MAN L20001992-2005, M2000 1992-2005, F2000 1992-2005 User Manual

L2000 M2000 F2000 construction period 1992-2005 (according to model)

PUBLISHER

MAN Nutzfahrzeuge AG

ESC Department

Engineering Services

Consultation (formerly TDB)

Dachauer Str. 667

D - 80995 Munich

E-Mail:

esc@man.eu

Fax:

+ 49 (0) 89 1580 4264

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

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

Where designations are trademarks they are, even without the

and MANTED® are registered trademarks of MAN Nutzfahrzeuge AG

or ™ sign, acknowledged as the proprietor‘s protected marks.

L2000 M2000 F2000 construction period 1992-2005 (according to model)

1. Applicability of the Guide

2. Vehicle designations

2.1 Model ranges

2.2. Model number, model code, vehicle identiﬁ cation number, basic vehicle number,

vehicle number

2.3 Wheel formula

2.4 Vehicle designation

2.4.1 Vehicle designation for the L2000, M2000, F2000, and E2000 model ranges

2.4.2 Model numbers, model codes

2.5 Engine designations

3. General

3.1 Legal agreements and approval procedure

3.1.1 Preconditions

3.2 Responsibility

3.3 Quality assurance (QA)

3.4 Approval

3.5 Submission of documents

3.6 Warranty

3.7 Liability

3.8 Type approval

3.9 Safety

3.9.1 Functional and operational safety

3.9.2 Manuals for MAN trucks

3.9.3 Manuals from body and conversion companies

3.10 Limitation of liability for accessories/spare parts

3.11 Special-case approvals

3.12 Change of tyre type

3.13 Increasing the permissible trailer load

3.14 Increasing the permissible axle load

3.15 Increasing the permissible gross weight

3.16 Reducing the permissible gross weight

3.17 Deﬁ nitions, dimensions and weights

3.17.1 Axle overload, one-sided loading

1 1 1 2 2 2 2 2 5

9 10 10 10 11 11 12 12 13 14 14 15 15 16 17 17 17 18 20 20 21 21 21 22

L2000 M2000 F2000 construction period 1992-2005 (according to model) I

3.18 Minimum front axle load

3.19 Permissible overhang

3.20 Theoretical wheelbase, overhang, theoretical axle centreline

3.21 Calculating the axle load and weighing procedure

3.22 Weighing vehicles with trailing axles

4. Modifying the chassis

4.1 Safety at work

4.2 Corrosion protection

4.3 Storage of vehicles

4.4 Materials and frame data

4.4.1 Materials for frames and subframes

4.4.2 Frame data

4.5 Modifying the frame

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

4.5.2 Cut-outs in the frame

4.5.3 Welding the frame

4.5.4 Modifying the frame overhang

4.6 Modiﬁ cations to the wheelbase

4.7 Retroﬁ tting equipment

4.8 Retroﬁ tting of leading and trailing axles

4.9 Propshafts

4.9.1 Single joint

4.9.2 Jointed shaft with two joints

4.9.3 Three-dimensional propshaft layout

4.9.3.1 Propshaft train

4.9.3.2 Forces in the propshaft system

4.9.4 Modifying the propshaft layout in the driveline of MAN chassis

4.10 Central lubrication system

4.11 Modifying the cab

4.11.1 General

4.11.2 Extending the cab

4.11.3 Spoilers, aerodynamics kit

4.11.4 Roof sleeper cabs and raised roofs

4.11.4.1 Fundamentals for the installation of roof cabs

4.11.4.2 Roof openings

4.12 Axle location, suspension, steering

4.12.1 General

4.12.2 Stability, body roll

23 24 24 27 27 28 28 28 29 29 29 29 34 34 37 38 40 43 46 46 46 46 47 48 49 50 50 51 51 51 51 52 52 52 54 55 55 55

L2000 M2000 F2000 construction period 1992-2005 (according to model) II

4.13 Add-on frame components

4.13.1 Underride guard

4.13.2 Sideguards

4.13.3 Spare wheel

4.13.4 Wheel chocks

4.13.5 Fuel tanks

4.13.6 Liqueﬁ ed gas systems and auxiliary heaters

4.14 Gas engines: Handling of high-pressure gas installations

4.15 Modiﬁ cations to the engine

4.15.1 Air intake, exhaust gas path

4.15.2 Engine cooling

4.15.3 Engine encapsulation, noise insulation

4.16 Coupling devices

4.16.1 General

4.16.2 Trailer coupling, D value

4.16.3 Rigid drawbar trailers, central axle trailers, D

value, V value

4.16.4 End cross members and trailer couplings

4.16.5 Ball-type coupling

4.16.6 Fifth-wheel coupling

4.16.7 Converting the vehicle type - truck / tractor

5. Bodies

5.1 General

5.1.1 Accessibility, Clearances

5.1.2 Lowering the body

5.1.3 Platforms and steps

5.1.4 Corrosion protection

5.2 Subframes

5.2.1 Designing the subframe

5.2.2 Attaching subframes and bodies

5.2.2.1 Screw connections and riveted joints

5.2.2.2 Flexible connections

5.2.2.3 Rigid connections

5.2.2.4 Self-supporting bodies without subframe

5.3 Special bodies

5.3.1 Testing of bodies

5.3.2 Single-pivot body

5.3.3 Tank and container bodies

5.3.3.1 General

5.3.3.2 Body ﬁ xtures, mountings

5.3.3.3 Tankers and container bodies without subframes

56 56 57 61 61 61 62 62 63 63 63 63 64 64 66 67 69 83 83 86 86 86 87 89 89 90 90 92 95 95 96

102 104 105 105 105 106 106 106 107

L2000 M2000 F2000 construction period 1992-2005 (according to model) III

5.3.4 Tippers

5.3.5 Set-down, sliding set-down and sliding roll-off skip loaders

5.3.6 Platform and box bodies

5.3.7 Interchangeable containers

5.3.7.1 Factory-ﬁ tted interchangeable platform chassis

5.3.7.2 Other interchangeable equipment

5.3.8 Loading cranes

5.3.8.1 Loading crane behind the cab

5.3.8.2 Rear loading crane

5.3.8.3 Subframe for loading crane

5.3.9 Tail-lifts

5.3.10 Cable winches

5.3.11 Transport mixers

6. Electrics

6.1 Introduction

6.2 References to repair manuals and standards

6.3 Starting, tow-starting and operating

6.4 Handling batteries

6.5 Additional wiring diagrams and wiring harness drawings

6.6 Fuse, power for additional consumers

6.7 Type of electrical conductors and relays to be used

6.8 Lighting installations

6.9 Interference suppression

6.10 Electromagnetic compatibility

6.11 Interfaces on the vehicle

6.12 Body ﬁ ttings

6.13 Setting customer-speciﬁ c parameters with MAN-cats

6.14 Earth cable

6.15 Installation and routing of electric cabling/pipework

7. Power take-offs (see separate booklet)

8. Brakes, lines

8.1 Brake and compressed air lines

8.1.1 Basic principles

8.1.2 Plug connectors, changeover to Voss 232 system

8.1.3 Installing and attaching lines

8.1.4 Compressed air loss

8.2 Connecting ancillary consumers

8.3 Adjusting the automatic load-dependent brake system

8.4 Continuous brakes (retarders)

8.4.1 Hydrodynamic retarders

109

111 112 113 113 113 114 116 117 118 127 147 148 149 149 149 149 149 150 151 151 151 152 152 152 153 153 153 154 154 155 155 155 155 157 159 159 162 162 162

L2000 M2000 F2000 construction period 1992-2005 (according to model) IV

8.4.2 Eddy-current brakes

9. Calculations

9.1 Speed

9.2 Efﬁ ciency

9.3 Tractive force

9.4 Gradeability

9.4.1 Distance travelled on uphill or downhill gradients

9.4.2 Angle of uphill or downhill gradient

9.4.3 Calculating the gradeability

9.5 Torque

9.6 Power output

9.7 Rotational speeds for power take-offs at the transfer case

9.8 Driving resistances

9.9 Turning circle

9.10 Axle load calculation

9.10.1 Performing an axle load calculation

9.10.2 Calculation of weight with trailing axle lifted

9.11 Support length for bodies without subframes

9.12 Coupling devices

9.12.1 Trailer coupling

9.12.2 Rigid drawbar trailers / central axle trailers

9.12.3 Fifth-wheel coupling

163 165 165 166 167 168 168 168 169 173 174 176 177 180 182 182 185 187 188 188 188 190

L2000 M2000 F2000 construction period 1992-2005 (according to model) V

1. Gültigkeit der Aufbaurichtlinien

This „Guide to Fitting Bodies for Trucks“ (hereinafter also called the „Guide“) is published by MAN Nutzfahrzeuge. The Guide is also available via our „MANTED

The user is responsible for ensuring that he is working with the latest issue. Our TDB Department (see „Publisher“ above) can provide information about the current status of the document.

This Guide serves as instructions and as a technical aid for companies that carry out the design and installation of bodies for truck chassis as well as companies that carry out modiﬁ cations to truck chassis.

This Guide applies to:

• New vehicles

• Old vehicles

if retrospective work is being carried out on these vehicles.

A Guide to Fitting Bodies for bus chassis can be obtained from NEOMAN.

Responsibilities concerning trucks are as follows: for

• Sales enquiries → the nearest MAN branch → Sales Support

• Technical enquiries → for sales negotiations

- the nearest MAN branch

- the ESC Department (for address see “Publisher” above)

• Customer service matters → After Sales

Technical Data“ software and on the Internet.

2. Vehicle designations

To identify and differentiate MAN vehicles, components and assemblies, Sections 2.1 to 2.5 of this chapter will describe some of the designations in greater detail. The ﬁ gures contained in model designations serve only as an indication and are not deﬁ nite ﬁ gures for actual maximum load carrying capacity for speciﬁ c components or assemblies; in addition, they do not always agree with the legally speciﬁ ed limits.

2.1 Model ranges

Within the MAN vehicle programme there are different vehicle classes or model ranges. When reference is made in this Guide to vehicle families or model ranges, it is referring to the following vehicles:

L2000 7,5t - 10,5t see Table 12 M2000L 12t - 26t see Table 13 M2000M 12t - 25t see Table 14 F2000 19t - 41t see Table 15 E2000 19t - 50t see Table 16

L2000 M2000 F2000 construction period 1992-2005 (according to model) 1

2.2 Model number, model code, vehicle identiﬁ cation number, basic vehicle number, vehicle number

The three-digit model number, also called model code, provides a technical description of the MAN chassis and also identiﬁ es which vehicle range it belongs to. The 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 given instead of the 17-digit vehicle identiﬁ cation number in the event of any technical queries regarding conversions and bodies.

2.3 Wheel formula

For more accurate identiﬁ cation, the wheel formula can be used alongside the vehicle designation. This is a familiar, but not standardised term. Twin tyres are regarded as one wheel, i.e. it is the „wheel locations“ that are counted. The wheel formula does not indicate which axles are driven. On all-wheel drive vehicles, not all axles are necessarily driven; instead, it may be that all-wheel drive components are merely present in the drivetrain.

Tabl e 1: Example of a wheel formula

6x4/2 6 = Number of wheel locations, in total x = Has no function 4 = Number of driven wheels / = Only the front wheels are steered

- = Combined front and rear wheel steering 2 = Number of steered wheels

In normal parlance, the number of steered wheels is not stated if only two wheels are steered. However, for consistency, MAN’s technical documents do indicate the number of steered wheels.

2.4 Vehicle designation

2.4.1 Vehicle designation for the L2000, M2000, F2000, and E2000 model ranges

The following section explains how the vehicle designations are formulated. Vehicle designations comprise a preﬁ x and a sufﬁ x.

Tabl e 2: Example of a vehicle designation

26.464 FNLL

26.464 Preﬁ x FNLL Sufﬁ x

A preﬁ x comprises:

• Technical design gross weight*

• Engine power rating in DIN-hp/10

• Version code

L2000 M2000 F2000 construction period 1992-2005 (according to model) 2

Tabl e 3: Example of a preﬁ x

26.464 FNLL

26. = Technical design gross weight* 46 = Engine power rating in DIN-hp/10. 46x10 = 460 hp power output; ratings that end in 5 hp are rounded up 4 = Version code

* The technically possible permissible gross weight is only achieved if the vehicle is also ﬁ tted with the appropriate components. The vehicle designation does not provide any information on the equipment ﬁ tted to a vehicle

The sufﬁ x comprises:

• Chassis section

• Factory-ﬁ tted body section

• Dimensions section

• Body/conversion section

Tabl e 4: Example of a sufﬁ x

19.364 FLK/N-LV FL = Chassis section K = Factory-ﬁ tted body section /N = Dimensions section

-LV = Body/conversion section

Chassis section:

The ﬁ rst character (on two-axle vehicles) or the ﬁ rst and second characters in the case of vehicles with more than two axles, mean the following:

Tabl e 5: Sufﬁ x codes indicating vehicle model ranges and conﬁ guration

L = Light-duty L2000 or medium-duty M2000L range, cab from light-duty L2000 range LN = Medium-duty M2000L range, cab from light-duty L2000 range, trailing axle M = Medium duty, cab from heavy-duty F2000 range MN = Trailing axle, medium-duty range, cab from heavy-duty F2000 range MV = Leading axle, medium-duty range, cab from heavy-duty F2000 range F = Two-axle truck, cab from heavy-duty F2000 range FN = Trailing axle, cab from heavy-duty F2000 range FV = Leading axle, cab from heavy-duty F2000 range DF = Three-axle truck, tandem axle, cab from heavy-duty F2000 range VF = Four-axle truck, cab from heavy-duty F2000 range

There are also optional details specifying whether a vehicle has all-wheel drive and/or whether it has single tyres on the driven rear axles:

Tabl e 6: Sufﬁ x codes for all-wheel drive/single tyres

A = All-wheel drive E = Single tyres

L2000 M2000 F2000 construction period 1992-2005 (according to model) 3

Suspension:

Vehicles with leaf suspension on all axles are not specially marked. Air suspension is indicated by the letter „L“, hydropneumatic suspension by the letter „P“. The suspension code starts at the second character of the chassis section of the sufﬁ x at the earliest. A distinction is made between the following suspension systems:

Tabl e 7: Sufﬁ x codes for suspension systems

Suspension system Code Description

Leaf-leaf none Front and rear axle(s) have leaf suspension

Leaf-air L Front axle(s) have leaf suspension, rear axles have air suspension

Air-air LL Full air suspension, front and rear axle(s) have air suspension

Leaf-hydro P

Steering layout:

Left-hand drive vehicles are not specially marked. Right-hand drive vehicles contain the letter “R” in the last position of the chassis section of the sufﬁ x, but before the factory-ﬁ tted body section.

Tabl e 8: Marking for right-hand drive

FLRS F = Forward-control truck with 2 axles and driveline like a two-axle vehicle L = Leaf-air suspension R = Right-hand drive vehicle S = Semitrailer tractor unit

Front axle(s) have leaf suspension, rear axle(s) have hydropneumatic

suspension

Factory-ﬁ tted body section:

This letter indicates that an appropriate body type can be factory-ﬁ tted; however, the vehicle can also be delivered without a body.

Tabl e 9: Factory-ﬁ tted body section

C = Chassis with and without factory-ﬁ tted platform K = Tipper S = Semitrailer tractor W = Interchangeable platform chassis

Dimensions section:

If the overall height differs from the normal height, this is indicated by a forward slash. The chassis as a whole dictates whether a special overall height is required. Changes to vehicle equipment such as the ﬁ tting of different tyres, a low mounting plate or a low ﬁ fth-wheel coupling do not require the vehicle designation to be changed to indicate that the vehicle is a low-level design.

Table 10: Overall heights

19.414 FLS/N / = Special overall height N = Low M = Medium-height H = High

L2000 M2000 F2000 construction period 1992-2005 (according to model) 4

Body/conversion section:

If a chassis is intended for a speciﬁ c body or conversion, the body/conversion section of the number is indicated by a hyphen. This is always followed by a combination of two letters.

Table 11: Body/conversion section

Example:

19.314 FLL - PT

- KI = Fittings for tipper body

- HK = Fittings for tipper body (rear)

- KO = Fittings for municipal service body

- LF = Fittings for ﬁ re-ﬁ ghting vehicle

- LV = Fittings for loading crane structure in front of the platform

- PT = Fittings for car transporter

- TM = Fittings for concrete mixer

- NL = Fittings for the installation of a trailing axle

2.4.2 Model numbers, model codes

Table 12: L2000

Model no. Tonnage Designation Suspension Engine Wheel formula

L20 8/9t

L21 8/9t

L22 8t 8.xxx LAE BB R4 4x4/2 L23 8t 8.xxx LAE BB R6 4x4/2 L24 10t 10.xxx L BB R4 4x2/2 L25 10t 10.xxx L BB R6 4x2/2 L26 10t 10.xxx LAE BB R4 4x4/2 L27 10t 10.xxx LAE BB R6 4x4/2

L33 8/9t

L34 8/9t

L35 10t 10.xxx LL BL R4 4x2/2 L36 10t 10.xxx LL BL R6 4x2/2

8.xxx L

9.xxx L

8.xxx L

9.xxx L

8.xxx LL

9.xxx LL

8.xxx LL

9.xxx LL

BB R4 4x2/2

BB R6 4x2/2

BL R4 4x2/2

BL R6 4x2/2

*) = The type of suspension is indicated by the following code letters: B = leaf suspension, L = air suspension, H = hydropneumatic suspension. A code letter is assigned to each axle (starting with the ﬁ rst axle).

*) = The type of engine is indicated by up to three characters, the letter (R/V) represents the design, i.e. in-line or V, and the number represents the number of cylinders.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 5

Tabl e 13: M2000L with compact, medium or twin cab

Model no. Tonnage Designation Suspension Engine Wheel formula

L70 12t 12.xxx L BB R4 4x2/2 L71 12t 12.xxx L BB R6 4x2/2 L72 12t 12.xxx LL BL R4 4x2/2 L73 12t 12.xxx LL BL R6 4x2/2 L74 14t 14.xxx L BB R4 4x2/2 L75 14t 14.xxx L BB R6 4x2/2 L76 14t 14.xxx LL BL R4 4x2/2 L77 14t 14.xxx LL BL R6 4x2/2 L79 14t 14.xxx LLL LL R6 4x2/2 L80 14t 14.xxx LA BB R6 4x4/2 L81 15t 15.xxx L BB R4 4x2/2 L82 15t 15.xxx L BB R6 4x2/2 L83 15t 15.xxx LL BL R4 4x2/2

L84

L86

15t 20t

15.xxx LL

20.xxx LNL

15.xxx LLL

20.xxx LNLL

BLL

LLL

R6 R6

R6 L87 18t 18.xxx L BB R6 4x2/2 L88 18t 18.xxx LL BL R6 4x2/2 L89 18t 18.xxx LLL LL R6 4x2/2 L90 18t 18.xxx LA BB R6 4x4/2 L95 26t 26.xxx DL BBB R6 6x4/2

4x2/2 6x2-4

Tabl e 14: M2000M with short or long-haul cab

Model no. Tonnage Designation Suspension Engine Wheel formula

M31 14t 14.xxx M BB R6 4x2/2 M32 14t 14.xxx ML BL R6 4x2/2 M33 14t 14.xxx MLL LL R6 4x2/2 M34 14t 14.xxx MA BB R6 4x4/2 M38 18t 18.xxx M BB R6 4x2/2 M39 18t 18.xxx ML BL R6 4x2/2 M40 18t 18.xxx MLL LL R6 4x2/2 M41 18t 18.xxx MA BB R6 4x4/2 M42 25t 25.xxx MNL BLL R6 6x2/2 M43 25t 25.xxx MNLL LLL R6 6x2/2 M44 25t 25.xxx MVL BLL R6 6x2/4

L2000 M2000 F2000 construction period 1992-2005 (according to model) 6

Tabl e 15: F2000

Model no. Tonnage Designation Suspension Engine Wheel formula

T01 19t 19.xxx F BB R5 4x2/2 T02 19t 19.xxx FL BL R5 4x2/2 T03 19t 19.xxx FLL LL R5 4x2/2 T04 19t 19.xxx FA BB R5 4x4/2

T05 23t 23.xxx FNLL LLL R5

T06 26t 26.xxx FNL BLL R5

T07 26t 26.xxx FNLL LLL R5

T08 26t 26.xxx FVL BLL R5 6x2/4 T09 26t 26.xxx DF BBB R5 6x4/2 T10 26t 26.xxx DFL BLL R5 6x4/2 T12 27/33t 27.xxx DFA BBB R5 6x6/2 T15 32t 32.xxx VF BBBB R5 8x4/4 T16 35/41t 35.xxx VF BBBB R5 8x4/4 T17 32t 32.xxx VFLR BBLL R5/R6 8x4/4 T18 27/33t 27.xxx DF BBB R5 6x4/2 T20 19t 19.xxx FLL LL R5 4x2/2 T31 19t 19.xxx F BB R6 4x2/2 T32 19t 19.xxx FL BL R6 4x2/2 T33 19t 19.xxx FLL LL R6 4x2/2 T34 19t 19.xxx FA BB R6 4x4/2

T35 23t 23.xxx FNLL LLL R6

T36 26t 26.xxx FNL BLL R6

T37 26t 26.xxx FNLL LLL R6

T38 26t 26.xxx FVL BLL R6 6x2/4 T39 26t 26.xxx DF BBB R6 6x4/2 T40 26t 26.xxx DFL BLL R6 6x4/2 T42 27/33t 27.xxx DFA BBB R6 6x6/2 T43 40t 40.xxx DF BBB R6 6x4/2 T44 40t 40.xxx DFA BBB R6 6x6/2 T45 32t 32.xxx VF BBBB R6 8x4/4 T46 35/41t 35.xxx VF BBBB R6 6x2/4 T48 27/33t 27.xxx DF BBB R6 6x2/2 T50 19t 19.xxx FLL LL R6 4x2/2 T62 19t 19.xxx FL BB V10 4x2/2 T70 26t 26.xxx DFL BLL V10 6x4/2 T72 27/33t 27.xxx DFA BBB V10 6x6/2 T78 27/33t 27.xxx DF BBB V10 6x4/2

6x2/2 6x2-4

L2000 M2000 F2000 construction period 1992-2005 (according to model) 7

Tabl e 16: ÖAF special-purpose vehicles

Model no. Tonnage Designation Suspension Engine Wheel formula

E40 26t 26.xxx DFLR BBB R6 6x4/2

E41 41t 41.xxx VFA

BBBB

BBLL

E42 26t 26.xxx FVL BLL R6 6x2/4

E47 28t

28.xxx FAN

28.xxx DFA

BBB R5

E50 30/33t 33.xxx DFAL BLL R5 6x6/2 E51 19t 19.xxx FL BL R5 4x2/2 E52 19t 19.xxx FAL BL R5 4x4/2

E53 26t 26.xxx FNL BLL R5

E54 26t 26.xxx FN BBB R5 6x2/2

E55 32t 32.xxx VFL BBLL R5

E56 26t 26.xxx FAVL BLL R5 6x4/4

E58 41/50t 41.xxx VFA BBBB R5

E59 33t 33.xxx DFL BLL R5

E60 30/33t 33.xxx DFAL BLL R6 6x6/2 E61 19t 19.xxx FL BL R6 4x2/2 E62 19t 19.xxx FAL BL R6 4x4/2

E63 26t 26.xxx FNL BLL R6

E64 26t 26.xxx FN BBB R6 6x2/2

E65 32t 32.xxx VFL BBLL R6

E66 26t 26.xxx FAVL BLL R6 6x4/4

E67 28t

28.xxx FANL

28.xxx FNAL

BLL R6

E68 41/50t 41.xxx VFA BBBB R6

E69 33t 33.xxx DFL BLL R6

E72 33t 33.xxx DFAP BHH R6 6x6-4

E73 32/35t 32.xxx FVNL BLLL R6

E74 42t 42.xxx VFP BBHH R6 8x4-6

E75 41t 41.xxx DFVL

BLBB

BLLL

R6 8x4/4

8x8/4 8x4/4

6x4-4 6x6-4

6x2-4 6x4-4

8x2/4 6x2-6 8x4/4

8x8/4 8x6/4 8x4/4

6x2/2 6x4/2

6x2-4 6x4-4

8x2/4 8x2-6 8x4/4

6x4-4 6x6-4

8x8/4 8x6/4 8x4/4

6x2/2 6x4/2

8x2/4 8x2-6

L2000 M2000 F2000 construction period 1992-2005 (according to model) 8

Tabl e 16: ÖAF special-purpose vehicles

Model no. Tonnage Designation Suspension Engine Wheel formula

E77 50t 50.xxx VFVP BBHHH R6 10x4-8 E78 42t 42.xxx VFAP BBHH R6 8x8-6 E79 50t 50.xxx VFAVP BBHHH R6 10x8-8 E88 35t 36.xxx VFL BBLL V10 8x4/4

E94 40t

E95 41t 41.xxx DFVL

E98 50t 50.xxx VFA BBBB V10 8x8/4

E99 33t

40.xxx DFA

40.xxx DFAL

33.xxx DF

33.xxx DFL

BBB

BLL

BLBB

BLLL

BBB

BLL

V10 6x6/2

V10 8x4/4

V10 6x4/2

2.5 Engine designations

Tabl e 17: Engine designation

X XX X X X(X) (X) (X) (X) D 08 2 6 L F Diesel engine D + 100mm = cylinder bore diameter in mm 08 Times 10 + 100 = stroke in mm 2 Number of cylinders 6 Intake system L Power variant Engine installation F

Key to abbreviations:

D = Diesel E = Natural gas L = Intercooling F = Front installation, engine vertical H = Rear installation, engine vertical (bus)

Tabl e 18: Example of engine designation

D 28 4 0 L F Diesel engine D + 100mm = 128mm bore 28 Times 10 + 100 = 140mm stroke 4 0 = 10 cylinders 0 Intercooling L Front installation, vertical F

L2000 M2000 F2000 construction period 1992-2005 (according to model) 9

3. General

3.1 Legal agreements and approval procedure

National regulations must be adhered to. The company carrying out the work remains responsible even after the vehicle has been approved if the authorities responsible issue an approval unaware of the operational safety of the product.

3.1.1 Preconditions

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. Particular consideration is given to the regulations in force in Germany, such as the Strassenverkehrs-Zulassungs-Ordnung (Road Trafﬁ c Licensing Regulations). 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.

The following can be obtained from the respective professional association or from the Carl-Heymanns-Verlag (publishers):

• Accident prevention regulations

• Guidelines

• Safety regulations

• Leaﬂ ets

• Other health and safety at work documents from professional associations.

These documents are available as individual documents and as directories.

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.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 10

3.2 Responsibility

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.

3.3 Quality assurance (QA)

In order to meet our customers’ high quality expectations and in view of international product 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:

• Self-certiﬁ cation in accordance with the VDA checklist or that of another vehicle manufacturer

• A positive system audit carried out by other vehicle manufacturers (second party audit)

• Auditing of the QA system by an accredited institute (third party audit)

• Possession of a corresponding certiﬁ cate.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 11

If MAN is the party awarding the contract for the body or conversion, one of the above is required as evidence of qualiﬁ cation. MAN Nutzfahrzeuge 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. At MAN, the QS department is responsible for the approval of body manufacturers as suppliers. VDA volume 8 has been agreed with the following body manufacturers’ associations: ZKF (Zentralverband Karosserie- und 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

„Quality assurance at trailer, body and container manufacturers“, obtainable from the Verband der Automobilindustrie e.V (VDA) (German Motor Industry Association). http://www.vda-qmc.de/de/index.php.

3.4 Approval

Approval from MAN for a body or a chassis modiﬁ cation is not required if the bodies or modiﬁ cations are being carried out in accordance with this Guide.

If MAN approves a body or a chassis modiﬁ cation, 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 observations only refer 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.

3.5 Submission 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 MAN, department ESC (see „Addresses“ booklet for address). Chassis drawings, data sheets etc. can also be requested from this ofﬁ ce.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 12

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

• Documents should be submitted in duplicate, at the very least

• The number of individual documents should be kept to a minimum

• All the technical data and documents must be submitted.

The following information should be included:

• Vehicle model with

- cab design

- wheelbase

- frame overhang

- length of rear overhang (vehicle overhang)

• Vehicle identiﬁ cation number

• Vehicle number (see 2.2)

• Dimension from the centre of the body to the centre of the last axle

• Centre of gravity position of the payload and body

• Body dimensions

• Material and dimensions of the subframe that is to be used

• Body mountings on the chassis frame

• Description of any deviations from this „MAN Guide to Fitting Bodies for Trucks“

• Any references to identical or similar vehicles

The following are not sufﬁ cient for inspection or approval:

• Parts lists

• Brochures

• Information that is not binding

• Photographs.

Some types of bodies, such as loading cranes, cable winches etc., necessitate information speciﬁ c to their type.

In the documents submitted, all main length dimensions must be stated with respect to the wheel centre of the ﬁ rst axle, as appropriate.

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.

3.6 Warranty

Warranty claims only exist within the framework of the purchasing contract between buyer and seller. In accordance with this, the warranty obligation lies with the respective seller of the goods.

Warranty 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.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 13

3.7 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.

3.8 Type approval

Each vehicle that is to be used on the road in Germany must be ofﬁ cially approved. Approval is carried out by the local Vehicle Licensing Agency after submission of the vehicle documentation.

EBE approval (EBE = Einzel-Betriebserlaubnis = single certiﬁ cation)

The vehicle documentation is drawn up by a technical agency (DEKRA, TÜA, TÜV) after the vehicle has been examined.

ABE approval for complete vehicles (ABE = Allgemeine Betriebserlaubnis = National Type Approval = NTA)

The vehicle documentation is drawn up by the vehicle manufacturer.

ABE approval for chassis (ABE = Allgemeine Betriebserlaubnis = National Type Approval = NTA)

The vehicle documentation is drawn up by the chassis manufacturer and completed after the body has been approved by a technical agency (DEKRA, TÜA, TÜV).

Vehicles that are to be used for transporting hazardous goods require additional approval in accordance with GGVS or ADR.

Modiﬁ cations that affect the certiﬁ cation may only be added by the ofﬁ cial agency responsible. Expiry of the certiﬁ cation will also cancel insurance cover.

The responsible authorities, the ofﬁ cially recognised expert, the customer or a MAN department may request submission of a drawing bearing the MAN approval mark; in some circumstances, evidence in the form of calculations or the submission of this Guide may sufﬁ ce.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 14

3.9 Safety

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.

3.9.1 Functional and operational safety

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.

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.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 15

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.

3.9.2 Manuals for MAN trucks

Each MAN truck has:

• Operating instructions

• Inserts that form part of the operating instructions

• Maintenance recommendations

• Maintenance booklet

• Maintenance instructions (available for a fee from the spare parts department).

Operating instructions

provide the driver and vehicle owner with all they need to know about how vehicles are operated and maintained in a ready-to-use condition. Important safety instructions for the driver/vehicle owner are also included.

Inserts

provide technical data on a speciﬁ c type of vehicle or several similar types of vehicle, thus supplementing the operating instructions. Inserts are also published for new technical features and modiﬁ cations to speciﬁ c vehicles if the operating instructions themselves are not being revised.

Maintenance recommendations

are published in the same format as the operating instructions, i.e. DIN A5. They describe the maintenance systems and list speciﬁ cations for the various operating ﬂ uids, ﬁ ll quantities for various components and list approved operating ﬂ uids. They are a supplement to every operating and maintenance manual. The „Maintenance recommendations“ brochure is published every 6 – 12 months.

Maintenance instructions

indicate the scope of the maintenance to be carried out, provide the technical data that is required for maintenance and describe the individual jobs in detail. Both operating instructions and maintenance instructions are compiled for „vehicle families“. This means for example, that the „F2000 forward-control heavy-duty range“ operating instructions will include all the heavy-duty forward-control vehicles, regardless of which and how many axles it has or which engine is ﬁ tted. In exceptional cases for major customers, model-speciﬁ c operating and maintenance instructions may be compiled.

Maintenance booklet

provides information about the necessary maintenance services and contains boxes that are ﬁ lled in as evidence that maintenance work has been carried out properly and on time.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 16

3.9.3 Manuals 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 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

• Product-speciﬁ c safety instructions and

• To check that they can be correctly understood.

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.

3.10 Limitation 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 Nutzfahrzeuge Aktiengesellschaft (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 Nutzfahrzeuge Aktiengesellschaft (or the seller) has sold the accessory itself or ﬁ tted it to the vehicle (or the subject of the contract).

3.11 Special-case approvals

Upon written application, MAN may approve exceptions to existing technical regulations, provided that such exceptions are in agreement with functional safety, trafﬁ c safety and operational safety. These actions refer to, for example:

• Permissible axle loads

• Permissible gross weight

• Modiﬁ cations to

- installed parts

- retroﬁ t installation of equipment

- changes to dimensions.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 17

A special case approval granted by MAN is not binding on the responsible authorities. MAN has no inﬂ uence on the issuing of special case approvals by the respective authorities. If the measure in question is intended for use outside the area covered by the StVZO, then a special case approval must be obtained in advance from the respective provincial government department.

Each special case approval must be examined and approved by an ofﬁ cially recognised expert and must be entered into the vehicle documentation by the responsible approval agency. If a parts inspection has been issued in accordance with § 19/3 StVZO (Road Trafﬁ c Licensing Regulations), then conﬁ rmation of the part’s correct installation by an ofﬁ cially recognised examiner will sufﬁ ce.

The most common reasons for requesting special case approval are:

• A change of tyre type (see 3.12)

• An increase in the permissible trailer load (see 3.13)

• An increase in the permissible front axle load (see 3.14)

• An increase in the permissible gross weight (see 3.15).

3.12 Change of tyre type

The tyre load rating inﬂ uences the permissible axle load. If the load rating is less than the truck’s technically or legally permissible axle load, then the permissible axle load reduces accordingly. However, the permissible axle load does not increase if tyres with a higher load rating than the standard permissible axle load are ﬁ tted. The marks located on the tyres and the manufacturer’s tyre manuals will provide technical tyre data. The following points must therefore be observed:

• Load index (rating)

- for single tyres

- for twin tyres

• Speed code

• Tyre pressure

• Vehicle’s maximum design speed.

The size of the tyre and rim must match. Assignment of a tyre to:

• A speciﬁ c rim must be approved by the tyre and rim manufacturers, whilst assignment of a tyre to

• A speciﬁ c vehicle must be approved by MAN.

A written approval from MAN is required only if the tyres intended for use are not listed in the vehicle documents.

Changing the tyres will affect:

• Driving properties

- road speed

- pulling power

- gradeability

- braking

- fuel consumption

• Vehicle dimensions

- height above ground

- tyre compression

- steer angle

- turning circle

- clearance circle

- tyre clearance

• Handling properties.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 18

The reference speed of a tyre must not be exceeded or may only be exceeded if the load rating is reduced. In the case of reference speed, it is not the permissible maximum speed of the vehicle that is critical but the maximum design speed. The maximum design speed is the maximum speed achievable at a particular engine speed and overall gear ratio or the maximum speed achievable because of the speed limiter.

There are tyres that should not exceed the speciﬁ ed maximum design speed, regardless of their load rating or the respective loading.

Some vehicles, such as ﬁ re service vehicles and airport tanker vehicles, can have a higher load rating on account of their special conditions of use (see tyre and rim manufacturers’ documents).

On all-wheel drive vehicles, different tyre sizes on the front and rear axle(s) are only possible if the circumferences of the tyres used do not differ by more than 2%. The instructions in the „Bodies“ chapter in respect of snow chains, load ratings and clearances must be observed.

If different tyre sizes are ﬁ tted to the front and rear axle(s), the basic headlamp settings must be checked and adjusted if necessary. This must be done directly at the headlamps even if the vehicles are ﬁ tted with a headlamp range adjustment facility (see also the „Lighting installation“ section in the „Electrics, wiring“ chapter).

Vehicles ﬁ tted with maximum speed limiters or ABS and ASR must have these devices reprogrammed after the tyres have been changed. This can only be carried out with the MAN-CATS diagnostics system. The following information must be provided for MAN to conﬁ rm a tyre change:

• MAN vehicle model

• Vehicle identiﬁ cation number (see 2.2)

• Vehicle number (see 2.2)

• Whether the vehicle’s tyres will be changed:

- on the front axle(s) only

- on the rear axle(s) only

- on all wheels

• Required tyre size:

- front

- rear

• Required rim size:

- front

- rear

• Required permissible axle load:

- front

- rear

• Required permissible gross weight

• Current permissible loads

• Permissible front axle load

• Permissible rear axle load

• Permissible gross weight

• Current maximum design speed.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 19

3.13 Increasing the permissible trailer load

If a higher trailer load than the standard one is required, MAN can issue a technical clearance certiﬁ cate. The maximum trailer load is limited by:

• Ofﬁ cial regulations

• The trailer coupling ﬁ tted

• The end cross-member

• The minimum engine power

• The braking system

• The driveline design (e.g. transmission, ﬁ nal drive ratio, engine cooling).

Standard end cross-members for trailer couplings are normally not suitable for operation with rigid drawbar trailers/centre axle trailers. It is not possible to use the ﬁ nal cross-member with such trailers even if the permissible nose weight for the trailer coupling currently ﬁ tted would permit this. Nose weight and D value alone are not adequate criteria for selecting the end cross-member. To help in the selection of a suitable end cross-member the „Coupling devices“ section of the „Modifying the chassis“ chapter contains two tables that list the suitable end cross-members for particular vehicles.

If a truck is being used as a tractor unit, then in some circumstances it will have to be converted into a tractor unit. The converted vehicle must comply with the term „tractor unit“. The relevant regulations deﬁ ne this term.

If MAN is required to issue a conﬁ rmation the following information must be available:

• MAN vehicle model

• Vehicle identiﬁ cation number or vehicle number (see 2.2)

• Permissible gross weight

• Trailer coupling to be used

• Required trailer load.

3.14 Increasing the permissible axle load

If the standard permissible axle load is not sufﬁ cient, then a higher permissible axle load may be approved for some vehicles. However, there is a precondition that the vehicle concerned should also have those components ﬁ tted that a higher front axle load necessitates, such as suitable springs, tyres and braking system.

The following information must be provided for conﬁ rmation:

• MAN vehicle model

• Vehicle identiﬁ cation number or vehicle number (see 2.2)

• Permissible gross weight

• Permissible front axle load

• Permissible rear axle load

• Maximum design speed

• Tyre and rim sizes for all axles

• Required permissible loads.

L2000 M2000 F2000 construction period 1992-2005 (according to model) 20

3.15 Increasing the permissible gross weight

A precondition for a higher permissible gross weight than standard is that the components that a higher gross weight necessitates are ﬁ tted. If the higher permissible gross weight exceeds the legally permissible one, then the law in Germany will normally only allow higher permissible weights if the loads that are to be transported cannot be separated. There is no legal entitlement to an ofﬁ cial exemption.

Consult the ESC department at MAN to discuss the technical options for increasing the gross weight. (For address see „Publisher“ above).

A request for conﬁ rmation must include the following data:

• MAN vehicle model

• Vehicle identiﬁ cation number or vehicle number (see 2.2)

• Permissible gross weight

• Permissible front axle load

• Permissible rear axle road

• Maximum speed

• Current tyre size front and rear

• Current rim size front and rear

3.16 Reducing the permissible gross weight

If the permissible gross weight is reduced, then MAN does not specify any technical modiﬁ cations. The respective person carrying out the work himself determines the new permissible axle loads. The respective authorities will specify whether any technical modiﬁ cations are required.

3.17 Deﬁ nitions, dimensions and weights

National and international regulations take precedence over technically permissible dimensions and weights if they limit the technically permissible dimensions and weights. The following data for series standard vehicles can be obtained from the tender documents and the daily updated MANTED

• Dimensions

• Weights

• Centre of gravity position for payload and body (minimum and maximum position for body).

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 manufacturing 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. MAN itself takes advantages of permissible tolerances. 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. Dimensional changes from the series-production status, e.g. alteration of the centre of gravity of the body, may affect the axle loads and the payload.

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

• That the permissible axle weights are not exceeded under any circumstances (see 3.17.1)

• That a sufﬁ cient minimum front axle load is achieved (see 3.18)

• That loading and the centre of gravity position cannot be displaced to one side (see 3.17.1)

• That the permissible overhang (vehicle overhang) is not exceeded (see 3.19).

documents:

L2000 M2000 F2000 construction period 1992-2005 (according to model) 21

3.17.1 Axle overload, one-sided loading

Fig. 1: Overloading the front axle ESC-052

Fig. 2: One-sided loading ESC-054

Fig. 3: Difference in wheel load ESC-126

L2000 M2000 F2000 construction period 1992-2005 (according to model) 22

Formula 1: Difference in wheel load

∆G ≤ 0,04 • G

tat

In design of the body, one-sided wheel loads are not permitted. When verifying checks are made, a maximum wheel load difference of 4% is permitted. In this case, 100% is the actual axle load and not the permissible axle load.

Example:

Actual axle load G

= 11.000kg

tat

Therefore, the permissible wheel load difference is:

∆G = 0,04 · G

= 0,04 · 11.000kg

tat

∆G = 440kg

Therefore, wheel load on the left is 5,720kg and wheel load on the right is 5,280kg. The calculated maximum wheel load does not give any information about the permissible individual wheel load for the tyres ﬁ tted. Information on this can be found in the technical manuals from the tyre manufacturers.

3.18 Minimum front axle load

In order to maintain steerability, the vehicle must have the stipulated minimum front axle load in all load conditions, see Table 19.

Tabl e 19: Minimum front axle loading for any load condition, as a % of vehicle gross weight

SDAH = Rigid drawbar trailer ZAA = centre axle trailer GG = Vehicle weight

Model range

No. of axles

All 2-axle

vehicles

Wheel

formula

4x2, 4x4 4x2, 4x4 4x2, 4x4

GG [t] With SDAH

ZAA

≤ 10 ≤ 15 > 15

25% 25% 25%

With SDAH

ZAA

GG ≤ 11t

30% 30% 25%

With SDAH

ZAA

GG ≤ 18t

35% 30% 25%

Triple SDAH

ZAA

GG > 18t

not perm. not perm. not perm.

TGA and F2000

More than 2

axles

6x2, 6x4,

6x6

> 19 20% 25%* 25%* 30% 25%

8x4, 8x2 8x6, 8x8

If there are more than one front axles the % value is the sum of the front axle loads. When operating with SDAH / ZAA + additional rear loads (e.g. tail-lift, crane) the higher value applies *) = -2% for steered leading/trailing axles

Since the values are related to the gross vehicle weight, they are inclusive of any additional rear loads such as

• Nose weights applied by a centre axle trailer

• Loading crane at rear of vehicle

• Tail-lifts

• Transportable fork-lifts.

Other rear load

e.g. crane

30% 30% 30%

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