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MAN TGA Service Manual

Guidelines to fitting bodies

TRUCKNOLOGY® GENERATION A (TGA)

Edition 2011 Version 1.0

P U B L I S H E R

MAN Truck & Bus AG

(mentioned in the text below “MAN“)

ESC Department

Engineering Services

Consultation

D a c h a u e r S t r. 6 6 7

D — 8 0 9 9 5 M u n i c h

E-Mail: esc@man.eu

Fax:

+ 49 (0) 89 1580 4264

We reserve the right to make changes in the course of technical development.

© 2011 MAN Truck & Bus Aktiengesellschaft

Reprinting, reproduction or translation, even of excerpts, is not permitted without the written permission of MAN. All rights, in particular under copyright, are strictly reserved by MAN.

Trucknology® and MANTED® are registered trademarks of MAN Truck & Bus AG

Where designations are trademarks they are, even without the ® or ™ sign, acknowledged as the proprietor‘s protected marks.

TRUCKNOLOGY® GENERATION A (TGA)

1.

Applicability and legal agreements

1

1.1

Applicability

1

1.2

Legal agreements and approval procedure

1

1.2.1

Preconditions

1

1.2.2

Responsibility

2

1.2.3

Quality assurance

2

1.2.4

Approval

3

1.2.5

Submission of documents

3

1.2.6

Liability for defects

4

1.2.7

Product liability

5

1.2.8

Safety

5

1.2.9

Manuals from body and conversion companies

6

1.2.10

Limitation of liability for accessories/spare parts

7

2.

Product designations

7

2.1

Vehicle designation and wheel formula

7

2.1.1

Door designation

7

2.1.2

Variant descriptor

7

2.1.3

Wheel formula

8

2.1.4

Suffi x

9

2.2

Model number, vehicle identification number, vehicle number, basic vehicle number

10

2.3

Use of logos

13

2.4

Cabs

14

2.5

Engine variants

16

3.

General

17

3.1

Axle overload, one-sided loading

17

3.2

Minimum front axle load

19

3.3

Wheels, rolling circumference

20

3.4

Permissible overhang

20

3.5

Theoretical wheelbase, overhang, theoretical axle centreline

21

3.6

Calculating the axle load and weighing procedure

23

3.7

Checking and adjustment procedures once body has been fi tted

24

3.8

Notes on MAN Hydrodrive®

25

TRUCKNOLOGY® GENERATION A (TGA)

I

4.

Modifying the chassis

25

4.1

Frame material

25

4.2

Corrosion protection

30

4.3

Drill holes, riveted joints and screw connections on the frame

30

4.4

Modifying the frame

33

4.4.1

Welding the frame

33

4.4.2

Modifying the frame overhang

35

4.4.3

Modifi cations to the wheelbase

37

4.5

Retrofi tting additional equipment add-on components or accessories

43

4.5.1

Retrofi tting additional or larger fuel tanks after factory delivery

44

4.6

Propshafts

45

4.6.1

Single joint

45

4.6.2

Jointed shaft with two joints

46

4.6.3

Three-dimensional propshaft layout

47

4.6.3.1 Propshaft train

48

4.6.3.2 Forces in the propshaft system

48

4.6.4

Modifying the propshaft layout in the driveline of MAN chassis

49

4.7

Modifying the wheel formula

49

4.8

Coupling devices

51

4.8.1

Basics

51

4.8.2

Trailer coupling, D value

52

4.9

Tractor units and converting the vehicle type — truck / tractor

52

4.9.1

Articulated vehicles

52

4.9.2

Converting trucks into tractor units or tractor units into trucks

55

4.10

Modifying the cab

55

4.10.1

General

55

4.10.2

Spoilers, roof extensions, roofwalk

55

4.10.3

Roof sleeper cabs

58

4.11

Add-on frame components

59

4.11.1

Rear underride guard

59

4.11.2

FUP — front underride protection

61

4.11.3

Sideguards

62

4.12

Modifi cations to engine systems

64

4.12.1

Modifi cations to the air intake and exhaust gas routing for engines up to and

64

including Euro4 with On Board Diagnosis

64

4.12.2

Additional requirements if changes are made to the AdBlue® system/exhaust

66

system on Euro5 vehicles

66

4.12.3

Engine cooling

74

4.12.4

Engine encapsulation, noise insulation

74

4.13

Fitting other manual gearboxes, automatic transmissions and transfer boxes

74

TRUCKNOLOGY® GENERATION A (TGA)

II

5.

Bodies

74

5.1

General

74

5.2

Corrosion protection

76

5.3

Subframes

76

5.3.1

General

76

5.3.2

Permissible materials, yield points

77

5.3.3

Subframe design

79

5.3.4

Attaching subframes and bodies

80

5.3.5

Screw connections and riveted joints

81

5.3.6

Flexible connection

84

5.3.7

Rigid connection

87

5.4

Bodies

87

5.4.1

Testing of bodies

87

5.4.2

Platform and box bodies

88

5.4.3

Tail-lifts

96

5.4.4

Interchangeable containers

97

5.4.5

Self-supporting bodies without subframe

98

5.4.6

Single-pivot body

98

5.4.7

Tank and container bodies

101

5.4.8

Tippers

103

5.4.9

Set-down, sliding set-down and sliding roll-off tippers

104

5.4.10

Propping air-sprung vehicles

105

5.4.11

Loading cranes

106

5.4.12

Cable winches

116

5.4.13

Transport mixers

116

5.4.14

Car transporter

117

TRUCKNOLOGY® GENERATION A (TGA)

III

6.

Electrics, electronics, wiring

118

6.1

General

118

6.2

Routing cables, earth cable

118

6.3

Handling batteries

118

6.3.1

Handling and maintaining the batteries

118

6.3.2

Handling and maintaining batteries with PAG technology

119

6.4

Additional wiring diagrams and wiring harness drawings

120

6.5

Fuses, additional power consumers

120

6.6

Lighting installations

123

6.7

Electromagnetic compatibility

123

6.8

Radio equipment and aerials

124

6.9

Interfaces on the vehicle, preparations for the body

126

6.9.1

Electrical connections for tail-lifts

126

6.9.2

Start-stop control on frame end

126

6.10

Electronics

127

6.10.1

Display and instrumentation concept

127

6.10.2

Diagnostics concept and parameterisation using MAN-cats®

127

6.10.3

Parameterisation of the vehicle electronics

127

TRUCKNOLOGY® GENERATION A (TGA)

IV

7.

Power take-off

(See separate booklet)

127

8.

Brakes, lines

128

8.1

ALB, EBS braking system

128

8.2

Brake and compressed air lines

128

8.2.1

Basic principles

128

8.2.2

Voss 232 system plug connectors

129

8.2.3

Installing and attaching lines

130

8.2.4

Compressed air loss

132

8.3

Connecting additional air consumers

132

8.4

Retrofi tting continuous brakes not manufactured by MAN

134

9.

Calculations

134

9.1

Speed

134

9.2

Effi ciency

135

9.3

Tractive force

136

9.4

Gradeability

137

9.4.1

Distance travelled on uphill or downhill gradients

137

9.4.2

Angle of uphill or downhill gradient

137

9.4.3

Calculating the gradeability

138

9.5

Torque

142

9.6

Power output

143

9.7

Rotational speeds for power take-offs at the transfer case

145

9.8

Driving resistances

146

9.9

Turning circle

149

9.10

Axle load calculation

151

9.10.1

Performing an axle load calculation

151

9.10.2

Calculation of weight with trailing axle lifted

154

9.11

Support length for bodies without subframes

156

9.12

Coupling devices

157

9.12.1

Trailer coupling

157

9.12.2

Rigid drawbar trailers / central axle trailers

157

9.12.3

Fifth-wheel coupling

159

The ESC numbers stated in the illustrations are purely for internal reference.

They are of no consequence to the reader.

If not otherwise stated: all dimensions in mm, all weights and loads in kg

TRUCKNOLOGY® GENERATION A (TGA)

V

1.Applicability and legal agreements

1.1Applicability

The statements in this guide are binding. If technically feasible, exceptions will be approved only if a written request has been submitted to the ESC department at MAN, (see „Publisher“ above).

1.2Legal agreements and approval procedure

1.2.1Preconditions

In addition to this Guide, the company carrying out the work must observe all

laws and decrees

accident prevention regulations

operating instructions

relating to the operation and construction of the vehicle. Standards are technical standards; they are therefore minimum requirements. Anyone who does not endeavour to observe these minimum requirements is regarded as operating negligently.

Standards are binding when they form part of regulations.

Information given by MAN in reply to telephone enquiries is not binding unless confi rmed in writing. Enquiries are to be directed to

the relevant MAN department. Information refers to conditions of use that are usual within Europe. Dimensions, weights and other basic data that differ from these must be taken into consideration when designing the body, mounting the body and designing the subframe. The company carrying out the work must ensure that the entire vehicle can withstand the conditions of use that it is expected

to experience.

For certain types of equipment, such as loading cranes, tail-lifts, cable winches etc, the respective manufacturers have developed their own body regulations. If, when compared with this MAN Guide, they impose further conditions, then these too must be observed.

References to

legal stipulations

accident prevention regulations

decrees from professional associations

work regulations

other guidelines and sources of information

are not in any way complete and are only intended as ideas for further information. They do not replace the company’s obligation to carry out its own checks.

Fuel consumption is considerably affected by modifi cations to the vehicle, by the body and its design and by the operation of equipment driven by the vehicle’s engine. It is therefore expected that the company carrying out the work implements a design that facilitates

the lowest possible fuel consumption.

TRUCKNOLOGY® GENERATION A (TGA)

1

1.2.2Responsibility

The responsibility for proper

design

production

installation of bodies

modifi cation to the chassis

always lies fully with the company that is manufacturing the body, installing it or carrying out modifi cations (manufacturer’s liability). This also applies if MAN has expressly approved the body or the modifi cation. Bodies/conversions that have been approved in writing by MAN do not release the body manufacturer from his responsibility for the product. Should the company carrying out the work detect a mistake either in the planning stage or in the intentions of

the customer

the user

its own personnel

the vehicle manufacturer

then that mistake must be brought to the attention of the respective party.

The company is responsible for seeing that the vehicle’s

operational safety

traffi c safety

maintenance possibilities and

handling characteristics

do not exhibit any disadvantageous properties.

With regard to traffi c safety, the company must operate in accordance with the state of the art and in line with the recognised rules in the fi eld in matters relating to

the design

the production of bodies

the installation of bodies

the modifi cation of chassis

instructions and

operating instructions.

Diffi cult conditions of use must also be taken into account.

1.2.3Quality assurance

In order to meet our customers’ high quality expectations and in view of international product/manufacturer liability legislation an on-going quality monitoring programme is also required for conversions and body manufacture/installation. This requires a functioning quality assurance system. It is recommended that the body manufacturer sets up and provides evidence of a quality system that complies with the general requirements and recognised rules (e.g. DIN EN ISO 9000 et seq. or VDA 8).

Evidence of a qualifi ed system can be provided for example by:

TRUCKNOLOGY® GENERATION A (TGA)

2

If MAN is the party awarding the contract for the body or conversion evidence of qualifi cation will be requested.

MAN Truck & Bus AG reserves the right to carry out its own system audit in accordance with VDA 8 or a corresponding process check at the supplier’s premises. VDA volume 8 has been agreed with the following body manufacturers’ associations:

ZKF (Zentralverband Karosserieund Fahrzeugtechnik – Central Association of Body and Vehicle Engineering) and

BVM (Bundesverband Metall Vereinigung Deutscher Metallhandwerke – Federation of German Metal Trades Associations).

It has also been agreed with the ZDH (Zentralverband des Deutschen Handwerks – Central Association of German Craft Trades).

Documents:

VDA Volume 8

„Minimum quality assurance requirements for trailer, body manufacturers“, obtainable from the Verband der Automobilindustrie e.V (VDA) (German Engine Industry Association), http://www.vda-qmc.de.

1.2.4Approval

Approval from MAN for a body or a chassis modifi cation is not required if the bodies or modifi cations are carried out in accordance with this Guide. If MAN approves a body or a chassis modifi cation, then this approval refers

In the case of bodies only to the body’s fundamental compatibility with the respective chassis and the interfaces to the body (e.g. dimensions and mounting of the subframe)

In the case of chassis modifi cations only to the fact that, from a design point of view, the modifi cations to the chassis in question are fundamentally permissible.

The approval note that MAN enters on the submitted technical documents does not indicate a check on the

Function

Design

Equipment of the body or the modifi cation.

Observance of this Guide does not free the user from responsibility to perform modifi cations and manufacture bodies properly from

a technical point of view. The approval note only refers to such measures or components as are to be found in the submitted technical documents.

MAN reserves the right to refuse to issue approvals for bodies or modifi cations, even if a comparable approval has already been issued. Later submissions for approval are not automatically treated the same as earlier ones, because technical advances achieved in

the interim period have to be taken into account.

MAN also reserves the right to change this Guide at any time or to issue instructions that differ from this Guide for individual chassis.

If several identical chassis have the same bodies or modifi cations MAN can, to simplify matters, issue a collective approval.

1.2.5Submission of documents

Documents should only be sent to MAN if bodies/conversions diverge from this Guide. Before work begins on the vehicle, technical documents that require approval or inspection must be sent to the ESC Department at MAN (see „Publisher“ above).

For an approval process to proceed swiftly, the following are required:

Documents should be submitted in duplicate

The number of individual documents should be kept to a minimum

All the technical data and documents must be submitted.

TRUCKNOLOGY® GENERATION A (TGA)

3

The following information should be included:

Vehicle model (see Chapter 2.2 for model code) with

cab design

wheelbase

frame overhang

· Vehicle identifi cation number or vehicle number (if already available, see Chapter 2.2)

Identifi cation of deviations from this Guide to Fitting Bodies in all documentation!

Loads and their load application points:

Forces from the body

Axle load calculation

Special conditions of use:

Subframe:

Material and cross-sectional data

Dimensions

Type of section

Arrangement of cross members in the subframe

Special features of the subframe design

Cross-section modifi cations

Additional reinforcements

Upsweeps, etc.

Means of connection:

Positioning (in relation to the chassis)

Type

Size

Number.

The following are not suffi cient for inspection or approval:

Parts lists

Brochures

Photographs

Other not binding information.

Drawings are only valid if they bear the number that has been assigned to them. It is therefore not permitted to draw in the bodies or modifi cations on chassis drawings that have been provided by MAN and to submit these for approval.

1.2.6Liability for defects

Liability claims in respect of defects only exist within the framework of the purchasing contract between buyer and seller. In accordance with this, liability for defects lies with the respective seller of the goods.

Claims against MAN are not valid if the fault that is the subject of the complaint was due to the fact that

This Guide was not observed

In view of the purpose for which the vehicle is used, an unsuitable chassis has been selected

The damage to the chassis has been caused by

the body

the type of body mounting or how the body has been mounted

the modifi cation to the chassis

improper use.

TRUCKNOLOGY® GENERATION A (TGA)

4

1.2.7Product liability

Any faults in the work that are identifi ed by MAN are to be corrected. Insofar as is legally permissible, MAN disclaims all liability, in particular for consequential damage.

Product liability regulates:

The liability of the manufacturer for its product or component

The compensation claim made by the manufacturer against whom a claim has been made against the manufacturer of an integral component, if the damage that has occurred is due to a fault in that component.

The company that has made the body or carried out the modifi cation is to relieve MAN of any liability to its customer or other third party if the damage that has occurred is due to the fact that

The company did not observe this Guide

The body or chassis modifi cation has caused damage on account of its faulty

design

manufacture

installation

instructions

The fundamental rules that are laid down have not been complied with in any other way.

1.2.8Safety

Companies carrying out work on the chassis/vehicle are liable for any damage that may be caused by poor functional and operational safety or inadequate operating instructions. Therefore, MAN requires the body manufacturer or vehicle conversion company to:

Ensure the highest possible safety, in line with the state of the art

Provide comprehensible, suffi cient operating instructions

Provide permanent, easily visible instruction plates on hazardous points for operators and/or third parties

Observe the necessary protection measures (e.g. fi re and explosion prevention)

Provide full toxicological information

Provide full environmental information.

Safety is top priority! All available technical means of avoiding incidents that will undermine operational safety are to be implemented. This applies equally to

Active safety = prevention of accidents. This includes:

Driving safety achieved by the overall vehicle design, including the body

Safety as a consequence of the driver’s well-being achieved by keeping occupant stress caused by vibrations, noise, climatic conditions etc. to a minimum

Safety as a consequence of observation and perception, in particular through the correct design of lighting systems, warning equipment, providing suffi cient direct and indirect visibility

Safety as a consequence of operating equipment and controls this includes optimising the ease of operation of all equipment, including that of the body.

Passive safety = avoidance and reduction of the consequences of accidents. This includes:

Exterior safety such as the design of the outside of the vehicle and body with respect to deformation behaviour and the installation of protective devices

Interior safety including the protection of occupants of vehicles and cabs that are installed by the body builders.

TRUCKNOLOGY® GENERATION A (TGA)

5

Climatic and environmental conditions have effects on:

Operational safety

Readiness for use

Operational performance

Service life

Cost-effectiveness.

Climatic and environmental conditions are, for example:

The effects of temperature

Humidity

Aggressive substances

Sand and dust

Radiation.

Suffi cient space for all parts required to carry out a movement, including all pipes and cables, must be guaranteed. The operating instructions for MAN trucks provide information about the maintenance points on the vehicle. Regardless of what type of body is fi tted, good access to the maintenance points must be ensured in all cases. It must be possible to carry out maintenance unhindered and without having to remove any components. Suffi cient ventilation and/or cooling of the components is to be guaranteed.

1.2.9Manuals from body and conversion companies

In the event of a body being added or modifi cations to the vehicle being carried out, the operator of the vehicle is also entitled to receive operating instructions from the conversion company. All specifi c advantages offered by the product are of no use if the customer is

not able to:

Handle the product safely and properly

Use it rationally and effortlessly

Maintain it properly

Master all of its functions.

As a result, every vehicle body builder and converter must check his technical instructions for:

Clarity

Completeness

Accuracy

Comprehensibility

Product-specifi c safety instructions.

Inadequate or incomplete operating instructions carry considerable risks for the user. Possible effects are:

Reduced benefi t, because the advantages of the product remain unknown

Complaints and annoyance

Faults and damage, which are normally blamed on the chassis

Unexpected and unnecessary additional cost through repairs and time lost

A negative image and thereby less inclination to buy the same product or brand again.

Depending on the vehicle body or modifi cation, the operating personnel must be instructed about operation and maintenance. Such instruction must also include the possible effects on the static and dynamic performance of the vehicle.

TRUCKNOLOGY® GENERATION A (TGA)

6

1.2.10Limitation of liability for accessories/spare parts

Accessories and spare parts that MAN has not manufactured or approved for use in its products may affect the traffi c safety and operational safety of the vehicle and create hazardous situations. MAN Truck & Bus AG (or the seller) accepts

no liability for claims of any kind resulting from a combination of the vehicle together with an accessory that was made by another manufacturer, regardless of whether MAN Truck & Bus AG (or the seller) has sold the accessory itself or fi tted it to the vehicle (or the subject of the contract).

2.Product designations

2.1Vehicle designation and wheel formula

To enable unique and easily comprehensible identification of the different variants new vehicle designations have been systematically introduced. The vehicle designation system is based on three levels:

Door designation

Variant descriptor (in the sales and technical documentation e.g. data sheets, chassis drawings)

Model code.

2.1.1Door designation

The door designation comprises:

Model range + permissible weight + engine power

TGA 18.400

Model range

+ Permissible weight

+ Engine power

T G A

1 8

. 4 0 0

Abbreviated notation of model range TGA = Trucknology® Generation A, technically permissible weight in [t],

engine power [DIN-hp] rounded to the nearest 10hp

2.1.2Variant descriptor

The variant descriptor = vehicle designation which comprises the door designation + wheel formula + suffi x. The terms ‘wheel formula’ and ‘suffi x’ are defi ned in the following sections.

Model range + permissible weight + engine power + wheel formula + suffi x

TGA 25.480 6×2-2 LL-U

Model range

+ Permissible weight

+ Engine power

T G A

2 5

. 4 8 0

6 x 2 — 2

L L — U

Wheel formula

Suffi x

TRUCKNOLOGY® GENERATION A (TGA)

7

2.1.3Wheel formula

The wheel formula stipulates the number of axles and provides additional identifi cation of drive, steered and leading/trailing axles. Wheel formula is a commonly used, but not standardised term. It is “wheel locations” that are counted and not the individual wheels. Twin tyres are therefore regarded as one wheel.

The following two examples illustrate the wheel formula:

Table 1: Wheel formula examples

6 x 2 — 4

6 x 2 / 4

6= Total number of wheel locations, i.e. 3 axles x = No function

2= Number of driven wheels

= Trailing axle behind the rear drive-axle assembly

/= Leading axle ahead of the rear drive-axle assembly

4= Number of steered wheels

The number of steered wheels is only stated if, aside from steered front wheels, leading axles or trailing axles are also involved. A leading axle is located “ahead of” a rear drive-axle assembly and a trailing axle is “behind” the rear drive-axle assembly.

A slash “/” represents a leading axle and a hyphen “-” represents a trailing axle.

If a chassis is fi tted with both leading and trailing axles the number of steered wheels follows the hyphen “-”.

If the vehicle is fi tted with MAN HydroDrive® hydrostatic front axle drive then the wheel formula receives an additional H, e.g. 6x4H = a front axle with MAN HydroDrive®, 2 rear axles, one of which is driven.

Currently the following wheel formulae are available ex-works:

Table 2: TGA wheel formulae

4×2 Two-axle vehicle with one drive axle

4×4 Two-axle vehicle with two drive axles “All-wheel drive”

4x4H Two-axle vehicle with two drive axles, front axle with MAN HydroDrive®

6×2/2 Three-axle vehicle with non-steered “Pusher” leading axle

6×2/4 Three-axle vehicle with steered leading axle

6×2-2 Three-axle vehicle with non-steered trailing axle

6×2-4 Three-axle vehicle with steered trailing axle

6×4 Three-axle vehicle with two driven non-steered rear axles

6×4/4 Three-axle vehicle with 2 driven axles (fi rst and last axles), steered leading axle

6×4-4 Three-axle vehicle with 2 driven axles, (fi rst and second axles), steered trailing axle

6x4H/2 Three-axle vehicle with MAN HydroDrive® front axle drive, one driven rear axle, non-steered leading axle

6x4H/4 Three-axle vehicle with MAN HydroDrive® front axle drive, one driven rear axle, steered leading axle

6x4H-2 Three-axle vehicle with MAN HydroDrive® front axle drive, one driven rear axle, non-steered trailing axle

6x4H-4 Three-axle vehicle with MAN HydroDrive® front axle drive, one driven rear axle, steered trailing axle

TRUCKNOLOGY® GENERATION A (TGA)

8

Table 2: TGA wheel formulae (continuation)

6×6 Three-axle vehicle with all-wheel drive

6×6-4 Three-axle vehicle with all-wheel drive, steered and driven trailing axle

6x6H Three-axle vehicle with all-wheel drive, front axle with MAN HydroDrive®

8×2-4 Four-axle vehicle with one drive axle, two steered front axles, non steered trailing axle or four-axle vehicle with three rear axles with front and trailing axles steered

8×2-6 Four-axle vehicle with one drive axle, two steered front axles, steered trailing axle

8×4 Four-axle vehicle with two steered front axles and two driven rear axles

8×4/4 Four-axle vehicle with one front axle, one steered leading axle and two driven rear axles

8×4-4 Four-axle vehicle with one front axle, two driven rear axles and one steered trailing axle

8x4H-4 Four-axle vehicle with two steered front axles (2nd front axle with MAN HydroDrive®), one driven rear axle and a non-steered trailing axle

8x4H-6 Four-axle vehicle with two steered front axles (2nd front axle with MAN HydroDrive®), one driven rear axle and a steered trailing axle

8×6 Four-axle vehicle “All wheel drive” with two front axles (2nd driven) and two driven rear axles

8x6H Four-axle vehicle “All wheel drive” with two front axles (2nd front axle with MAN HydroDrive®) and two driven rear axles

8×8 Four-axle vehicle “All wheel drive” with two front axles and two rear axles, all driven

2.1.4Suffix

The suffi x to the vehicle designation defi nes the type of suspension, differentiates trucks from tractor units and describes special product features.

T G A 2 5 . 4 8 0 6 x 2 — 2

LL-U

Suffi x

Types of suspension (Digits 1 and 2 of suffi x)

Table 3:

Types of suspension

BB

Leaf suspension on front axle(s), leaf suspension on rear axle(s)

BL

Leaf suspension on front axle(s), air suspension on rear axle(s)

LL

Air suspension on front axle(s), air suspension on rear axle(s)

BH

Leaf suspension on front axle(s), hydropneumatic on rear axle(s)

Semitrailer tractor units are designated with an ‘S’ suffi x. Trucks have no special designation.

Example for semitrailer tractor:

T G A 3 3 . 4 4 0 6 x 6

BBS

S = Semitrailer tractor

TRUCKNOLOGY® GENERATION A (TGA)

9

Special product (design) features are added separately following a hyphen ‘-’ after the fi rst section of the suffi x:

Example for special product features:

T G A 1 8 . 3 5 0 4 x 2 B L S

-TS

-TS = Weight optimised version for silo tanker

Table 4:

Designations for special designs produced to-date (to be supplemented with further designs)

-U

For low design ‘Ultra’ e.g.: TGA 18.410 4×2 LLS-U

-TS

Weight optimised version for silo tanker, e.g.: TGA 18.400 4×2 BLS-TS

-WW

“World wide” variant, eligible for licensing outside Europe only, e.g. TGA 40.460 6×6 BB-WW

-LE

“Low entry” cab with lowered entry, e.g.: TGA 28.310 6×2-4 LL-LE

-CKD

“Completely knocked down”, for assembly in MAN factory of the recipient country, e.g.: TGA 40.480 6×4-4 WW-CKD

2.2Model number, vehicle identification number, vehicle number, basic vehicle number

The three-digit model number, also called model code, provides a technical identifi cation of the MAN chassis and also identifi es

to which vehicle range it belongs. This number is part of the 17-digit vehicle identifi cation number (VIN) and is located at digits 4 to 6 in the VIN. The basic vehicle number, formulated for sales purposes, also contains the model number at digits 2 to 4.

The seven-fi gure vehicle number describes the technical equipment on a vehicle; it contains the model number at digits 1 to 3, followed by a four-digit sequential number. The vehicle number is to be found in the vehicle papers and on the vehicle’s manufacturing plate. The vehicle number can be quoted instead of the 17-digit vehicle identifi cation number in the event of any technical queries regarding conversions and bodies. Table 5 gives some examples of the model number, vehicle identifi cation number, basic vehicle number and vehicle number.

Table 5: Example vehicle designation, model number, vehicle identifi cation number, basic vehicle number and vehicle number

Vehicle designation

Model number

Vehicle identifi cation number

Basic vehicle

Vehicle number

Model code

(VIN)

number

TGA 18.440 4×2 BLS

H06

WMAH06ZZ14M000479

LH06AG53

H060057

TGA 26.410 6×2-4 LL

H21

WMAH21ZZ94G144924

LH21E 05

H210058

TGA 33.540 6×4 BB

H26

WMAH26ZZ75M350354

LH26LR04

H261158

Up to the date of going to press (03/2007) the Trucknology® Generation A or TGA for short, comprises the following model numbers:

TRUCKNOLOGY® GENERATION A (TGA)

10

Table 6: Model numbers, tonnage class, vehicle designation and suspension on the TGA

Model number

Tonnage

Designation , xxx stands for

Engine

Suspension

various engine powers

H01

18 t

TGA 18.xxx 4×2 BLS-TS

D28 R6

BL

H02

18 t

TGA 18.xxx 4×2 BB

D28 R6

BB

H03

18 t

TGA 18.xxx 4×2 BB

D20/D26 R6

BB

H05

18 t

TGA 18.xxx 4×2 BL

D28 R6

BL

H06

18 t

TGA 18.xxx 4×2 BL

D20/D26 R6

BL

H07

18 t

ECT 18.ISM 4×2 BL

ISMe

BL

H08

18 t

TGA 18.xxx 4×2 BLS-TS

D20/D26 R6

BL

H09

18 t

TGA 18.xxx 4×2 LL

D28 R6

LL

H10

18 t

TGA 18.xxx 4×2 LL

D20/D26 R6

LL

H11

40 t

TGA 40.xxx 6×4 BB-WW-CKD

D20/D26 R6

BBB

H12

18 t

TGA 18.xxx 4×2 LLS-U

D28 R6

LL

H13

18 t

TGA 18.xxx 4×2 LLS-U

D20/D26 R6

LL

H14

18 t

TGA 18.xxx 4×2 LL-U

D28 R6

LL

H15

18 t

TGA 18.xxx 4×2 LL-U

DD20/D26 R6

LL

H16

26 t

TGA 26.xxx 6×2-4 BL

D08 R6

BLL

H17

26 t

TGA 26.xxx 6×2-2, 6×2-4 BL

D28 R6

BLL

H18

26 t

TGA 26.xxx 6×2-2, 6×2-4 BL

D20/D26 R6

BLL

H19

26 t

TGA 26.xxx 6×2-4 LL

D08 R6

LLL

H20

26 t

TGA 26.xxx 6×2-2, 6×2-4 LL

D28 R6

LLL

H21

26 t

TGA 26.xxx 6×2-2, 6×2-4 LL

D20/D26 R6

LLL

H22

18 t

TGA 18.xxx 4x4H BL

D20/D26 R6

BL

H23

26 t

TGA 26.xxx 6×2/2, 6×2/4 BL

D28 R6

BLL

H24

26 t

TGA 26.xxx 6×2/2, 6×2/4 BL

D20/D26 R6

BLL

H25

26/33 t

TGA 26/33.xxx 6×4 BB

D28 R6

BBB

H26

26/33 t

TGA 26/33.xxx 6×4 BB

D20/D26 R6

BBB

H27

26 t

ECT 26.ISM 6×2-2, 6×2-4 BL

ISMe

BLL

H28

33 t

TGA 33.xxx 6×4 BB-WW

D28 R6

BBB

H29

26/33 t

TGA 26/33.xxx 6×4 BL

D28 R6

BLL

H30

26/33 t

TGA 26/33.xxx 6×4 BL

D20/D26 R6

BLL

H31

26 t

ECT 26.ISM 6×2-2 LL

ISMe

LLL

H32

26 t

ECT 26.ISM 6×2/2 BL

ISMe

BLL

H33

40 t

TGA 40.xxx 6×4 BB-WW

D28 R6

BBB

H34

40 t

TGA 40.xxx 6×4 BB-WW

D20/D26 R6

BBB

H35

26 t

TGA 26.xxx 6x4H-2 BL, 6x4H-4 BL

D20/D26 R6

BLL

H36

35 t

TGA 35.xxx 8×4 BB

D28 R6

BBBB

H37

35 t

TGA 35.xxx 8×4 BB

D20/D26 R6

BBBB

TRUCKNOLOGY® GENERATION A (TGA)

11

Model number

Tonnage

Designation , xxx stands for

Engine

Suspension

various engine powers

H38

41 t

TGA 41.xxx 8×4 BB

D28 R6

BBBB

H39

41 t

TGA 41.xxx 8×4 BB

D20/D26 R6

BBBB

H40

35 t

TGA 35.xxx 8×4 BL

D28 R6

BBLL

H41

35 t

TGA 35.xxx 8×4 BL

D20/D26 R6

BBLL

H42

26 t

TGA 26.xxx 6x4H/2 BL, 6x4H/4 BL

D20/D26 R6

BLL

H43

19 t

TGA 19.xxx 4×2 BBS-WW

D28 R6

BB

H44

25 t

TGA 25.xxx 6×2-2 LL-U

D28 R6

LLL

H45

25 t

TGA 25.xxx 6×2-2 LL-U

D20/D26 R6

LLL

H46

41 t

TGA 41.xxx 8×4 BB-WW

D28 R6

BBBB

H47

26/33 t

TGA 26/33.xxx 6x6H BB

D20/D26 R6

BBB

H48

32 t

TGA 32.xxx 8×4 BB

D28 R6

BBBB

H49

32 t

TGA 32.xxx 8×4 BB

D20/D26 R6

BBBB

H50

35 t

TGA 35.xxx 8x6H BB

D20/D26 R6

BBBB

H51

18 t

TGA 18.xxx 4×4 BB

D28 R6

BB

H52

18 t

TGA 18.xxx 4×4 BB

D20/D26 R6

BB

H54

33 t

TGA 33.xxx 6×6 BB-WW

D28 R6

BBB

H55

26/33 t

TGA 26/33.xxx 6×6 BB

D28 R6

BBB

H56

26/33 t

TGA 26/33.xxx 6×6 BB

D20/D26 R6

BBB

H57

40 t

TGA 40.xxx 6×6 BB-WW

D28 R6

BBB

H58

40 t

TGA 40.xxx 6×6 BB-WW

D20/D26 R6

BBB

H59

35 t

TGA 35.xxx 8x6H BL

D20/D26 R6

BBLL

H60

19 t

TGA 19.xxx 4×2 BBS-WW-CKD

D28 R6

BB

H61

18 t

TGA 18.xxx 4×2 BLS-WW-CKD

D28 R6

BL

H62

33 t

TGA 33.xxx 6×4 BB-WW-CKD

D28 R6

BBB

H63

26 t

TGA 26.xxx 6×4 BL-WW-CKD

D28 R6

BLL

H64

19 t

TGA 19.xxx 4×2 BBS-WW-CKD

D20/D26 R6

BB

H65

18 t

TGA 18.xxx 4×2 BLS-WW-CKD

D20/D26 R6

BL

H66

33 t

TGA 33.xxx 6×4 BB-WW-CKD

D20/D26 R6

BBB

H67

26 t

TGA 26.xxx 6×4 BL-WW-CKD

D20/D26 R6

BLL

H68

40 t

TGA 40.xxx 6×4 BB-WW-CKD

D28 R6

BBB

H69

39 t

TGA 39.xxx 8×2-4 BL

D20/D26 R6

BBLL

H70

18 t

TGA 18.xxx 4×4 BL

D28 R6

BL

H71

28 t

TGA 28.xxx 6×2-4 BL

D28 R6

BLLLLL

TGA 28.xxx 6×2-4 LL

H72

26/33 t

TGA 26/33.xxx 6×6 BL

D28 R6

BLL

H73

35/41 t

TGA 35/41.xxx 8×6 BB

D28 R6

BBBB

H74

28 t

TGA 28.xxx 6×2-4 BL

D20/D26 R6

BLL

H75

28 t

TGA 28.xxx 6×2-4 LL

D20/D26 R6

LLL

H76

35/41 t

TGA 35/41.xxx 8×8 BB

D28 R6

BBBB

H77

28 t

TGA 28.xxx 6×4-4 BL

D20/D26 R6

BLL

H80

18 t

TGA 18.xxx 4×4 BL

D20/D26 R6

BL

TRUCKNOLOGY® GENERATION A (TGA)

12

Model number

Tonnage

Designation , xxx stands for

Engine

Suspension

various engine powers

H81

28 t

TGA 28.xxx 6×4-4 BL

D28 R6

BLL

H82

26/33 t

TGA 26/33.xxx 6×6 BL

D20/D26 R6

BLL

H83

28 t

TGA 28.xxx 6×6-4 BL

D20/D26 R6

BLL

H84

28 t

TGA 28.xxx 6×4-4 BL

D20/D26 R6

BLL

H85

28 t

TGA 28.xxx 6×2-2 LL

D20/D26 R6

LLL

H86

28 t

TGA 28.xxx 6×2-2 BL

D28 R6

BLL

H87

28 t

TGA 28.xxx 6×2-2 LL

D28 R6

LLL

H88

35 t

TGA 35.xxx 8×2-4, 8×2-6 BL

D28 R6

BBLL

H89

28 t

TGA 28.xxx 6×2-2 BL

D20/D26 R6

BLL

H90

35 t

TGA 35.xxx 8×2-4, 8×2-6 BL

D20/D26 R6

BBLL

H91

35 t

TGA 35.xxx 8×4-4 BL

D28 R6

BLLL

H92

35 t

TGA 35.xxx 8×4-4 BL

D20/D26 R6

BLLL

H93

35/41 t

TGA 35/41.xxx 8×6 BB

D20/D26 R6

BBBB

H94

41 t

TGA 41.xxx 8×4/4 BB

D28 R6

BLBB

TGA 41.xxx 8×4/4 BL

BLLL

H95

41 t

TGA 41.xxx 8×4/4 BB

D28 V10

BLBB

TGA 41.xxx 8×4/4 BL

BLLL

H96

35/41 t

TGA 35/41.xxx 8×8 BB

D20/D26 R6

BBBB

H97

18 t

TGA 18.xxx 4×2 LL-LE

D20/D26 R6

LL

H98

26 t

TGA 26.xxx 6×2/4 LL-LE

D20/D26 R6

LLL

H99

28 t

TGA 28.xxx 6×2-4 LL-LE

D20/D26 R6

LLL

HH1

26/33 t

TGA 26/33.xxx 6x6H BL

D20/D26 R6

BLL

HH2

28 t

TGA 28.xxx 6x4H-4

D20/D26 R6

BLL

HH4

35 t

TGA 35.xxx 8x4H-4, 8x4H-6 BL

D20/D26 R6

BBLL

HV1

26 t

TGA 26.xxx 6X2-2, 6X2-4 BL-WW

D20/D26 R6

BLL

HV2

26/33 t

TGA 26/33.xxx 6X4 BL-WW

D20/D26 R6

BLL

HV3

39 t

TGA 39.xxx 8X2-4 BL-WW

D20 R6

BBLL

HV4

28 t

TGA 28.xxx 6X2-2 BL-WW

D20/D26 R6

BLL

HV5

18 t

TGA 18.xxx 4X4 BB-WW

D20 R6

BB

HV6

35/41 t

TGA 35/41.xxx 8X8 BB-WW

D20 R6

BBBB

HV7

28 t

TGA 28.xxx 6X2-2 BL-WW-CKD

D20/D26 R6

BLL

HV8

32 t

TGA 32.xxx 8X4 BB-WW

D20 R6

BBBB

HW1

19 t

TGA 19.xxx 4×2 BBS-WW

D20/D26 R6

BB

HW2

33 t

TGA 33.xxx 6×4 BB-WW

D20/D26 R6

BBB

HW3

41 t

TGA 41.xxx 8×4 BB-WW

D20/D26 R6

BBBB

HW4

33 t

TGA 33.xxx 6×6 BB-WW

D20/D26 R6

BBB

HW5

19 t

TGA 19.xxx 4×2 BLS-WW-CKD

D20/D26 R6

BL

HW6

41 t

TGA 41.xxx 8×4 BB-WW-CKD

D20/D26 R6

BBBB

HW7

19 t

TGA 19.xxx 4×2 BLS-WW

D20/D26 R6

BL

HW8

33 t

TGA 33.xxx 6×4 BBS-WW

D20/D26 R6

BBB

HW9

33 t

TGA 33.xxx 6×4 BBS-WW-CKD

D20/D26 R6

BBB

TRUCKNOLOGY® GENERATION A (TGA)

13

2.3Use of logos

MAN logos on the chassis may not be removed or modifi ed in any way without prior approval from MAN.

Modifi cations to the chassis or body that do not conform with this Guide to Fitting Bodies and that have not received MAN approval by the ESC department (for address see „Publisher“ above) must receive a new vehicle identifi cation number (VIN) from the manufacturer responsible for the modifi cation (normally the vehicle conversion company).

In such cases where the chassis/vehicle has received a new VIN, the logos on the radiator grille (MAN lettering, lion emblem) and the doors (door designation – see Section 2.1.1) must be removed.

TRUCKNOLOGY® GENERATION A (TGA)

14

2.4Cabs

There are 6 different Trucknology® Generation A cabs:

Table 7:

Trucknology® Generation A cabs

Description

Dimensions*

Views

Name

Technical

Length

Width

High roof

Side

Front

description

M

LHD

1.880

2.240

F99L15S

RHD

F99R15S

L

LHD

2.280

2.240

F99L32S

RHD

F99R32S

LX

LHD

2.280

2.240

yes

F99L37S

RHD

F99R37S

*) Dimensions refer to the cab without attachments such as mudguards, front spoiler, mirrors, roof spoiler etc.

TRUCKNOLOGY® GENERATION A (TGA)

15

Description

Dimensions*

Views

Name

Technical

Length

Width

High roof

Side

Front

description

XL

LHD

2.280

2.440

F99L40S

RHD

F99R40S

XLX

LHD

2.280

2.440

yes, low

F99 L47 S

RHD

F99 R47 S

XXL

LHD

2.280

2.440

yes

F99L41S

RHD

F99R41S

*) Dimensions refer to the cab without attachments such as mudguards, front spoiler, mirrors, roof spoiler etc.

TRUCKNOLOGY® GENERATION A (TGA)

16

2.5Engine variants

In-line six-cylinder Diesel engines (R6) and a V10 with 4-valve technology from the D28 family of engines are installed in the TGA (D28 = 1st – 3rd digits of the engine designation). Engines with common rail injection are new additions to the range.

The engine programme has been extended since 2004 with two further engine ranges – the well known engines from the D08 range and the new D20 Common Rail range that are also available as Euro 4 engines with the PM-Kat®. Cummins engines of the ISMe range are only installed in ERF brand trucks (see table 6, model numbers).

Table 8: TGA engines/engine designations D08D08 / D20 / D26 / D28

Vehicle

Emission

Power [kW]

OBD

EGR

Exhaust gas

Max. torque

Engine

Engine

designation

class

at [rpm]

generation

after treatment

[Nm] / at [rpm]

type

designation

xx.280

206 kW / 2.400

1.100 at 1.200 — 1.800 rpm

D0836LF41

xx.330

240 kW / 2.400

1.250 at 1.200 — 1.800 rpm

D0836LF44

xx.310

228 kW / 1.900

1.500 at 900 — 1.300 rpm

D2866LF26

xx.310

228 kW / 1.900

1.550 at 1.000 — 1.300 rpm

D2066LF04

xx.360

265 kW / 1.900

1.700 at 900 — 1.400 rpm

D2866LF27

xx.350

257 kW / 1.900

1.750 at 1.000 — 1.300 rpm

D2066LF03

xx.410

301 kW / 1.900

1.850 at 900 — 1.300 rpm

R6

D2866LF28

xx.390

287 kW / 1.900

1.900 at 1.000 — 1.300 rpm

D2066LF02

xx.430

Euro 3

316 kW / 1.900

None

2.100 at 1.000 — 1.300 rpm

D2066LF01

xx.460

338 kW / 1.900

2.100 at 900 — 1.300 rpm

D2876LF04

xx.510

375 kW / 1.900

No OBD

2.300 at 1.000 — 1.300 rpm

D2876LF05

xx.480

353 kW / 1.900

2.300 at 1.000 — 1.400 rpm

D2876LF12

xx.530

390 kW / 1.900

2.400 at 1.000 — 1.400 rpm

D2876LF13

xx.660

485 kW / 1.900

With

2.700 at 1.000 — 1.600 rpm

V10

D2840LF25

xx.360

265 kW / 1.900

1.800 at 1.000 — 1.400 rpm

D2066LF48

AGR

xx.400

294 kW / 1.900

1.900 at 1.000 — 1.400 rpm

D2066LF49

xx.440

324 kW / 1.900

2.100 at 1.000 — 1.400 rpm

D2066LF50

xx.480

353 kW / 1.900

2.300 at 1.050 — 1.400 rpm

D2676LF31

xx.310

228 kW / 1.900

1.550 at 1.000 — 1.400 rpm

D2066LF14

xx.350

257 kW / 1.900

1.750 at 1.000 — 1.400 rpm

D2066LF13

xx.390

287 kW / 1.900

1.900 at 1.000 — 1.400 rpm

D2066LF12

xx.430

316 kW / 1.900

2.100 at 1.000 — 1.400 rpm

R6

D2066LF11

xx.320

235 kW / 1.900

1.600 at 1.000 — 1.400 rpm

D2066LF35

Euro 4

PM-Kat®

xx.360

265 kW / 1.900

1.800 at 1.000 — 1.400 rpm

D2066LF33

xx.400

294 kW / 1.900

OBD 1

1.900 at 1.000 — 1.400 rpm

D2066LF32

xx.440

324 kW / 1.900

2.100 at 1.000 — 1.400 rpm

D2066LF31

xx.480

353 kW / 1.900

2.300 at 1.050 — 1.400 rpm

D2676LF01

xx.320

235 kW / 1.900

OBD 1 +

1.600 at 1.000 — 1.400 rpm

D2066LF39

NOX control

TRUCKNOLOGY® GENERATION A (TGA)

17

Vehicle

Emission

Power [kW]

OBD

EGR

Exhaust gas

Max. torque

Engine

Engine

designation

class

at [rpm]

generation

after treatment

[Nm] / at [rpm]

type

designation

xx.360

Euro 4

265 kW / 1.900

OBD 1 +

With

PM-Kat®

1.800 at 1.000 — 1.400 rpm

D2066LF38

xx.400

294 kW / 1.900

NOX control

EGR

1.900 at 1.000 — 1.400 rpm

D2066LF37

xx.440

324 kW / 1.900

2.100 at 1.000 — 1.400 rpm

D2066LF36

xx.480

353 kW / 1.900

2.300 at 1.050 — 1.400 rpm

D2676LF05

xx.400

294 kW / 1.900

NO OBD

1.900 at 1.000 — 1.400 rpm

D2066LF22

xx.440

321 kW / 1.900

2.100 at 1.000 — 1.400 rpm

D2066LF21

xx.400

294 kW / 1.900

1.900 at 1.000 — 1.400 rpm

D2066LF24

xx.440

324 kW / 1.900

OBD 1

2.100 at 1.000 — 1.400 rpm

D2066LF23

xx.480

353 kW / 1.900

2.300 at 1.050 — 1.400 rpm

D2676LF12

xx.540

397 kW / 1.900

2.500 at 1.050 — 1.350 rpm

D2676LF11

xx.320

235 kW / 1.900

1.600 at 1.000 — 1.400 rpm

R6

D2066LF28

xx.360

265 kW / 1.900

1.800 at 1.000 — 1.400 rpm

D2066LF27

xx.400

Euro 5

294 kW / 1.900

No

SCR

1.900 at 1.000 — 1.400 rpm

D2066LF26

xx.440

324 kW / 1.900

EGR

2.100 at 1.000 — 1.400 rpm

D2066LF25

xx.480

353 kW / 1.900

2.300 at 1.050 — 1.400 rpm

D2676LF14

xx.540

397 kW / 1.900

OBD 1 +

2.500 at 1.050 — 1.350 rpm

D2676LF13

xx.320*

235 kW / 1.900

NOX control

1.600 at 1.000 — 1.400 rpm

D2066LF20

xx.360*

265 kW / 1.900

1.800 at 1.000 — 1.400 rpm

D2066LF19

xx.400*

294 kW / 1.900

1.900 at 1.000 — 1.400 rpm

D2066LF18

xx.440*

324 kW / 1.900

2.100 at 1.000 — 1.400 rpm

D2066LF17

xx.480*

353 kW / 1.900

2.300 at 1.050 — 1.400 rpm

D2676LF16

xx.540*

397 kW / 1.900

2.500 at 1.050 — 1.350 rpm

D2676LF15

* = In case of NOX system failure, engines fi tted with OBD 1b or OBD 2 are without torque reduction (TR). Only applies to engines for fi re services, rescue services and military vehicles in accordance with Annex I.6558 of Directive 2005/55/EC, version 2006/81/EC

3.General

National and international regulations take priority over technically permissible dimensions and weights if they limit the technically permissible dimensions and weights. The following data can be obtained from the quotation documents and documents contained in MANTED® at www.manted.de:

Dimensions

Weights

Centre of gravity position for payload and body (minimum and maximum position for body) for the production standard chassis / tractor unit.

The data contained in these documents may vary depending on what technical features the vehicle is actually fi tted with upon delivery. The critical factor is the vehicle’s actual confi guration and condition at the time delivery.

To achieve optimum payload carrying capability the chassis must be weighed before work starts on the body.

Calculations can then be made to determine the best centre of gravity position for payload and body as well as the optimum body length. As a result of component tolerances the weight of the standard chassis is allowed to vary by ± 5%, in accordance with DIN 70020. Any deviations from the standard equipment level will have a greater or lesser effect on dimensions and weights.

Changes in equipment may result in deviations in the dimensions and weights, particularly if different tyres are fi tted that then also lead to a change in the permissible loads.

TRUCKNOLOGY® GENERATION A (TGA)

18

In each individual case when a body is fi tted care needs to be taken to ensure the following

Under no circumstances may the permissible axle weights be exceeded

A suffi cient minimum front axle load is achieved

The position of the centre of gravity and loading must not be one-sided

The permissible overhang (vehicle overhang) is not exceeded.

3.1Axle overload, one-sided loading

Fig. 1: Overloading the front axle ESC-052

Fig. 2: Difference in wheel load ESC-126

G G

Formula 1: Difference in wheel load

∆G ≤ 0,05 • Gtat

The body must be designed such that one-sided wheel loads do not occur. Following checks, a maximum wheel load difference of 5 %

is permitted (where 100 % represents the actual axle load and not the permissible axle load).

TRUCKNOLOGY® GENERATION A (TGA)

19

Example:

Actual axle load Gtat = 11.000kg

Therefore, the permissible wheel load difference is:

∆G

=

0,05 Gtat = 0,05 · 11.000 kg

∆G

=

550 kg

This means for example that the wheel load on one side is 5,225 kg and 5,775 kg on the other.

The calculated maximum wheel load provides no information on the permissible individual wheel load for the tyres fi tted. Information on this can be found in the technical manuals supplied by the tyre manufacturers.

3.2Minimum front axle load

In order to maintain steerability, the stipulated minimum front axle load must be ensured under all vehicle load conditions, see table 11.

Fig. 3: Minimum front axle loading ESC-051

TRUCKNOLOGY® GENERATION A (TGA)

20

Table 9: Minimum front axle loading for any load condition as a % of the respective actual vehicle weight

Minimum front axle loading for any load condition as a % of the respective actual vehicle weight

SDAH = Rigid drawbar trailer ZAA = Centre-axle trailer

GVW = Gross vehicle weight (vehicle/trailer)

Number of axles

Wheel formula

Without SDAH

With SDAH /ZAA

Tridem SDAH /ZAA

Other rear load

/ZAA

GG ≤ 18 t

GG > 18 t

e.g. crane

Two-axle vehicle

4×2, 4x4H

25 %

25 %

30 %

30 %

4×4

More than 2 axles

6×2/2, 6×2/4

20 %*

25 %*

30 %*

25 %*

Three axle vehicles with lifting

6×2-2, 6×2-4

leading or trailing axles must be

6×4, 6×4-4

treated as having two axles when

6x4H/2, 6x4H/4

the lifting axles are raised. In this

6x4H-2, 6x4H-4

condition the higher minimum

6×6, 6x6H

front axle load for two axle vehi-

8×2-4, 8×2-6

cles applies.

8×4, 8×4/4,

8×4-4

8x4H-6, 8×6,

8x6H, 8×8

If more than one front axle is fi tted the % value is the total of the front axle loads. When operating with rigid drawbar trailers / centreaxle trailers + additional rear loads (e.g. tail-lift, crane) the higher value should be applied *= -2 % for steered leading/trailing axles

These values are inclusive of any additional rear loads such as: Nose weights exerted by a centre-axle trailer

loading cranes

tail lifts

fork lift trucks.

3.3Wheels, rolling circumference

Different tyre sizes on the front and rear axle(s) can only be fi tted to all-wheel-drive vehicles if the difference in rolling circumference of the tyres used does not exceed 2% or 1.5% if the MAN HydroDrive® system is installed. The notes in Chapter 5 “Body” relating to anti-skid chains, load rating and clearance must be observed.

3.4Permissible overhang

The permissible overhang length is defi ned as the distance between the rear axle centreline (resulting from the theoretical wheelbase) and the end of the vehicle (including the bodywork). For defi nition see the following the following paragraph 3.5.

The following maximum values are permitted, expressed as a percentage of the theoretical wheelbase

Two-axle vehicles 65 %

all other vehicles 70 %.

If the vehicle is not equipped to tow trailers the above values may be exceeded by 5 %.

The basic requirement is that the minimum front axle loads given in table 9 (par. 3.2.) must be observed for every operating condition.

TRUCKNOLOGY® GENERATION A (TGA)

21

3.5Theoretical wheelbase, overhang, theoretical axle centreline

The theoretical wheelbase is an aid for calculating the position of the centre of gravity and the axle loads. The defi nition is given in the following fi gures.

Fig. 4: Theoretical wheelbase and overhang – two-axle vehicle ESC-046

Theoretical rear axle centreline

l12= lt ut

G G

G G

permissible1zul1

permissible2zul2

Formula 2: Theoretical wheelbase for a two-axle vehicle

lt = l12

Formula 3: Permissible overhang for a two-axle vehicle

Ut ≤ 0,65 • lt

Fig. 5: Theoretical wheelbase and overhang for a three-axle vehicle with two rear axles and identical rear axle loads ESC-047

Theoretical rear axle centreline

l12

l23

G

Gzul1

G G

G G

permissible1

lt

permissible2zul2

permissible3zul3

ut

TRUCKNOLOGY® GENERATION A (TGA)

22

Formula 4: Theoretical wheelbase for a three-axle vehicle with two rear axles and identical rear axle loads

lt = l12 + 0,5 • l23

Formula 5: Permissible overhang for a three-axle vehicle with two rear axles and identical rear axle loads

Ut ≤ 0,70 • lt

Fig. 6: Theoretical wheelbase and overhang for a three-axle vehicle with two rear axles and different rear axle loads (e.g. in the MAN vehicle range all 6×2’s) ESC-048

Theoretical rear axle centreline

l12

l23

G

G

G G

GG

permissible1zul1

lt

permissible2zul2

permissible3zul3

ut

Formula 6: Theoretical wheelbase for a three-axle vehicle with two rear axles and different rear axle loads

G permissible3 • l23

lt = l12 +

G permissible2 + G permissible3

Formula 7: Permissible overhang length three-axle vehicle with two rear axles and unequal rear axle loads

Ut ≤ 0,70 • lt

TRUCKNOLOGY® GENERATION A (TGA)

23

Fig. 7: Theoretical wheelbase and overhang for a four-axle vehicle with two front and two rear axles (any axle load distribution) ESC-050

Theoretical front axle centreline

Theoretical rear axle centreline

l12

l23

l34

Gpermissible1

Gpermissible2

Gpermissible3

Gpermissible4

lt

Ut

Formula 8: Theoretical wheelbase for a four-axle vehicle with two front and two rear axles (any axle load distribution)

lt = l23 +

Gpermissible1 • l12

+

Gpermissible4 • l34

Gpermissible1 + Gpermissible2

Gpermissible3 + Gpermissible4

Formula 9: Permissible overhang length for a four-axle vehicle with two front and two rear axles

Ut ≤ 0,70 • lt

3.6Calculating the axle load and weighing procedure

It is essential that an axle load calculation be completed in order to ensure correct design of the body.

Achieving optimum compatibility between bodywork and truck is only possible if the vehicle is weighed before any work on the body is commenced. The weights thus obtained are then taken as a basis for an axle load calculation. The weights given in the sales documents only apply to production standard vehicles. Manufacturing inaccuracies (within tolerances) may occur.

The vehicle must be weighed:

Without the driver

With a full fuel tank

With the handbrake released and the vehicle secured with chocks

If fi tted with air suspension, raise the vehicle to normal driving position

Lower any liftable axles

Do not actuate any moving-off aid.

TRUCKNOLOGY® GENERATION A (TGA)

24

Observe the following sequence when weighing a vehicle:

Two-axle vehicles

1st axle

2nd axle

whole vehicle as a check

Three-axle vehicles with two rear axles

1st axle

2nd together with 3rd axle

whole vehicle as a check

Four axle vehicle with two front and two rear axles

1st together with 2nd axle

3rd together with 4th axle

whole vehicle as a check

Four-axle vehicle with one front and three rear axles

1st axle

2nd together with 3rd and 4th axles

whole vehicle as a check.

3.7Checking and adjustment procedures once body has been fitted

On the TGA do not check or adjust:

ALB settings: No adjustments necessary once bodywork has been fi tted

Tachograph ‘MTCO’ – this has already been calibrated at the factory

Digital tachograph ‘DTCO’ – this has also been calibrated at the factory.

According to EU Directives however, a person authorised to carry out tests must enter the registration number (normally this has not been issued when the vehicle leaves the MAN factory).

Checking and adjustment procedures that must be completed by the bodybuilder once the body has been fi tted:

Basic beam alignment of the headlamps, see also Section 6.6 in this booklet for details

Check battery charge status according to the charging schedule, sign battery charging log. See also the Chapter “Electrics, electronics, wiring”

Check rear underride protection for compliance with statutory regulations, see Section 4.11.1” and adjust as necessary.

Check sideguards for compliance with statutory regulations (for dimensions see the Chapter “Modifying the chassis”) and adjust as necessary.

TRUCKNOLOGY® GENERATION A (TGA)

25

3.8Notes on MAN Hydrodrive®

MAN Hydrodrive® is a hydrostatic front axle drive that employs wheel hub motors. The system is selectable and operates in the speed range between 0 and 28 km/h. Vehicles fi tted with Hydrodrive® are legally regarded as off-road vehicles as defi ned by 70/156 EEC (as last amended by 2005/64/EU and 2005/66/EG).

The Hydrodrive® hydraulic circuit is solely approved for the regulated drive of the front axle and may not be used to supply other hydraulic systems. Modifi cations to the Hydrodrive® hydraulic system (including relocating pipework) may only be carried out by specifi cally authorised companies.

In the case of semi-trailer tippers and other bodies where there is a risk of the cargo falling into the area around the oil cooler an oil cooler cover must be fi tted. This is available fi tted ex-works or as a retrofi t solution under the name ‚Protective cover for oil cooler/fan for HydroDrive®’. (Installation no. 81.36000.8134).

4.Modifying the chassis

To provide customers with the products they want, additional components sometimes need to be installed, attached or modifi ed.

For uniformity of design and ease of maintenance, we recommend that original MAN components be used as long as these comply with the vehicle’s structural design. To keep maintenance work to a minimum, we recommend the use of components that have the same maintenance intervals as the MAN chassis.

Modifi cations to safety-critical components of wheel/axle guides, steering and brakes are not allowed. Existing anti-roll bars may neither be removed nor modifi ed.

Installation and/or modifi cation of components frequently requires intervention in the control unit’s CAN architecture (e.g. when extending the EBS electronic braking system). The necessary modifi cations and/or expansion of the vehicle programming are described under the corresponding topic in these guidelines.

Such modifi cations may only be undertaken with assistance from the electronics experts at MAN service centres and the programming must be approved by the ESC department (for address see “Publisher” above). Retrofi tted systems may, under certain circumstances, not be assimilated into the vehicles’ on-board Trucknology® systems “Time maintenance system” of “Flexible maintenance system”.

For this reason it is not possible to achieve the same degree of maintenance convenience as is possible with original equipment.

4.1Frame material

When carrying out modifi cations to the chassis longitudinal and cross-members only use of the original frame material S500MC (QStE 500TM) is approved.

Exception: For profi le 33, the longitudinal members are made of S420MC = QStE420TM.

Table 10: Steel for TGA frame

Material

Previous

Previous

σ0,2

σB

New material

New

Profi le codes as

number

material

standard

N/mm2

N/mm2

designation

standard

per table 11

designation

1.0980

QStE420TM

SEW 092

≥ 420

480-620

S420MC

DIN EN

33

10149-2

1.0984

QStE500TM

SEW 092

≥ 500

550-700

S500MC

DIN EN

31 32 34

10149-2

For subframe longitudinal and cross-members only steels with a yield point of σ0,2 ≥ 350 N/mm2 may be used. For additional details on subframes see the Subframe Chapter 5.3.3.

For the TGA the following longitudinal frame members are used, depending on the model.

TRUCKNOLOGY® GENERATION A (TGA)

26

Fig. 8: Profi le data for longitudinal frame members ESC-112

Bo

Surface centre of gravity S

h H

R

Bu

Table 11:

Profile data for longitudinal frame members, profi les in bold are used for the TGA range

No

H

h

Bo

Bu

t

R

G

σ0,2

σB

A

ex

ey

lx

Wx1

Wx2

ly

Wy1

Wy2

mm

mm

mm

mm

mm

mm

kg/m

N/mm2

N/mm2

Mm2

mm

mm

cm4

cm3

cm3

cm4

cm3

cm3

1

220

208

80

85

6

10

17

420

480..620

2.171

21

110

1.503

138

135

135

64

21

2

222

208

80

80

7

10

20

420

480..620

2.495

20

111

1.722

155

155

142

71

24

3

222

208

75

75

7

10

19

420

480..620

2.425

18

111

1.641

148

148

118

66

21

4

224

208

75

75

8

10

22

420

480..620

2.768

19

112

1.883

168

168

133

70

24

5

220

208

70

70

6

10

16

420

480..620

2.021

16

110

1.332

121

121

85

53

16

6

322

306

80

80

8

10

29

420

480..620

3.632

17

161

4.821

299

299

176

104

28

7

262

246

78

78

8

10

24

420

480..620

3.120

18

131

2.845

217

217

155

86

26

8

260

246

78

78

7

10

21

420

480..620

2.733

18

130

2.481

191

191

138

77

23

9

224

208

80

80

8

10

22

420

480..620

2.848

20

112

1.976

176

176

160

80

27

10

262

246

80

80

8

10

25

420

480..620

3.152

19

131

2.896

221

221

167

88

27

11

273

247

85

85

71)

62)

31

355

510

3.836

26

136

4.463

327

327

278

108

47

12

209

200

65

65

4,5

8

11

260

420

1.445

15

105

868

83

83

52

35

10

13

210

200

65

65

5

8

13

260

420

1.605

15

105

967

92

92

58

39

12

14

220

208

70

80

6

10

16

420

480..620

2.081

18

107

1.399

131

124

105

58

17

15

222

208

70

80

7

10

19

420

480..620

2.425

18

108

1.638

152

144

120

67

19

16

234

220

65

65

7

8

19

420

480..620

2.381

15

117

1.701

145

145

80

53

16

17

220

208

75

75

6

10

16

420

480..620

2.081

18

110

1.400

127

127

103

57

18

18

218

208

70

70

5

10

13

420

480..620

1.686

16

109

1.105

101

101

72

45

13

19

222

208

70

70

7

10

18

420

480..620

2.355

17

111

1.560

141

141

97

57

18

20

260

246

70

70

7

10

21

420

480..620

2.621

15

130

2.302

177

177

101

67

18

21

210

200

65

65

5

8

13

420

480..620

1.605

15

105

967

92

92

58

39

12

22

330

314

80

80

8

10

29

420

480..620

3.696

17

165

5.125

311

311

177

104

28

23

270

254

80

80

8

10

25

420

480..620

3.216

18

135

3.118

231

231

168

93

27

24

274

254

80

80

10

10

31

420

480..620

4.011

19

137

3.919

286

286

204

107

33

25

266

254

80

80

6

10

19

420

480..620

2.417

18

133

2.325

175

175

130

72

21

26

224

208

70

70

8

10

21

420

480..620

2.688

17

112

1.789

160

160

109

64

21

27

268

254

70

70

7

10

21

420

480..620

2.677

15

134

2.482

185

185

102

68

19

28

270

254

70

70

8

10

24

420

480..620

3.056

15

135

2.843

211

211

114

76

21

TRUCKNOLOGY® GENERATION A (TGA)

27

Table 11:

Profile data for longitudinal frame members, profi les in bold are used for the TGA range

No

H

h

Bo

Bu

t

R

G

σ0,2

σB

A

ex

ey

lx

Wx1

Wx2

ly

Wy1

Wy2

mm

mm

mm

mm

mm

mm

kg/m

N/mm2

N/mm2

Mm2

mm

mm

cm4

cm3

cm3

cm4

cm3

cm3

29

334

314

80

80

10

10

36

420

480..620

4.611

17

167

6.429

385

385

215

126

34

30

328

314

80

80

7

10

25

420

480..620

3.237

16

164

4.476

273

273

158

99

25

31

270

254

85

85

8

10

26

500

550..700

3.296

20

135

3.255

241

241

201

101

31

32

270

251

85

85

9,5

10

30

500

550..700

3.879

21

135

3.779

280

280

232

110

36

33

334

314

85

85

10

10

37

420

480..620

4.711

19

167

6.691

401

401

257

135

39

34

270

256

85

85

6,8

10

22

500

550..700

2.821

19

135

2.816

209

209

174

92

26

35

220

212

70

70

4

10

11

420

480..620

1.367

16

110

921

84

84

59

37

11

36

220

211

70

70

4,5

10

12

420

480..620

1.532

16

110

1.026

93

93

65

41

12

37

220

206

70

70

7

10

18

420

480..620

2.341

17

110

1.526

139

139

97

57

18

38

220

204

70

70

8

10

21

420

480..620

2.656

17

110

1.712

156

156

108

64

20

39

270

256

70

70

7

10

21

420

480..620

2.691

15

135

2.528

187

187

102

68

19

40

270

256

70

70

7

10

21

500

550..700

2.691

15

135

2.528

187

187

102

68

19

41

270

254

70

70

8

10

24

420

480…620

3.056

15

135

2.843

211

211

114

76

21

42

270

254

85

85

8

10

26

500

480…620

3.296

20

135

3.255

241

241

201

101

31

433

270

254

85

85

8

10

26

500

560…700

3.296

20

135

3.255

241

241

201

101

31

1)Upper and lower fl ange 13 mm thick

2)Outside radius 10 mm

3)LNE500 in accordance with Brazilian Standard NBR 6656:2008, for TGX in Latin America (status 03 2010: CKD types 28X. 88X)

Table 12 gives the standard model-related allocation of longitudinal frame members valid on the date of publication of this guide. No guarantee is given or implied as to the currentness or completeness of this data.

Up-to-date and binding instructions on the longitudinal frame member profi le to be used can be found in:

the chassis drawing

the technical data sheet

which can be found for the corresponding vehicle at www.manted.de under “Chassis”.

TRUCKNOLOGY® GENERATION A (TGA)

28

Table 12:

Model-related allocation of longitudinal frame member profi les for TGA

Tonnage

Vehicle

Suffi x

Model

Profi le code

Specifi cs

18 t

TGA 18.xxx 4×2

BLS-TS

H01

34

Tractor unit for tanker /Silo

BLS-TS

H08

BLS-TS

H11

BB

H02

31

BB

H03

BL

H05

BL

H06

BL

H07

LL

H09

LL

H10

LLS-U

H12

42

LLS-U

H13

31

LL-U

H14

LL-U

H15

BL-WW

H61

TGA 18.xxx 4×4

BB

H51

31

TGA 18.xxx 4x4H

BB

H52

BL

H22

BL

H70

BL

H80

19 t

TGA 19.xxx 4×2

BBS-WW

H43

32

BB-WW

H60

32

25 t

TGA 25.xxx 6×2-2, 6×2-4

LL-U

H44

31

LL-U

H45

26 t

TGA 26.xxx 6×2-2, 6×2-4

BL

H16

31

TGA 26.xxx 6x4H

BL

H17

BL

H18

LL

H19

LL

H20

LL

H21

BL

H35

BL

H27

LL

H31

26 t

TGA 26.xxx 6×2/2, 6×2/4

BL

H23

31

TGA 26.xxx 6x4H

BL

H24

BL

H32

BL

H42

26 t

TGA 26.xxx 6×4

BB

H25

31/32

Profi le 31 for wheelbase ≤ 3.900+1.400

BB

H26

Profi le 32 for wheelbase > 3.900+1.400

BL

H29

31

BL

H30

BL-WW

H63

26 t

TGA 26.xxx 6×6

BB

H55

31/32

Profi le 31 for wheelbase ≤ 3.900+1.400

TGA 26.xxx 6x6H

BB

H47

Profi le 32 for wheelbase > 3.900+1.400

BB

H56

BL

H72

BL

H82

TRUCKNOLOGY® GENERATION A (TGA)

29

Tonnage

Vehicle

Suffi x

Model

Profi le code

Specifi cs

28 t

TGA 28.xxx 6×2-4

BL, LL

H71

31

TA steered

LL

H85

TA with twin tyres

TGA 28.xxx 6×2-2

BL

H86

TA with twin tyres

LL

H87

TA with twin tyres

BL

H89

TA with twin tyres

28 t

TGA 28.xxx 6×4-4

BL

H81

31

TA steered

28 t

TGA 28.xxx 6×6-4

BL

H83

31

TA steered and driven

32 t

TGA 32.xxx 8×4

BB

H48

34

Only transport mixers and rear tippers

BB

H49

33 t

TGA 33.xxx 6×4

BB

H25

31/32

Profi le 31 for wheelbase ≤ 3.900+1.400

BB

H26

Profi le 32 for wheelbase > 3.900+1.400

BB-WW

H28

BB-WW

H62

BLBL

H29

31

H30

33 t

TGA 33.xxx 6×6

BB

H47

31/32

Profi le 31 for wheelbase ≤ 3.900+1.400

TGA 33.xxx 6x6H

BB-WW

H54

Profi le 32 for wheelbase > 3.900+1.400

BB

H55

BB

H56

BL

H72

BL

H82

35 t

TGA 35.xxx 8×2-4,

BL

H88

31

8×2-6

BL

H90

TGA 35.xxx 8×4

BB

H36

31

BB

H37

BL

H40

BL

H41

TGA 35.xxx 8×4-4

BL

H91

31

BL

H92

35 t

TGA 35.xxx 8×6

BB

H73

31

At permissible gross weights ≤ 35 t

BB

H93

35 t

TGA 35.xxx 8×8

BB

H76

31

At permissible gross weights ≤ 35 t

BB

H96

40 t

TGA 40.xxx 6×4

BB-WW

H33

32

BB

H34

40 t

TGA 40.xxx 6×6

BB-WW

H57

32

BB

H58

41 t

TGA 41.xxx 8×4

BB

H38

32

BB

H39

BB-WW

H46

41 t

TGA 41.xxx 8×4/4

BB, BLBB,

H94

33

BL

H95

41 t

TGA 41.xxx 8×6

FFDA

H73

32

At permissible gross weights > 35 t

FFDA

H93

TGA 41.xxx 8×8

FFDA

H76

32

At permissible gross weights > 35 t

FFDA

H96

TRUCKNOLOGY® GENERATION A (TGA)

30

4.2Corrosion protection

Surface and corrosion protection affects the service life and appearance of the product. In general, the quality of the coatings on body components should be equal to that of the chassis.

In order to fulfi l this requirement, the MAN Works Standard M 3297 “Corrosion protection and coating systems for non-MAN bodies” is binding for bodies that are ordered by MAN. If the customer commissions the body, this standard becomes a recommendation only. Should the standard not be observed, MAN provides no guarantee for any consequences.

MAN-works standards may be sourced via www.normen.man-nutzfahrzeuge.de, registration required.

Series production MAN chassis are coated with environmentally friendly, water-based 2-component chassis top-coat paints at approx. 80°C. To guarantee uniform coating, the following coating structure is required for all metal component assemblies on the body and subframe:

Bare metal or blasted component surface (SA 2.5)

Primer coat: 2-component epoxy primer, approved in accordance with MAN works standard M 3162-C or, if possible, cathodic dip painting to MAN works standard M 3078-2, with zinc phosphate pre-treatment

Top coat: 2-component top-coat paint to MAN works standard M 3094, preferably water-based; if there are no

facilities for this, then solvent-based paint is also permitted. (www.normen.man-nutzfahrzeuge.de, registration required).

Instead of priming and painting the vehicle with a top coat, the substructure of the body (e.g. longitudinal and cross-members, corner plates) may also be galvanised. See the relevant paint manufacturer’s data sheets for information on tolerances for drying and curing times and temperatures. When selecting and combining materials the compatibility of the different metals (e.g. aluminium and steel) must be taken into consideration as must the effects of the ‘electrochemical series’ (cause of contact corrosion).

After all work on the chassis has been completed:

Remove any drilling swarf

Remove burrs from the edges

Apply wax preservative to any cavities

Mechanical connections (e.g. bolts, nuts, washers, pins) that have not been painted over must be given optimum corrosion protection. To prevent the occurrence of salt corrosion whilst the vehicle is stationary during the body-building phase, all chassis must be washed with clean water to remove any salt residues as soon as they arrive at the body manufacturer’s premises.

4.3Drill holes, riveted joints and screw connections on the frame

If possible, use the holes already drilled in the frame. No drilling should be carried out in the fl anges of the longitudinal frame member profi les, i.e. in the upper and lower fl anges (see Fig. 9). The only exception to this is at the rear end of the frame, outside the area of all the parts fi tted to the frame that have a load-bearing function for the rearmost axle (see Fig. 10).

This also applies to the subframe.

TRUCKNOLOGY® GENERATION A (TGA)

31

Fig. 9:

Frame drill holes in the upper and lower fl ange ESC-155

Fig. 10:

Drill holes at frame end ESC-032

It is allowable to make drillings in the frame along its total useable length. However, the permissible distances between holes must be observed (see Fig. 11). After drilling, rub down all holes and remove any burrs.

Fig. 11: Distances between drill holes ESC-021

a ≥ 40 b ≥ 50 c ≥ 25

TGA: d ≤ 16

TRUCKNOLOGY® GENERATION A (TGA)

32

Several frame components and add-on components (e.g. corner plates with cross member, shear plates, platform corner pieces) are riveted to the frame during production. If modifi cations to these components need to be carried out afterwards, screw connections with a minimum strength class of 10.9 and mechanical locking device are permitted. MAN recommends double nip countersunk bolts/nuts to MAN standard M 7.012.04 (may be sourced via www.normen.man-nutzfahrzeuge.de). The manufacturer’s stipulated tightening torque must be observed. If double nip countersunk bolts are reinstalled then new bolts/nuts must be used on the tightening side.

The tightening side can be recognised by slight marks on the bolt’s nips or nut fl ange (see Fig. 12).

Fig. 12: Marks on the bolt’s nips on the tightening side ESC-216

Alternatively, it is possible to use high-strength rivets (e.g. Huck®-BOM, blind fasteners) – manufacturers’ installation instructions must be followed. The riveted joint must be at least equivalent to the screw connection in terms of design and strength.

In principle it is also possible to use fl ange bolts. MAN draws your attention to the fact that such fl ange bolts place high requirements on installation accuracy. This applies particularly when the grip length is short.

TRUCKNOLOGY® GENERATION A (TGA)

33

4.4Modifying the frame

4.4.1Welding the frame

As a rule, no welding work is to be carried out on the frame and axle mountings other than that described in these guidelines or in the MAN repair instructions. Welding work on components and assemblies that are subject to design approval (e.g. coupling devices, underride protection) may only be carried out by the design approval holder. Welding work on these components will otherwise lead to the withdrawal of the design approval!

Welders must have specialist knowledge in chassis welding. The workshop must therefore employ suitably trained and qualifi ed personnel to carry out the required welding work (e.g. in Germany, according to the DVS leafl ets 2510 – 2512 “Carrying out repair welding work on commercial vehicles”, available from the DVS publishing house).

The frames of MAN commercial vehicles are made from high-strength fi ne-grain steels. Welding work on the frame is only permitted using the respective original frame material; see Chapter 4.1. The fi ne-grain steels used during manufacture are well suited for welding. Performed by a qualifi ed welder, the MAG (metal-active gas) and MMA (manual metal arc) welding methods ensure high quality,

long lasting welded joints.

Recommended welding materials:

MAG SG 3 welding wire

EB 10 electrode.

It is important to prepare the area of the weld thoroughly before welding so that a high-quality joint can be achieved.

Heat-sensitive parts must be protected or removed. The areas where the part to be welded joins the vehicle and the earth terminal on the welding equipment must be bare; therefore any paint, corrosion, oil, grease, dirt, etc., must be removed.

Only direct current welding may be employed; note the polarity of the electrodes.

Pipes/wires (air, electric) in the vicinity of the weld must be protected against heat. It is better to remove them completely.

Fig. 13: Protecting heat-sensitive parts ESC-156

Plastic tube

Welding should not be attempted if the ambient temperature falls below +5°C.

No undercuts are to be made whilst carrying out welding work (see fi llet welds, Fig. 14). Cracks in the weld seam are not permitted. Joint seams on the longitudinal members are to be made as V or X seams in several passes. Vertical welds should be carried out from bottom to top (see Fig. 16).

TRUCKNOLOGY® GENERATION A (TGA)

34

Fig. 14:

Undercuts ESC-150

Fig. 15:

Welding at X and Y seam ESC-003

at least 2 passes

No undercuts

Root pass

Fig. 16: Vertical welds on the frame ESC-090

Direction of welding

To prevent damage to electronic assemblies (e.g. alternator, radio, FFR, EBS, EDC, ECAS), adhere to the following procedure:

Disconnect the positive and negative leads at the battery; join the loose ends of the cables together (- with +)

Turn on the battery master switch (mechanical switch) or bypass the electric battery master switch on the solenoid (disconnect cables and join together)

Attach the earth clip of the welding equipment directly to the area to be welded, ensuring there is good conductivity (see above)

If two parts are to be welded together, connect them together fi rst, ensuring good conductivity (e.g. connect both parts to the earth clip)

It is not necessary to disconnect electronic components and assemblies if the procedure detailed above is followed exactly.

TRUCKNOLOGY® GENERATION A (TGA)

35

4.4.2Modifying the frame overhang

If the rear overhang is modifi ed, the centre of gravity of the payload and the body shifts and, as a result, the axle loads change.

Only an axle load calculation can show whether this is within the permissible range. Such a calculation is therefore essential and must be carried out before beginning the work. The frame overhang may only be extended using the same material as was used for the frame during manufacture, see Chapter 4.1.

Extending the frame using several profi le sections is not permissible.

Fig. 17: Extending the frame overhang ESC-093

Frame extension

Frame extension

CAN wiring harnesses may never be cut and lengthened.

Pre-prepared wiring harnesses are available from MAN for rear lights, auxiliary rear lights, trailer sockets, side marker lamps and ABS cables. Detailed procedures are given the booklet ‘TG Interfaces’.

If it is intended to extend vehicles with short overhangs, the existing cross member between the rear spring hangers must be left in place.

An additional frame cross member must be fi tted if the distance between the cross members is more than 1,500 mm (see Fig. 18). A tolerance of +100 mm is permitted. There must always be an end cross member fi tted.

TRUCKNOLOGY® GENERATION A (TGA)

36

Fig. 18: Max. distance between frame cross members ESC-092

The rear frame end may be tapered (see Fig. 19).

The resulting reduced cross-section of the longitudinal frame member profi le must still be of suffi cient strength.

No taperings are allowed in the vicinity of the axle locating parts.

Fig. 19: Tapered frame end ESC-108

Interior height ≥ end cross member height

No taper in the area of axle location parts

If a frame overhang is shortened as far as the axle guide or suspension (e.g. rear spring hanger, stabiliser bracket) the cross members in this area (normally tubular cross-members) must either remain in place or be replaced with suitable original MAN end cross members (see Fig. 20).

TRUCKNOLOGY® GENERATION A (TGA)

37

Fig. 20: Frame end of a tractor unit ESC-503

4.4.3Modifications to the wheelbase

Technical design specifi cations applicable to steering (in particular 70/311 EEC, last amended by 2004/09/24) mean that, depending upon the number and type of steered axles, wheelbase, tyres axle loads and permissible gross weight, chassis of the TGA range are fi tted with different steering wheels (diameter), steering gear (range of ratios) and steering oil piping (cooling coils). Therefore, when considering wheelbase extensions the ESC Department at MAN (for address see “Publisher” above) should always be first consulted as to whether the planned change to the wheelbase will require other steering component modifications.

Parameterisation of the wheelbase modifi cation (see next paragraph) is only possible if the correct components have been installed. MAN shall not be liable for errors, made as a result of late consultations, that lead to increased cost. In addition, before commencing any work, an application must be made to the MAN repair shop for a conversion data fi le (vehicle parameterisation) quoting the new wheelbase. Parameterisation is carried out using the MAN-cats® diagnosis system.

Modifi cations to the wheelbase can be made by:

Moving the entire rear axle assembly

Disconnecting the longitudinal frame members and inserting or removing a section of frame.

Provided modifi cations are carried out in accordance with all of the following points, wheelbase modifi cations will have been carried out properly and approval will not be necessary.

TRUCKNOLOGY® GENERATION A (TGA)

38

The new wheelbase must remain between the minimum and maximum standard wheelbase for the same model according to model code (see Chapter 2.2, Table 5). Exceptions only with the approval of the ESC department (for address see “Publisher” above). The maximum distance between the cross members following a wheelbase modifi cation is 1,500 mm. A tolerance of +100 mm is

permitted. Any modifi cations to the driveshaft section of the driveline must be carried out according to the guidelines contained in this Guide to Fitting Bodies, see Chapter 4.6.3.1 and the instructions provided by the driveshaft manufacturer. If the new wheelbase is the same as a series wheelbase on a production model, then the arrangement of the driveshaft and cross members must be the same as that for a series wheelbase vehicle. Guidelines on moving air pipes and electric cables are contained in Chapter 6, “Electrics, electronics and wiring”). CAN wiring harnesses may not be cut, therefore when shortening the wheelbase, the wiring harness should simply be routed over a longer distance. Do not form rings or loops. During wheelbase extensions all rear axle related control units and sensors must be moved with the axle. Appropriate wiring harness adapters are therefore available for all rear axle related control units and sensors. System, method and item numbers are described in detail in the booklet ‘Interfaces TG’. Axle guide components and suspension (e.g. spring hangers, trailing arm brackets) may not be located in the area ahead of and within the bends in the frame, a minimum clearance of 100 mm to the 2nd frame break must be adhered to (see Fig. 21).

Fig. 21: Forbidden zone for rear axle locating parts ESC-500

On types with hydraulic forced steering of the trailing axle “ZF-Servocom® RAS” (all 6×2-4), depending upon the extent of the wheelbase modifi cation, steering arms with different steering angles must be installed on the 1st and 2nd axles, according to table 13.

Table 13: Steering arms for 6×2-4 with “ZF-Servocom® RAS” trailing axle steering

Wheelbase [mm]

Steering armitem no.

max. steering angle steering arm

1st –2nd axle

3.900 ≤ 4.200

81.46705.0508

19°

> 4.200 ≤ 4.800

81.46705.0004

16,5°

> 4.800 ≤ 5.500

81.46705.0509

14,5°

> 5.500

81.46705.0510

13,5°

On types fi tted with “ZF-Servocom® RAS-EC” electronic/hydraulic leading axle steering system (all 6×2/4 and 8×4/4 vehicles) extending the wheelbase is not possible – however shortening it is. Modifi cations to the steering system are inadmissible.

On vehicles with two mechanically steered front axles (e.g. 8×4) steered axles may only be moved by MAN vehicle modifi cation partners. This is because the steering system must be professionally modifi ed and only MAN vehicle modifi cation partners may receive the required software update.

TRUCKNOLOGY® GENERATION A (TGA)

39

Shortening the wheelbase is possible for these models if the guidelines listed here are followed.

Moving axles

The axle-mounting brackets, axle locating hardware and cross-members should be completed using rivets or MAN double nip countersunk bolts to MAN Standard M 7.012.04 (may be sourced via www.normen.man-nutzfahrzeuge.de) as described in Section 4.3. Observe the hole-to-hole distances specifi ed there!

Welding

The guidelines on welding in this Guide to Fitting Bodies (see Chapter 4.4.1) must be observed. If frame components are to be inserted, such as longitudinal frame members, frame inserts, the original frame material must be used. For frame materials see Chapter 4.1.

It is recommended that the longitudinal frame members are pre-heated to 150°C – 200°C.

The frame must not be disconnected in the vicinity of:

Points where loads are introduced from the body

Bends in the frame, minimum distance 100 mm

Axle guides and suspension (e.g. spring hangers, trailing arm mountings), minimum distance 100 mm

Transmission mountings (including transfer cases on all-wheel drive vehicles), engine mountings

The allowable area for welds when performing wheelbase modifi cations lies between the bend in the frame and the front-most rear axle guide. Welded seams along the longitudinal axis of the vehicle are not permitted!

Position of weld seams see Fig. 22.

Fig. 22: Allowable weld area ESC-501

If changing the wheelbase involves disconnecting the longitudinal frame members, the weld seams must be secured with inserts, in accordance with Fig. 23 or Fig. 24.

TRUCKNOLOGY® GENERATION A (TGA)

40

Fig. 23: Inserts for shortening the wheelbase ESC-012

1

Use the existing drill holes in the frame in the vicinity of the angle

1inserts. Distance between drill holes ≥ 50, Distance between edges ≥ 25

2Level the weld seam where parts should be in contact. Weld seam by assessment group BS, DIN 8563, part 3.

3Use profi le sections with equal fl ange lenghts.

Width is the same as the inner width of the frame. Tolerance — 5 mm.

Thickness same as frame thickness. Tolerance -1. Material min. S355J2G3 (St52-3)

≥40

3

TRUCKNOLOGY® GENERATION A (TGA)

41

Fig. 24: Inserts for extending the wheelbase ESC-013

2

4

Use the existing frame drill holes in the area of the angle inserts.

1Angle inserts must be of one piece.

Distance between drill holes ≥ 50, edge distance ≥ 25

Level the weld seam where parts should be in contact.

2Weld seam by assesment group BS, DIN 8563, part 3.

Use profi le sections with equal fl ange lengths.

3Width is the same as the inner width of the frame. Tolerance -5. Rolled sections are not permitted.

Thickness same as frame thickness. Tolerance -1. Material S355J3G3 (St52-3)

≥40

Extend the wheelbase using a section of the original frame longitudinal member.

4

Material as stated in the Guide to Fitting Bodies, frame profi le list.

Observe max. distance between frame cross members as stated in the Guide to Fitting

Bodies.

3

On some long-wheelbase chassis, frame inserts are already fi tted between the front and rear axles at the factory.

Frame inserts may not be welded together with the longitudinal frame members. This can be avoided for example, by inserting

a copper-based separating foil which is removed once the welding work is completed. Inserts used in changing the wheelbase may be simply butted-up to one another and may either be welded together or joined with an overlapping plate (see Fig. 25).

TRUCKNOLOGY® GENERATION A (TGA)

42

Fig. 25: Overlapping inserts on inside and outside ESC-504

The section point between the frame and the insert joint may not coincide with a welded joint in the frame.

A distance between the joints of 100 mm must be observed. This is easy to achieve if during cutting of the frame the location of the frame-insert joint is already taken into account.

Fig. 26: Overlapping insert on inside and outside ESC-505

TRUCKNOLOGY® GENERATION A (TGA)

43

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Wiring Diagrams MAN TG-A.

Схемы электрооборудования на английском языке грузовых автомобилей MAN TG-A.

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Руководство по эксплуатации + каталог запчастей грузовых автомобилей MAN TGA.

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Руководство по эксплуатации, ремонту и ТО MAN TGA с 2000 г.

Руководство по эксплуатации, техническому обслуживанию и ремонту грузовых автомобилей MAN TGA с 2000 года выпуска.

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Руководство по эксплуатации, ремонту и ТО MAN TGA с 2000 г.

Руководство по эксплуатации, техническому обслуживанию и ремонту + каталог запчастей грузовых автомобилей MAN TGA с 2000 года выпуска.

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MAN TGA Operator’s Manual

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MAN TGA

MAN TGA Truck Operator’s Manual & Electric Wiring Diagrams PDF are above the page.

The largest truck in the German company’s lineup, MAN TGA, is the benchmark for many manufacturers around the world.

MAN TGA heavy trucks replaced the popular F2000 series and immediately won many awards from journalists and
professionals in the field of cargo transportation, as a result of the assignment in the same year of the prestigious title of «Truck of The Year».

The MAN TGA range consists of truck tractors and chassis with a gross weight of 18 to 50 tons, depending on the curb weight, cars are 2-, 3- and 4-axle. So for trucks with curb
weight from 18 to 26 tons, trucks with one rear drive axle and one front steered axle are produced, it is also possible to install with two dual rear axles, one of which is the drive axle.

For tractors with a gross weight of more than 35 tons, three-axle versions with two or three steered axles are available.

Also, MAN TGA is made in the form of dump trucks with a wheel formula up to 8X8, these are exactly the cars used in the German army.

For variants with three axles, the wheelbase is from 2600 mm to 2800 mm, and for biaxial tractors, from 3500 mm to 3900 mm, respectively.

Engines — L6 from 310 to 530hp, and the flagship among the engines installed on the TGA, is the V10 engine with a volume of 18.3 liters with a power of 660 hp which complete only
a limited series of tractors.

Depending on the engine, two gearboxes are available — a 12-speed own production and a 16-speed ZF.

Trucks with several types of cabs leave the conveyor, each of which varies in size — LX, XLX and XXL, the last most comfortable cab has an internal height of 2.2 m.

The minimum internal height at the M cab is only 1.65 m, such a cab is offered only for trucks without a berth, whereas in XXL two beds can be installed.

Despite the fact that the MAN TGA has been replaced with the newer TGX model, thanks to the excellent price-quality ratio in many markets, this model is still
for sale.

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MAN TGA относится к категории крупногабаритных грузовиков производства немецкой компании, отличающихся отличными техническими характеристиками. Техника данного типа используется для перевозки грузов различного типа.

В данном разделе можно найти подробные руководства по эксплуатации для правильного содержания и обслуживания MAN TGA. Также здесь представлены и книги по ремонту, в которых содержатся подробные инструкции по поиску поломок и их устранению. Пособия можно заказать в формате PDF, который очень удобно использовать на различных современных устройствах. Скачать такие издания можно также и в иных форматах.

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Книга по ремонту MAN TGA предназначена для использования с автомобилями данной модели, выпущенными после 2000 года и оснащенными дизельными двигателями объемом 6.9, 10.5, 12.0, 12.4, 12.8 и 18.3 литра.

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Manuals, maintenance manuals, repair manuals, operating instructions, repair books, repair literature. Catalogs of auto parts, manuals on the device and driving cars, reference books and
educational literature for MAN 19, MAN F90, MAN F2000, MAN L2000, MAN M90, MAN M2000, MAN TGA, MAN TGL, MAN TGM, MAN TGX, MAN TGS.

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MAN L2000 M2000 F2000 construction period 1992-2005

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EDC7 MAN fault codes list PDF [PDF]

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MAN ECAS 2 Fault Codes PDF [PDF]

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MAN ECU EDC7 Engine Fault Codes List [PDF]

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MAN Fault Messages PDF Manual [PDF]

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MAN Fehlercodes PDF [PDF]

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MAN is a German engineering company specializing in the production of trucks, buses and engines. Formed in 1758, formerly known as Maschinenfabrik Augsburg-Nürnberg AG. The
headquarters is located in Munich.

Starting in 2013, restyled versions of the entire MAN TGX, TGS, TGM, TGL range are presented:

  • TGA — the model was discontinued since 2008, was replaced by more modern models of TGX and TGS
  • TGX — tractors and classic «singles» with the maximum level of comfort for the driver, payload from 15 to 70 tons (de facto) and engines from 360 to 680 hp.
  • TGS — truck tractors, classic «singles», dump trucks and various construction equipment on the MAN chassis with a payload of 18 to 70 tons (de facto) and engines from 360 to
    680 liters. from.
  • TGM — medium-tonnage trucks, including classic «singles» and dump trucks with a payload of 7 to 20 tons (de facto) and engines from 240 to 380 liters. from.
  • TGL — low-tonnage trucks for local urban transport with a payload of 5 to 7 tons (de facto) and engines from 150 to 250 liters. from.
MAN TGA PDF Manuals
MAN TGA

In the 1990s. MAN switched to a new range of «2000», including numerous models with a gross mass from 6 to 50 tons, and in the structure of road trains — up to 180 tons. This family consisted of
light, medium and heavy families «L2000», «M2000» and «F2000» respectively, replacing the series «G90», «M90» and «F90». These trucks are widely used electronic devices to regulate the engine,
air suspension, the position of the driver’s seat, the operation of the air conditioner, as well as anti-lock and traction control systems, etc. All cars have front disc ventilated brakes,
steering gear with hydraulic amplifier, pneumatic 2- contour brake system, brake lining with wear sensors.

Since the end of 2000, a new «high-tech» heavy family «TGA» or «Trucknology Generation», corresponding to the norms of «Euro-3», is being manufactured. It consists of numerous models with new
diesel engines (11,9-12,8 l, 310-510 hp), a mechanical 16-speed or automated 12-speed box with electronic control, all disc brakes, three computer systems and five variants of cabins with an
internal height of 1880-2100 mm. This scale was awarded the title «Truck of 2001». At the same time, the IAS started the introduction of a new simplified marking, in which the «L», «M» and «F»
series in the «Evolution» version received «LE», «ME» and «FE» indices with a digital pointer of the rounded engine power.

MAN TGX PDF manuals
MAN TGX

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