MAN 26-480 Road-Rail Review

As I arrived, the rail crew was busily removing their machines from the rail line at the rail crossing five minutes north of Violet Town in North East Victoria. The daily XPT train bound for Sydney was scheduled to roll through momentarily; after that, the rail line would be clear for a few hours. The next scheduled train service was a southbound freight train.

From an engineering standpoint, Hi-Rail vehicles are a marvel. Designing a vehicle capable of performing dual functions presents numerous challenges to ensure the vehicle complies with all road-going regulations and rail operation requirements.

Notably, road and rail requirements differ significantly. However, over the years, MAN trucks have proven to be a versatile choice as donor vehicles, thanks to their engineering excellence, reliability, adaptability, and safety features.

The MAN 26-480 Hi-Rail vehicle's robust design and construction provide a solid foundation for the demanding requirements of Hi-Rail vehicles. Its advanced suspension systems and high load-bearing capacities ensure it can handle the additional weight and mechanical stresses imposed by the rail gear and other modifications required for Hi-Rail operations.

This engineering prowess of MAN translates into enhanced performance and longevity of the Hi-Rail vehicles, significantly reducing downtime and maintenance costs.

The strength of the chassis directly impacts the vehicle’s load-bearing capacity. MAN chassis are engineered to handle substantial payloads, making them ideal for Hi-Rail tipper applications where heavy materials such as railway ballast are transported. The rigidity of the chassis helps maintain the alignment of the wheels and suspension system, providing a smoother and more controlled driving experience.

Hub reduction differentials are necessary for Hi-Rail applications because they provide an additional gear reduction at the wheel hubs, effectively multiplying the torque delivered to the wheels.

This is particularly advantageous in Hi-Rail applications where the vehicle often operates in low-speed, high-torque environments. The increased torque allows the MAN to easily handle the challenging terrain of steel rails, ensuring that it can maintain traction even in the wettest conditions.

Enhanced traction reduces the likelihood of wheel slip, ensuring the vehicle can progress even under adverse condition. Furthermore, by distributing the load more evenly across the drivetrain, hub reduction differentials reduce the stress on components such as the axles and transmission.

As expected, the MAN 26-480 Hi-Rail vehicle faces payload constraints due to its increased tare weight from the Hi-Rail system when operating as a conventional road-going tipper.

However, thanks to the robust construction of the MAN chassis, it enjoys a generous GVM, which allows the tipper body to carry a full load of rail ballast when operating on the train line, showcasing its adaptability and efficiency.

The core components of the Hi-Rail system are the rail gear assemblies, which are mounted at the front and rear of the truck. These assemblies have flanged wheels designed to fit and travel on railway tracks. The front and rear assembly have retractable wheels that can be lowered or raised.

A hydraulic system controls the operation of the rail gear. This system provides the necessary force to extend or retract the rail wheels. The hydraulic system is powered by the truck’s engine and controlled via a set of in-cab controls, allowing the driver to switch between road and rail modes easily.

The Hi-Rail system incorporates various guidance and safety systems to ensure secure and efficient rail operation. These include alignment sensors, braking systems, and locking mechanisms that secure the rail gear in position.

Additionally, lights and signals that adhere to railway standards are integrated into the truck to facilitate communication with other railway traffic, enhancing the overall safety of the operation.

When on the railway tracks, the truck’s inner drive tyres provide traction. Some advanced systems feature an auxiliary drive mechanism designed explicitly for rail operations, ensuring optimal performance and adherence to rail operational requirements.

The MAN 26-480 is a real all-rounder with a 68,000kg rating, making it ideal for vocational applications like Hi-Rail tipper tasks. At the heart of this MAN 26-480 is the six-cylinder, four-valve in-line engine, with common-rail injection, turbocharging and intercooling.

These older engines feature EDC electronic engine regulation, meet EURO 5 emission standards with OBD2 (onboard diagnosis) and NOx-control, and have SCR catalytic converter with AdBlue injection. However, later model MAN 26-480 are EURO-6 compliant and come with a standard MAN engine valve brake (EVB).

The MAN 12-speed TipMatic (ZF AStronic) gearbox is an automated constant-mesh gearbox that gets power to the ground (or rails) effectively. It features 12 forward speeds and two reverse ratios. It is suitable for gross weights up to 70T (occasionally up to 90T+GTW upon application).

With MAN’s TipMatic, shifting and clutching are electro-pneumatic; there is no clutch pedal. Normal mode is automated, with manual mode available, and shifting is via a fingertip lever. It can be driven with the PTO engaged only in the second and fourth gears. The ‘M’ setting is for precise low-speed manoeuvring in forward and reverse.

Transitioning the MAN Hi-Rail from its road-going form to a rail vehicle is relatively straightforward. At a level crossing where the road and rails are at the same level, you position the truck directly over the rails so that the small flanged Hi-Rail wheel will line up with the train track.

Then, lower the front Hi-Rail wheels until the truck steer tyres are clear of the train line and lock the front Hi-Rail system in place. Then, you lower the rear Hi-Rail wheels and lock them into position.

While the front Hi-Rail wheels support the front of the truck, the rear Hi-Rail wheels only support a small portion of the truck and act more as a guide to keep the truck on the railway line. The truck’s rear suspension and drive wheels still carry a portion of the load to ensure the vehicle retains maximum traction.

The truck can then travel safely along the railway tracks with the rail wheels engaged. The driver uses the in-cab controls to manage speed, braking, and other operational aspects.

By enabling seamless transitions between road and rail travel, these systems enhance the efficiency of railway maintenance and construction. Overall, the MAN 26-480 is a heavy-duty, robust machine well suited to specialised applications like this Hi-Rail job.

Specifications:
Model: MAN TGA 26-480
Engine: MAN D2876
Horsepower: 473hp (353kW) at 1900rpm
Torque: 1696lb/ft (2300Nm) at 1100rpm
Gearbox: AS2301 Tipmatic 12-speed
Electrical: 28V 80A 2240W alternator
Front Axle: MAN 9.5t
Front Suspension: Taper leaf 7000kg with stabilser
Rear Axles: MAN Hub Reduction with diff locks.
Rear Suspension: MAN Airbag
Fuel tank: Alloy 1 x 473lt
Brakes: Drum
Wheels: 10-stud steel
Safety: MAN (EBS) with ABS as standard.
Interior: Vinyl
Seats: High comfort ISRI driver’s seat

Used MAN 26-480 for sale:
Correct at the time of writing
2015 MAN TGS 26 480 FT 20 Cubic MT body auto X-locks $145,000

2012 MAN TGX 26.480 $190,000

2009 MAN TGS 26.480 $125,000

2014 MAN 26.540 $112,500

2007 MAN TGA $85,000