Modified vehicles for the most different fields of application in the construction industry and in the construction sector

Paul Nutzfahrzeuge GmbH at the Bauma 2016:

• Increased efficiency and profitability in applications on construction sites and in mining through efficient modification solutions

• Close co-operation within the conversion partner network of Custom Tailored Trucks (CTT) with the proven partner Paul Nutzfahrzeuge: Crew cab for the Mercedes-Benz Zetros truck

• Hydrostatic drive for Volvo three-axle sweeper from Faun

• Steered trailing lift axle with air suspension for the K60H concrete pump of Cifa S.p.A.

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Vilshofen on the Danube. From 11 - 17 April 2016 a cross section of the broadly based modification program of Paul Nutzfahrzeuge GmbH will be on display at the Bauma 2016 in Munich: a Mercedes-Benz Zetros 2733 A 6x6, equipped with a crew cab from Paul Nutzfahrzeuge will be shown at the exhibition stand 136/224 of Daimler AG in hall B4. The extremely maneuverable Viajet 12 sweeper which is based upon a Volvo FH 6x2 chassis is specially configured for sweeping operations at large construction sites. It has been fitted with an intermediate gear and a hydrostatic drive system by Paul Nutzfahrzeuge and will be on display at the open-air area exhibition stand FN 821/2 of Faun Umwelttechnik GmbH & Co.KG. The Italian manufacturer Cifa S.p.A. also focuses on Paul Nutzfahrzeuge: the company will show a five-axle carrier chassis for their concrete pump K60H on the openair area south at the joint exhibition stand of the Zoomlion Group (FS 905/2).

Crew cab for the transport of working crews in the Mercedes-Benz Zetros

At the Bauma 2016, the extremely robust Mercedes-Benz Zetros 2733 A cabover-engine truck is presented as 6x6 three-axle vehicle. It shows how a heavyduty truck for extremely harsh off-road crew transports in applications such as mining and open-cast mining has to be built. Equipped with a crew cab, it is an outstanding example for the efficient co-operation between Mercedes-Benz Special Trucks (MBS) at Wörth in Germany, the Mercedes-Benz manufacture Custom Tailored Trucks (CTT) at Molsheim in France and their qualified partner Paul Nutzfahrzeuge at Vilshofen, which is also located in Germany.

Paul Nutzfahrzeuge has extended the driver’s cab by 700 mm and expanded it to become a fully-fledged crew cab for safe staff transports of up to six crew members. The underbody was converted by additionally welded longitudinal beams and crossmembers, the roof area by inserting additional frame sections and cross bows. Furthermore, the Paul engineers moved the rear panel including the original trim of the Zetros to the rear by 700 mm altogether.

For the installation of the crew cab it became necessary to reposition the air dryer and the air valves on the left side of the vehicle to the rear end. The side panels and the doors including windows, interior trim etc. are taken from the crew cab of the Unimog U 5000 and were adapted accordingly.

On the rear bench seat with head restraints, coat hooks and three-point seat belts up to four crew members of the operational team can be seated in direction of travel. Three separate treads on the left as well as on the right side of the cab facilitate their rapid entry and exit. They are almost identical with the original Zetros treads for driver and front passenger in the front part of the cab and their mounting was also adapted accordingly by Paul Nutzfahrzeuge. After conversion the interior is equipped with a high-performance air conditioning system with two outlets which ensure comfortable temperatures for the crew on board even with high outside temperatures.

The robust ladder frame of the Zetros platform truck chassis on display in Munich with its steel-grey metallic paintwork offers high flexibility for customized bodies and superstructures within the scope of its gross vehicle weight of 25 tons and its maximum payload of 12 tons. The wheelbase of the three-axle truck is 4,450 mm + 1,450 mm. The permanent all-wheel drive with differential locks in combination with an Allison 3500 fully automatic transmission and a two-speed transfer case VG 1700 ensures high and uninterrupted traction. The Euro-5 engine with an output of 240 kW (326 hp) and the powertrain are specially designed for extreme climatic zones. The torsion-free platform body and the side-mounted rope winch with a pulling force of 80 kN and a rope length of 60 m are made by HPC Maschinenbau GmbH & Co. KG.

Hydrostatic drive for maneuverable three-axle sweeper from Faun

At the Bauma 2016 the currently most powerful truck-mounted sweeper available on the market is presented for heavy-duty application on major construction sites and in road construction. The Viajet 12 made by FAUN Viatec GmbH at Grimma was built for the Lopes company from Switzerland on the basis of a Volvo FH 6x2 chassis providing an output of 338 kW (460 hp) and a split range gearbox with 14 gears.

Paul Nutzfahrzeuge has installed a hydrostatic drive system into the powertrain of the three-axle chassis to achieve low speeds in sweeping operations, in particular for surface cleaning operations with high-pressure water. This also facilitates the handling for the driver during the difficult shunting and manoeuvering processes demanded at the construction site. The hydrostatic drive can be used up to a maximum speed of 20 km/h and a maximum incline of 16 %, thus allowing for a highly precise maneuvering of this large sweeper suction unit. To achieve this, an intermediate gearbox specially designed for this application by the Italian manufacturer Omsi Trasmissioni S.p.A. was installed with rigid through-drive into the driveline between gearbox and rear axle. The hydraulic pump as drive pump as well as the fixed displacement motor and the variable displacement motor for the hydrostatic drive are mounted on it. Both are hydraulically driven and in hydrostatic drive mode they are coupled with the drive shaft which runs from the gearbox to the rear axle.

When switching from mechanic to hydrostatic drive, the driver first disconnects the gearbox and the rear axle in the intermediate gear via a switch on the instrument panel. Then the drive shaft from the gearbox is connected to the hydraulic pump. The direction of travel (forward-backward) and the speed are controlled through the joystick in the driver’s cab. Paul Nutzfahrzeuge has fitted the cab with this joystick control, thus facilitating the handling enormously. Through this joystick via adjustment of the hydraulic pump the speed of the vehicle in forward and backward direction can be controlled continuously and be adapted precisely to the particular work assignment and driving condition.

With its gross vehicle weight of 26 tons this high-performance sweeper combines a tremendous payload with a large usable volume. The highly safety-critical operation on road and motorway construction sites under tremendous time pressure demands the highest degree of reliable sweeping technology and highest suction capacities. The new heavy-duty highperformance sweeper meets all these high requirements with its special underbody rear-mounted suction system, the Hydrojet surface cleaning system and the high dirt-collector body capacity configured for a sweeping volume of 12 m³.

Two additional reversing spotlights increase the safety during hydrostatic reversing. They serve as backup lamps. When the driver’s door is opened, the hydrostatic drive is automatically switched off for safety reasons.

Strong five-axle carrier chassis for Cifa concrete pump

Paul Nutzfahrzeuge configures special five-axle carrier chassis for the selfpropelled Carbotech truck-mounted concrete pumps of the type K60H which are produced by the concrete machine manufacturer Cifa S.p.A. from Senago near Milan, Italy. The installation of a steered and air-suspended trailing lift axle at the rear with a load capacity of 12 t is a characteristic feature. The installation on the exhibition vehicle at the Bauma 2016 is based upon a Euro-6 chassis of the Mercedes-Benz Arocs range delivering an output of 375 kW/510 hp. The modified five-axle chassis bears the type designation Arocs 5551 K 10x4/6 and offers an increased load capacity of 42 t at a maximum gross vehicle weight of 55 tons. The conversion measures optimize the distribution of weight on the individual axles when transporting the concrete pump which is fixed and firmly mounted on the frame of the chassis.

The electro-hydraulic steering system increases the maneuverability of the vehicle combination on narrow construction site areas so that the turning circle of the five-axle truck of 25 m does not exceed the radius of the Arocs standard chassis. Thus, pumping processes in extreme heights can be carried out even in cramped conditions – in the process, the lift mechanism of the rear axle automatically activates as soon as the signal to extend the support stands is sent.

The air suspension of the steered axle allows a particularly material-preserving transport of the heavy construction equipment to the site of operation. Apart from the load relief of the other axles it is at the same time a relevant precondition for the implementation of the starting assistance which is operative up to 30 km/h and which is also installed into the vehicle by Paul Nutzfahrzeuge.

The fact that the original wheelbase could be maintained to adhere to the overall length of the chassis (10.75 m) and of the complete vehicle (13.4 m), as well as the possibility to make use of the short CompactSpace-M driver cab from series production helps to keep the cost low. To allow this and at the same time adhere to the predetermined overall height of the vehicle of less than four meters the frame height was reduced to 1,060 mm. Furthermore, the frame overhang at the rear end was reduced to 2,450 mm, the end crossmember was removed and the second front axle is repositioned by 300 mm to the rear in combination with the adaptation of the spring and axle connection.

The battery tray including the two attached compressed air reservoirs, the electronically controlled compressed air unit (EAPU Electronic Air Pressure Unit), the air dryer, the catalytic converter as well as the two tanks for fuel and for the AdBlue supply have also been repositioned by 300 to 450 mm to the rear.