VW

New VW tractor unit can single-handedly tow the weight of a fully loaded Boeing 737

Volkswagen has just launched new models in the Constellation family of extra-heavy trucks, designed in Brazil and manufactured in Resende (Rio de Janeiro state).

The vehicle is designed for severe off-road operations—specifically sugarcane transport—and can tow up to 91 tons, which is the maximum takeoff weight of a Boeing 737 MAX 10, the largest model in the 737 family.

The new VW Constellation 33.540 features a 13-liter, 6-cylinder in-line MAN D26 Ultra engine producing 540 horsepower, paired with a ZF TraXon 12-speed automated transmission.

Its rear axle assembly, featuring a reinforced structure and hub reduction, enables it to handle the largest tractor-trailer combinations permitted in Brazil: 11-axle setups with a Gross Combined Weight (GCW) of 91 tons.

The truck includes various protective features to withstand off-road work, and its engine-transmission combination delivers 2,650 Nm (270.1 kgfm) of torque.

According to Volkswagen Trucks and Buses (VWCO), the maximum towing capacity—the machine's absolute limit—is 125 tons, though this can reach 150 tons with manufacturer consultation.

"Our new 540-horsepower extra-heavy truck family represents an evolution of the Constellation and Meteor platforms, and this engine has received a calibration specifically tailored for severe off-road applications," says Rodrigo Chaves, Vice President of Engineering at VWCO.

In addition to the uprated engine and protective elements for the headlights, chassis, and critical areas, the truck features raised suspension and an improved approach angle. In the cab, air suspension helps ensure occupant comfort, even during the roughest operations in plantation areas.

The VW Constellation 33.540 is available across the Brazilian market, offering maximum traction capacity in a 6x4 axle configuration. It is suited for sugarcane and forestry applications.

In the 11-axle configuration with a Gross Combined Weight (GCW) of 91 tonnes—known as "super road trains" (*super rodotrens*)—Brazilian regulations allow these combinations to transport sugarcane only from the plantation area to the processing plant via private roads.

To travel on public highways, the vehicle combination requires a Special Transit Authorization (AET), which imposes restrictions regarding operating hours, maximum speed (60 km/h), and travel distance (60 km).

Technology...The new Highline package features a fully digital instrument cluster with a 10-inch screen and over 80 functions—the most advanced on the Brazilian market. Customizable, intuitive, and practical, it offers a wide range of features and enhanced visibility. The modern 7-inch multimedia system provides constant entertainment, supporting mobile connectivity, screen mirroring, and voice assistants. With its touchscreen interface and integration with the instrument cluster, you can easily view various types of information with just a few taps.

Powertrain configured for economy...The entire powertrain of VW’s new extra-heavy-duty family was designed to offer operational gains to the customer. In addition to the domestically produced MAN D26 engine, a number of factors underpin this advantage—such as the new Traxon automated transmission, combined with more efficient components and intelligent systems—to ensure maximum operational efficiency.

The new injection system, together with new pistons and a new electronically controlled turbocharger, significantly improves combustion efficiency. This allows for increased power density, delivering high performance and durability alongside reduced fuel consumption.

These new extra-heavy-duty models introduce the ZF-manufactured Traxon automated transmission to the VW portfolio. Calibrated to meet market demands, it is available in 12- and 16-speed versions across all vehicle model configurations.

The result is improved fuel economy and superior performance for the country's driving conditions. This transmission processes information at high speed.

When combined with the onboard technology system, it enables smarter gear shifting across a wide range of topographical and load conditions, optimizing fuel consumption, safety, and comfort.

The new high-efficiency drive axles offer a wide range of gear ratios suited to diverse operating conditions, ensuring high performance and durability with low fuel consumption.

The vehicle also features onboard intelligence that uses georeferencing to enhance efficiency, uptime, safety, and robustness. This system, utilizing sensors and electronic functions, enables proper, automatic management of engine power, gear shifting, braking, and the use of vehicle momentum based on topography and the load being transported.

Thanks to this work, it has been possible to combine superior performance with a remarkable improvement in fuel economy. The new-generation MAN D26 engine, the new Traxon automated transmission, the electronic management system, and aerodynamic improvements drive a significant reduction in fuel consumption.

Evolution across all components...However, the secret behind the powertrain of the new VW heavy-duty trucks goes beyond just the MAN D26 engine and the Traxon transmission with its advanced programming. There have been improvements to every component, all developed with a focus on durability, operating costs, ease of maintenance, and modularity—enabling a wider range of variants to meet customer needs. This approach ensures the product is ideally suited to the market and delivers the high uptime required for these applications.

All models in the new family feature dual fuel tanks, with capacities ranging from 630 liters (two 315-liter plastic tanks) to 940 liters (two 470-liter aluminum tanks), depending on the chosen wheelbase. With the exception of the off-road model, all tanks are made of aluminum. The VW extra-heavy trucks also include a 100-liter tank for Arla 32 (AdBlue), ensuring a balanced operating range for their intended applications. The entire fuel and injection system has been engineered to operate using biodiesel.

Designed for the sugarcane sector...The new Constellation was developed with a focus on sugarcane transport, particularly for off-road operations. To this end, it features significant structural reinforcements, such as more robust axles, hub reduction, and a special suspension system designed to withstand harsh field conditions.

When configured as an 11-axle "super road train," the combination reaches a Gross Combined Weight (GCW) of 91 tonnes. Volkswagen states that the new engine calibration delivers fuel savings of up to 5% compared to the previous generation.

Highway travel is restricted...Despite their high load capacity, these 91-tonne combinations are primarily intended for use on private roads within processing plants and plantation areas. To operate on public highways, the vehicle requires a Special Transit Authorization (AET), a document regulating the transport of oversized or overweight loads. This authorization imposes certain limitations—such as a maximum speed of 60 km/h, a distance limit of 60 km per trip, and specific operating hours—to ensure road safety.

The launch reinforces the Constellation line's presence in the Brazilian extra-heavy truck market, a segment where the brand already has an established track record.

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