MAN on the Front line

Name: MAN on the Front line
Brand: MAN

Rugged MAN TGS 41-480 8x8 plays a pivotal role in the construction of Powerlink’s new high voltage power-line in Far North Queensland

The job that this MAN 8x8 was called on to help with involved the erection of some 170 towers throughout some very rough and dense tropical coastal countryside.

The old line has operated for around 50 years in this harsh tropical environment, and survived several cyclones during its lifetime and now it is due for progressive replacement to ensure a reliable supply of electricity can be maintained to the Far North into the future.

Downer’s Townsville operation was responsible for construction and maintenance of the access track, the surveying of all structure sites, geotechnical investigations to determine foundation types, prototype assembly and full tower testing, the supply, fabrication, delivery and erection of lattice towers and H-Frames, and the installation of tower earthing systems.

The decision to specify a fleet of MAN TGS 41-480 8x8 rigid trucks, as the backbone of their supply chain was an easy one according to Robert Ninnes, Plant and Equipment Co-Ordinator – Transmission/Engineering. “The robust construction of the MAN TGS 41-480 8x8, backup service and proven reliability were of the key factors in decision process,” Robert said.

“We have a few older MAN all-wheel drive models and they’ve been outstanding vehicles for us. Some of our work in the exploration side of the business means these trucks are sent to some of the remotest parts of the country, so remote in fact they even have to tow a trailer with extra fuel and supplies. They could be working out in the deserts for up to a month at a time. They’re great trucks because they always come home,” Robert added.

“One of the biggest challenges we faced with this Powerlink project was the high rainfall which made construction of roads to get heavy machinery to each tower sites a huge challenge.

“For example, Tully has an average annual rainfall exceeding 4,000 millimetres and is arguably the wettest town in Australia. In 2003 a giant gumboot (the "Golden Gumboot") was erected as a monument to the town's climate. Believe me its wet,” Robert explained.

“The MANs form our front-line of vehicles, because they are the first vehicles into a new area after the bulldozers have pushed through a new road. Due to the extreme wet conditions we have to lay special swamp mats to form a temporary road base in certain wet-areas to provide vehicle access without damaging delicate eco-system or equipment,” Robert added.

“One of the roles our MAN TGS 41-480 8x8 and their crew perform is the challenging task of trail blazing through the virgin rain forest with the bulldozers laying the swap-mats so the other vehicles such as cranes can get to each site,” Robert explained.

The heart of these MAN TGS 41-480 8x8s is the MAN six-cylinder four-valve in-line engine, with common-rail injection, turbocharging and intercooling. These engines feature EDC electronic engine regulation and meet EURO 5 emission standard with OBD2 (onboard diagnosis) and NOx-control and have SCR catalytic converter with AdBlue injection.

The MAN Engine Valve Brake (EVB) is fitted as standard.

Getting the power to the ground is the task given to the MAN 12-speed TipMatic (ZF AStronic) gearbox that is an automated constant-mesh gearbox. It features 12 forward two reverse gears. It is suitable for gross train 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 second and fourth gears. The ‘M’ setting is for precise low-speed manoeuvring in forward and reverse while the ‘X’ setting is for off-road use.

The raised air intake with pre-filter is mounted on the rear left-hand side of the cab with air filter housing mounted under rear of cabin. Meanwhile, the exhaust is upswept on the right-hand side with the muffler behind the cab.

The transfer case is extremely robust in construction to handle the harshest off-road conditions. All shafts and the ground gearwheels are manufactured from high-strength case-hardened grades of steel.

These transfer cases are now easier to install, thanks to increased shaft spacing and the resulting reduction in the propeller shaft connection angle. Noise has been reduced by improved gear tooth patterns and stiffening of the case, and oil change intervals lengthened by installation of a filter.

The weight of the transfer cases in these new model ranges has been reduced; especially the G 102 and G which have aluminium cases, and are significantly lighter.

Planetary-hub front axles are supplied as drive-through axles for tandem front-axle assemblies. Depending on the intended application, the axle beams are of spheroidal graphite cast iron or welded steel, rated for maximum operating strength.

The wheel assemblies pivot on kingpins in the forked ends of the axles. To absorb radial and axial forces, the kingpins pivot in plain bearings of high-quality tin-bronze, combined with hardened sliding blocks. Theses bearing points are filled with oil.

For ease of maintenance, the bevel-gear centre drive, the differential and, in the case of drive-through axles, the spur gears form a single assembly that can easily be exchanged as a complete unit. The shafts and gearwheels are of high-strength heat-treatable alloy steel and are carried in substantial taper-roller bearings. Through-drive front axles have a front-to-rear differential lock as standard equipment, and a cross-axle differential lock – between the wheels – can be supplied on request for all axles. The full torque is built up in the planetary hubs, which have either four or five planet wheels running in needle roller bearings.

The axles can be specified with either cam-type drum brakes or disc brakes and have automatic wear compensation. The axles can be equipped with an anti-lock brake system (ABS) and the brake linings contain no asbestos. Interestingly the double universal-joint shafts are maintenance-free.

These Downer MAN TGS 41-480 8x8s are fitted with the HMF 3000-K Series crane which has a 30-tm range with up to eight hydraulic extensions

The HMF 3000 Series is developed for users who need a high capacity with long reach. It is equipped with a user-friendly radio remote control system, offering the operator an increased visibility in all working situations. The HMF 3000-K is a flexible loader, suitable for both hook application as well as hydraulic accessory application such as grab and rotator.

The dual Power Plus link arm system gives very precise and regular boom movements in the entire working area and is particularly well suited for long reach and handling tall and bulky items. It is also equipped with a user-friendly speed control (the HDL system), which at the same time provides an increased lifting capacity. This system optimises the operator’s ability to finely adjust the movements of the loader.

Downer was impressed with the standard safety features of the HMF 3000-K, which include HMF’s new totally-integrated user-friendly RCL and EVS Safety System, which only intervenes when absolutely necessary.

“The RCL and EVS systems offer a higher degree of safety for our operators,” Robert explained. “The RCL system ensures the loader against an overload while the EVS ensures the necessary stability of the loader so that the loader can be used to its limits without risking that the loader tilts, overturns or is damaged in any way. That is what HMF call safety, taken to the limit,” Robert added.

“There is no question that some of our off-road jobs have added hazards that you wouldn’t see in many other day-to-day operations,” Robert explained.

“But that’s where the inherent built-in safety features of the MAN TGS 41-480 8x8 really provide peace of mind for our staff and us. There is no question that at the end of the day the job needs to be done, and with the right equipment like our MAN trucks and training we are able to do that and do it safely and efficiently.” Robert concluded.

Truck Specs:

Model: MAN TGS 41-480 8x8

Engine: MAN D26 12.4Litre

Power: 480hp (353kW) @ 1900RPM

Torque: 1696lb/ft (2300Nm) @ 1500-1400 RPM

Gearbox: ZF 12 AS 2330 OD (Ratios 12.33 – 0.78)

Retarder: MAN Engine Valve Brake (EVB)

Front Axle: MAN hub reduction VP/VPD-09 2 x 9,000kg

Front Suspension: Load sharing 2 x 8,000kg parabolic springs

Rear Axles: MAN Hub reduction HPD 1382 /HP 1352

Rear Axle Ratio: 4.00

Rear Suspension: MAN multi-leaf springs and stabilisers.