle
details: We want to take a look at what the
different body manufacturers have to offer.
Naturally a test drive is also on the agenda.
After all, there are 36 vehicles waiting to be
tried out under the supervision of MAN
ProfiDrive trainers on the circuit course here,
on country roads or on the motorway.
While the Bavarian firefighters are mov-
ing onto the test track, Jack Penders is
inspecting the vehicles displayed in front of
the Truck Forum. These include MAN trucks
built for practically all branches of industry.
Penders, who is Dutch, works at MANs service
centre in Venlo, Netherlands. I am here to
learn about new models and services, which
enables me to better answer many customer
questions. Sandra and Paul Schuler are less
interested in product information but rather
in the adventure of it all. Paul, 3, is blissfully
2/2014
37
Hands-on trucks: Visitors to
Trucknology Days were
able to experience MAN vehicles
up close and personal.
My turn today: Different generations
took to the truck wheels.
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Heavyweight: Even the
largest vehicles could be tried
out on the test circuit.
Use this QR code to
access a video about
Trucknology Days 2014.
Events like the
Trucknology Days
truly reflect the
quality of MAN.
Roberto Ruiz, proprietor of Transportes R. Ruiz e Hijos
Trucks to the horizon: The
test terrain is studded with vehicles
for a close-up view or a test drive.
seated behind the steering wheel. Such a
moment is precisely the kind of experience
that Trucknology Days offers its guests. MAN
has been organising its annual in-house exhi-
bition since 2008 with much success. The
number of visitors noted this year a notable
6,000 has set a new record. Guests from 27
countries travel to Munich, their homelands
ranging fromBrazil to Estonia and South Ko-
rea. Roberto Ruiz has come from Spain. The
proprietor of transport company Transportes
R. Ruiz e Hijos owns seven MAN trucks and
has been an MAN customer for more than 15
years. It is events like the Trucknology Days
and the reliability of the vehicles that truly
reflect the quality youget fromMAN, he says.
One of his highlights: He got to drive a Euro 6
truck for the first time on the test track. The
truck moves great, just like a Euro 5 vehicle,
comments Ruiz. Off the circuit, the MAN
trucks also demonstrate their capabilities on
the gravelly off-road track. Close-by, a special
agriculture and forestry exhibit displays trac-
tor-trailer units and complete vehicles that
have been modified to meet the specific re-
quirements of the agricultural industry.
THE TRUCKNOLOGY DAYS held in Munich
mark the launch of the MAN Trucknology
RoadShow 2014. A fleet of 65 vehicles of the
TGL, TGM, TGS and TGX classes will be tour-
ing all over Europe. MAN sales staff will offer
customers the opportunity to try out these
vehicles for several days. For Toni Estermann,
this is just another reason to emphasise the
MANquality that he has believed in for a long
time: I have garnered great experiences with
MAN for the past 20 years. The chassis are
light, yet still robust, and the price-perfor-
mance ratio is an excellent one. The 2014
Trucknology Days have only served to con-
firmhis opinion once again.
More images of the 2014 Trucknology
Days are posted at > www.flickr.com/photos/
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MAN MAGAZINE
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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.
Offs hore
Floating maintenance service: The
Eden Rose heads for the Sheringham Shoal
wind park off the coast of England.
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Offs hore
MAN MAGAZINE
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P





ainted blue and white, the cata-
maran 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 fewwalkers 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
SheringhamShoal offshore wind park.
The Tia Elizabeth is one of three supply
ships operated by the offshore access compa-
ny 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 produc-
tion 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 main-
tenance, 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 cant reach assigned job sites in
their own service van or car, but instead need
to rely on the supply vessels. And these must
The first British offshore wind park
went online in 2001. Since 2008, the
UK has been offshore world champion
with 1,075 wind turbines.
WIND TURBINES
Altogether, the 22 British wind parks
have an output of 3.6 gigawatts
more than half of the offshore wind
energy generated worldwide.
GIGAWATTS
3.6
be exceptionally reliable, especially since the
boats cannot set out to sea injust any weather
conditions. This also has implications for
what customers expect from the engines,
explains Eugen Maier, the Area Sales Manager
at MANEngines Marine who is responsible for
the English market. Apart from focusing on
fuel consumption, operators are mainly
mindful of reliability and service.
In todays hazy weather, the first wind
turbines appear on the horizon after a one-
hour journey. The gigantic towers rise 80 me-
tres 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 ina diamond formation,
each at a distance of around 500 metres from
the next. The SheringhamShoal wind park is
located about 17 kilometres fromthe 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
200,000Britishhouseholds withgreenenergy.
IN THE CABIN BELOWDECK, Robert Pennock,
Ross Gordon and Kevin English sit on cush-
ioned individual seats at one of the tables,
drinking tea aboard the Tia Elizabeth. These
ships are comfortable after all, the techni-
cians should be rested when they reach their
destination. The men work for Siemens, the
turbine manufacturer, andare 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.
Agreen 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
Powerful and effective: The 1,019-hp engines from MAN must
be exceptionally reliable to cope with their daily deployment.
1075
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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.
Climbing excursion: The
technicians mount the
turbine mast to carry out
maintenance at the top.
MAN MAGAZINE
44
pressing the bow of the ship against the plat-
formto facilitate the mens platformtransfer.
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. Its
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-
ject to powerful vibrations, explains Eugen
Maier of MANEngines Marine. During instal-
lation, the ships diesel engines must be set up
with highly elastic bearings, just as the ex-
haust. Eventhe engines ind the manoeuvres
a strain: These require almost maximum
torque, says Maier, and here we can refer to
previous experience. Weve long since en-
countered comparable challenges in the ferry
business. Ferries cant 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 catama-
ran. Anarrowstairway leads downintothe en-
gine room, the walls are lined with an insula-
tion layer of shiny silver. The two four-stroke
high-speed MAN diesel engines are installed
in this tightly conined space, where one per-
soncanbarely squeeze past the light-grey ma-
chine. Such catamarans have very cramped
engine rooms, says Maier, but that actually
works to our advantage. The MANengines are
exceptionally compact and much more light-
weight than anything else on the market.
Throughout the afternoon, radio calls are
repeatedly received from service teams who
have inished their work on one of the tur-
bines. The Tia Elizabeth picks them up and
takes them to the next installation similar
to a kind of radio taxi. By evening, all the ser-
vice 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, catch-
ing the late-morning tide at 10.30 am.
Find more information on MANs marine
engines at > www.man-engines.com
is calmand peaceful, so the transfer presents
no problems. In heavy winds and high water,
setting over is the most precarious part of
work. Eachwindturbine 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 plat-
form. Each of these manoeuvres is a delicate
operation for skipper Harry Getliffe. Anchor-
ing 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 ser-
vice team can safely make it across at a swell
of up to two metres. Getliffe steadily keeps
The MAN engines
are exceptionally
compact and much
more lightweight.
Eugen Maier, Area Sales Manager,
MAN Engines Marine
Precision work: The very
focused skipper Harry Getliffe
manoeuvres the Tia Elizabeth
through the wind park.
Stand-by position: Having completed their
work on the wind turbines, the service teams
will return to the Eden Rose.
More images of the trip
to Sheringham Shoal are
available in the app. P
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Good braking means better driving. Better driving means driving more economically, safely, and more environmen-
tally friendly. The ZF-Intarder hydrodynamic hydraulic brake allows for wear-free braking without fading, relieves
the service brakes by up to 90 percent, and in doing so, reduces maintenance costs. Taking into account the vehicles
entire service life, the Intarder oers a considerable savings potential ensuring quick amortization. In addition, the
environment benets from the reduced brake dust and noise emissions. Choose the ZF-Intarder for better performance
on the road. www.zf.com/intarder
GOOD BRAKING. BETTER DRIVING. INTARDER!
MAN MAGAZINE
46
Teamwork: While football star Sebastian Kehl
steers the new BVB coach into a parking
slot, Christian Schulz offers some useful tips.
Transport for stars: The players of Paris Saint-Germain arrive in their
MAN team coach to make a red-carpet appearance.
Luxury on wheels: Features of the
new BVB coach include are a real wooden
floor and top-quality leather seats.
2/2014
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Most Bundesliga clubs and
several Champions League
teams are transported in team
coaches provided by MAN.
C
onident of victory, Sebastian
Kehl squeezes in behind the
steering wheel. In contrast,
21-year-old Jonas Hofmann, the
teams young midield talent
seems a little bit nervous as he
climbs into the teamcoach. The two Borussia
Dortmund players competed against eachoth-
er in several disciplines during a team-only
duel on asphalt in the new and old team
coaches. The inal call was not made until the
very end, when Kehl coaxed the ever popular
Heja BVB song out of the new coach by acti-
vating a lever on the steering wheel. That was
the winning goal.
Hopefully Sebastian wont be competing
for my job, joked Christian Schulz after the
fun contest, held on the occasion of oficially
handing over the newMANcoach to Borussia
Dortmund. The 43-year-old driver has safely
and comfortably chauffeured the football
stars to their matches for the last three years.
The predecessor was already fabulous, but
what MAN has delivered this time is simply
fantastic. The 480-hp MAN Lions Coach L
represents the top class of the road a team
cabinonwheels, with every comfort imagina-
ble. Plush and lexibly adjustable leather seats
provide utter relaxation on any journey. The
three LCD monitors show movies or reports
from the days games. On the drive home,
the lads like to watch the recap of matches,
says Schulz. The onboard SAT systemrenders
it possible. There is also a DVDplayer, a sound
system, a multimedia system and a WLAN
router. Fixtures such as a fully automated cof-
fee machine or refrigerator naturally 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.
MAN PROVIDES THE MEANS of transport for
the Bundesliga stars to their games. What be-
gan in 2008 with a sponsorship of FC Bayern
Mnchen underwent continuous expansion.
Hamburger SV, Borussia Mnchengladbach,
VfL Wolfsburg and Borussia Dortmund are
also partners withanother sevenBundesliga
teams also using MAN coaches. Its a similar
picture on the international stage: Paris
Saint-Germain is an oficial partner, as are
AC Milan and FC Barcelona, joined by 15 top
league teams in Brazil, plus Brazils national
team, which all appreciate the amenities
offered by MAN coaches. As Patrick Eble,
Sponsoring and Events TeamLeader at MAN,
comments with pride: We are the premier
supplier worldwide for top-class sports. Our
partnerships make an important contribu-
tion to the positive perception of MAN as a
strong brand.
Christian Schulz covers around 60,000
kilometres in his Lions Coach every year.
What was his inest hour? Deinitely the trip
back to the hotel from Berlins Olympic
Stadium, after our 5-2 victory in the 2012 Cup
Final against Bayern Mnchen. 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 froma match in Munich,
Christian Schulz steers his team coach onto
the motorway in the opposite direction. As
long as hes driving an MAN coach, however,
hes certainly on the right course.
A making of report of the duel may be
found at > www.man.eu/discovermanbvbduel
Professionals
Watch a video of
Sebastian Kehl and
Jonas Hofmann in
the BVB team coach
on the app.
drive MAN
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MAN MAGAZINE
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The mileage masters
A passion for driving: Paul Kick has been at the
wheel of his truck for every mile.
Robust, not rusty:
Paul Kicks truck
receives top service.
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The mileage masters
Racking up mileage of a million kilometres sounds
like a very long life cycle for a truck. MAN vehicles,
however, keep performing lawlessly beyond the
million mark without a single engine replacement.
And not just on the well-maintained roads of Germany.
G
rass-greenontopandscarlet red
below, the love of Paul Kicks life
has no name, only a number. In
spite of its stately age, it is still
sprightly and a millionaire. A
mileage millionaire, to be pre-
cise. That love is a 2007 TGA19.440, Paul Kicks
oldest MAN truck and practically one of the
family by now. The 40-tonnes vehicle has
been part of the haulage contractors leet in
Kerpen, Germany, for seven years, shuttling
between Cologne and Berlin, on motorways,
mountain roads and local runs. The truck can
take a payload of up to 25 tonnes, and carries
everything fromfoodstuffs to trade fair goods
and construction materials. Naturally, other
heavy-duty vehicles canalsoperformthis service.
Once a truck begins to age, however, it might
start losing oil, the batteries become tired, and
rust patches can develop. My truck is as it as
ever, says Kick. The tractor-trailer unit has already
shouldered well over a millionkilometres, with
Kick at the steering wheel for the entire distance.
PAUL KICK HAS PRACTICALLY GROWN UP in
a truck. Even as a child, he was already riding
with his father, who founded the family busi-
ness. Today, he manages the company togeth-
er with his brothers. Over all these years, Kick
has become a big MAN fan. Besides superior
quality and good maintenance, intelligent
driving habits are also essential in order to
extract top performance from a truck, he
says. And when it comes to servicing, it is
important to always remember the oil
change, check the brakes and examine the
wheel bearings. Due to his training as a motor
mechanic at MAN, Kick can performall these
tasks himself. While there, he could already
learn about the quality of the vehicles he was
repairing. Well, actually:We didnt have
much to do, he says with a wink.
While Wolfgang Kamith doesnt perform
the repairs himself, the freight operator based
Busy commuter: Paul Kicks MAN
TGA has been carrying a range
of cargo goods between Berlin and
Cologne since 2007.
Read more on how buses
can also surpass a
million miles in the app.
MAN MAGAZINE
50
in Worms, Germany, has an authorized MAN
workshop at his doorstep that he has relied on
for two decades. They are not just interested
in doing more business, but will also provide
free advice, he says. Without these col-
leagues, we would have never hit the million
mark, A while ago, he also had the rear axle
of his 7.5-metric-ton truck repaired at the
workshop. Built in 1996, the vehicle already
had 950,000 kilometres on it. But I said to
myself, Its an MAN, it will be worth it.
Thomas Dillitzer, Head of Sales Management
MAN Trucks Germany, says, A repair is al-
ways economical, unless the cost surpasses
the value of the vehicle. Our trucks, however,
are built to run up to 1.5 million kilometres
and more. Kamith was attached to his truck,
with its grass-green drivers cab and generous
sleeping berth, and didnt want to let it go.
By now, it has logged 1,185,000 kilometres,
travelled through Sweden, England and Italy,
and remains fully functional.
Kamiths MAN 8 223 from the L 2000
series is still running with its original engine
from 1996, and even the heating system is
still the same. Its six-cylinder engine is so qui-
et that the radio is perfectly audible even
while driving on the motorway. And so pow-
erful with its 220 hp, that you dont need to
crawl even on mountainous inclines, but
rather just drive normally. Meanwhile the
boss also ensures that his drivers handle the
vehicle responsibly: no high revolutions, an
early gear change, and an immediate report
and check-up as soon as anybody hears any
strange noises. All things considered, the
truck is still far away fromthe scrap yard, he
says. Even if Kamith could no longer utilize
the vehicle for long-distance operations, he
could still sell it.
MAN ACHIEVES TOP PERFORMANCE and not
just on Germanys well-maintained roads,
but also in regions with lots of sand and swel-
tering heat. In the United Arab Emirates, for
instance, 6,000 kilometres to the southeast.
The Saif Bin Darwish corporate group, a spe-
cialist in civil engineering and construction
projects, has been relying on German trucks
for 30years. Three trucks have already passed
the one million mark. We were not really
astonished to find that our MAN TGA models
have so far kept going for more than a million
kilometres, says R.D. Pepler, General Man-
ager Plant Division at Saif Bin Darwish Civil
Engineering Contractors. From his point of
view, the principal reasons for the long
service life of the vehicles are the regular ser-
vicing provided by MAN and MANs special
training courses. These ProfiDrive courses
improve the drivers theoretical and practical
knowledge to prevent damage resulting from
faulty handling. The 750 vehicles of the Saif
Bin Darwish fleet are used on construction
sites all over the country. They total an aver-
age of 200,000 kilometres a year, half of it
off-road. Despite these tough conditions,
MANs robust trucks have low service costs
and operate faultlessly, even far beyond the
million-kilometre mark. It is therefore hard-
ly surprising that customers all over the
world are persuaded by this level of quality.
We would never
have hit the million
mark without
MANs service.
Wolfgang Kamith, Founder and Managing Director,
Kamith Lastentaxi
Desert assignment: Trucks operating for
the fleet of Saif Bin Darwish drive roughly
100,000 off-road kilometres every year.
Paul Kicks MAN TGA has already
passed the million milestone and has per-
formed impeccably and without any
major repairs for years. Not surprisingly,
as MAN trucks are designed for a service
life of 1.5 million kilometres and more.
MILLION KILOMETRES
1.04
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Visit us
at the
Hall 12, Stand B14
A new class of MAN power is approaching, enabling you to gather speed for success: with the
innovative D38 engine range in the MAN TGX a perfect merger of efciency and power takes to
the roads. And scores top marks in performance, reliability and economy. See how efcient the
new power is. Come to the world premiere of the D38 at the IAA Commercial Vehicles 2014.
www.mantruckandbus.com/tg
A new power just coming at you.
The premiere of the MAN TGX D38. MAN kann.
11538_ad_TPC_220x280_button_en.indd 1 18.06.14 17:07
The new KMAX range.
Drive further all year round.
ALL-SEASON
*
Compared to RHS II and RHD II+. Tests conducted in cooperation with different European eets under the supervision of Goodyear on size 315/80R22.5 between July 2011 and June 2013 show that
KMAX S and KMAX D have an improvement in mileage potential of respectively up to 30 % and 35 % vs. Goodyear RHS II and RHD II+.
The new KMAX line delivers up to 35% more mileage
compared to its predecessor and all-season capability.*
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