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

4.6 (8)

L2000 M2000 F2000 construction period 1992-2005

(according to model)

P U B L I S H E R

MAN Nutzfahrzeuge AG

ESC Depar t ment

Engineering Services

Consultation (formerly TDB)

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.

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 Nutzfahrzeuge AG

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

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


1.	Applicability of the Guide		1

2.	Vehicle designations		1
	2.1	Model ranges	1

	2.2.	Model number, model code, vehicle identiﬁ cation number, basic vehicle number,	2

		vehicle number	2

	2.3	Wheel formula	2

	2.4	Vehicle designation	2

		2.4.1 Vehicle designation for the L2000, M2000, F2000, and E2000 model ranges	2
		2.4.2 Model numbers, model codes	5
	2.5	Engine designations	9
3.	General		10

	3.1	Legal agreements and approval procedure	10

		3.1.1 Preconditions	10

	3.2	Responsibility	11
	3.3	Quality assurance (QA)	11
	3.4	Approval	12

	3.5	Submission of documents	12
	3.6	Warranty	13
	3.7	Liability	14
	3.8	Type approval	14

	3.9	Safety	15
		3.9.1 Functional and operational safety	15

		3.9.2 Manuals for MAN trucks	16
		3.9.3 Manuals from body and conversion companies	17

	3.10	Limitation of liability for accessories/spare parts	17
	3.11	Special-case approvals	17
	3.12	Change of tyre type	18
	3.13	Increasing the permissible trailer load	20

	3.14	Increasing the permissible axle load	20
	3.15	Increasing the permissible gross weight	21
	3.16	Reducing the permissible gross weight	21
	3.17	Deﬁ nitions, dimensions and weights	21

		3.17.1 Axle overload, one-sided loading	22

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


	3.18	Minimum front axle load				23
	3.19	Permissible overhang				24
	3.20	Theoretical wheelbase, overhang, theoretical axle centreline				24
	3.20					24
	3.21	Calculating the axle load and weighing procedure				27
	3.22	Weighing vehicles with trailing axles				27
4.	Modifying the chassis					28
	4.1	Safety at work				28
	4.2	Corrosion protection				28
	4.2	Corrosion protection				28
	4.3	Storage of vehicles				29
	4.4	Materials and frame data				29
		4.4.1 Materials for frames and subframes				29
		4.4.2	Frame data			29
		4.4.2	Frame data			29
	4.5	Modifying the frame				34
		4.5.1 Drill holes, riveted joints and screw connections on the frame				34
		4.5.2 Cut-outs in the frame				37
		4.5.3	Welding the frame			38
		4.5.4 Modifying the frame overhang				40
	4.6	Modiﬁ cations to the wheelbase				43
	4.7	Retroﬁ tting equipment				46
	4.8	Retroﬁ tting of leading and trailing axles				46
	4.9	Propshafts				46
		4.9.1	Single joint			46
		4.9.2 Jointed shaft with two joints				47
		4.9.3	Three-dimensional propshaft layout			48
			4.9.3.1	Propshaft train		49
			4.9.3.2 Forces in the propshaft system			50
		4.9.4 Modifying the propshaft layout in the driveline of MAN chassis				50
	4.10	Central lubrication system				51
	4.11	Modifying the cab				51
		4.11.1	General			51
		4.11.2	Extending the cab			51
		4.11.3	Spoilers, aerodynamics kit			52
		4.11.4 Roof sleeper cabs and raised roofs				52
			4.11.4.1 Fundamentals for the installation of roof cabs			52
			4.11.4.2		Roof openings	54
	4.12	Axle location, suspension, steering				55
		4.12.1	General			55
		4.12.2	Stability, body roll			55

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

	4.13	Add-on frame components				56
		4.13.1	Underride guard		56
		4.13.2	Sideguards			57
		4.13.3	Spare wheel			61
		4.13.3	Spare wheel			61
		4.13.4	Wheel chocks			61
		4.13.4	Wheel chocks			61
		4.13.5	Fuel tanks			61
		4.13.5	Fuel tanks			61
		4.13.6 Liqueﬁ ed gas systems and auxiliary heaters				62
	4.14	Gas engines:		Handling of high-pressure gas installations		62
	4.15	Modiﬁ cations to the engine				63
	4.15	Modiﬁ cations to the engine				63
		4.15.1 Air intake, exhaust gas path				63
		4.15.2	Engine cooling			63
		4.15.2	Engine cooling			63
		4.15.3 Engine encapsulation, noise insulation				63
	4.16	Coupling devices				64
	4.16	Coupling devices				64
		4.16.1	General			64
		4.16.2 Trailer coupling, D value				66
		4.16.2 Trailer coupling, D value				66
		4.16.3 Rigid drawbar trailers, central axle trailers, Dc value, V value				67
						67
		4.16.4 End cross members and trailer couplings				69
		4.16.5	Ball-type coupling			83
		4.16.6	Fifth-wheel coupling			83
		4.16.6	Fifth-wheel coupling			83
		4.16.7 Converting the vehicle type - truck / tractor				86
5.	Bodies					86
5.	Bodies					86
	5.1	General				86
		5.1.1	Accessibility, Clearances			87
		5.1.2	Lowering the body			89
		5.1.3	Platforms and steps			89
		5.1.4	Corrosion protection		90
	5.2	Subframes				90
		5.2.1	Designing the subframe			92
		5.2.2 Attaching subframes and bodies				95
			5.2.2.1 Screw connections and riveted joints			95
			5.2.2.2	Flexible connections		96
			5.2.2.3	Rigid connections		102
			5.2.2.4 Self-supporting bodies without subframe		104
	5.3	Special bodies				105
	5.3	Special bodies				105
		5.3.1	Testing of bodies		105
		5.3.2	Single-pivot body			105
		5.3.2	Single-pivot body			105
		5.3.3 Tank and container bodies				106
			5.3.3.1	General		106
			5.3.3.2	Body ﬁ xtures, mountings		106
			5.3.3.2	Body ﬁ xtures, mountings		106
			5.3.3.3 Tankers and container bodies without subframes			107

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

III

		5.3.4	Tippers			109
		5.3.5 Set-down, sliding set-down and sliding roll-off skip loaders				111
		5.3.6 Platform and box bodies				112
		5.3.7	Interchangeable containers			113
		5.3.7	Interchangeable containers			113
			5.3.7.1 Factory-ﬁ tted interchangeable platform chassis			113
			5.3.7.2		Other interchangeable equipment	113
			5.3.7.2		Other interchangeable equipment	113
		5.3.8	Loading cranes			114
			5.3.8.1 Loading crane behind the cab			116
			5.3.8.2		Rear loading crane	117
			5.3.8.2		Rear loading crane	117
			5.3.8.3 Subframe for loading crane			118
			5.3.8.3 Subframe for loading crane			118
		5.3.9	Tail-lifts			127
		5.3.9	Tail-lifts			127
		5.3.10	Cable winches			147
		5.3.11	Transport mixers			148
		5.3.11	Transport mixers			148
6.	Electrics					149
	6.1	Introduction				149
	6.1	Introduction				149
	6.2	References to repair manuals and standards				149
	6.2	References to repair manuals and standards				149
	6.3	Starting, tow-starting and operating				149
	6.4	Handling batteries				149
	6.4	Handling batteries				149
	6.5	Additional wiring diagrams and wiring harness drawings				150
	6.6	Fuse, power for additional consumers					151
	6.7	Type of electrical conductors and relays to be used				151
	6.8	Lighting installations				151
	6.9	Interference suppression				152
	6.9	Interference suppression				152
	6.10	Electromagnetic compatibility				152
	6.11	Interfaces on the vehicle				152
	6.11	Interfaces on the vehicle				152
	6.12	Body ﬁ ttings				153
	6.13	Setting customer-speciﬁ c parameters with MAN-cats®				153
	6.14	Earth cable				153
	6.15	Installation and routing of electric cabling/pipework				154
7.	Power take-offs			(see separate booklet)		154
8.	Brakes, lines					155
	8.1	Brake and compressed air lines				155
		8.1.1	Basic principles			155
		8.1.2 Plug connectors, changeover to Voss 232 system				155
		8.1.3 Installing and attaching lines				157
		8.1.4	Compressed air loss			159
	8.2	Connecting ancillary consumers				159
	8.2	Connecting ancillary consumers				159
	8.3	Adjusting the automatic load-dependent brake system				162
	8.4	Continuous brakes (retarders)				162
	8.4	Continuous brakes (retarders)				162
		8.4.1	Hydrodynamic retarders			162

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

		8.4.2	Eddy-current brakes	163
		8.4.2	Eddy-current brakes	163
9.	Calculations			165
	9.1	Speed		165
	9.2	Efﬁ ciency		166
	9.3	Tractive force		167
	9.4	Gradeability		168
		9.4.1 Distance travelled on uphill or downhill gradients		168
		9.4.2 Angle of uphill or downhill gradient		168
		9.4.3	Calculating the gradeability	169
	9.5	Torque		173
	9.5	Torque		173
	9.6	Power output		174
	9.7	Rotational speeds for power take-offs at the transfer case		176
	9.8	Driving resistances		177
	9.9	Turning circle		180
	9.10	Axle load calculation		182
		9.10.1 Performing an axle load calculation		182
		9.10.2 Calculation of weight with trailing axle lifted		185
	9.11	Support length for bodies without subframes		187
	9.12	Coupling devices		188
		9.12.1	Trailer coupling	188
		9.12.2 Rigid drawbar trailers / central axle trailers		188
		9.12.2 Rigid drawbar trailers / central axle trailers		188
		9.12.3	Fifth-wheel coupling	190

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

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® Technical Data“ software and on the Internet.

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

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.

2.1Model 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)

2.2Model number, model code, vehicle identiﬁcation 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.

2.3Wheel 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.

Table 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.

2.4Vehicle designation

2.4.1Vehicle 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.

Table 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)

Table 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

Table 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:

Table 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:

Table 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)

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:

Table 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	Front axle(s) have leaf suspension, rear axle(s) have hydropneumatic
Leaf-hydro	P	suspension
		suspension

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.

Table 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

Factory-ﬁtted 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.

Table 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)

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

2.4.2Model numbers, model codes

Table 12:	L2000

Model no.		Tonnage	Designation	Suspension	Engine	Wheel formula
L20		8/9t	8.xxx L	BB	R4	4x2/2
L20		8/9t	9.xxx L	BB	R4	4x2/2
			9.xxx L
L21		8/9t	8.xxx L	BB	R6	4x2/2
L21		8/9t	9.xxx L	BB	R6	4x2/2
			9.xxx L
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	8.xxx LL	BL	R4	4x2/2
L33		8/9t	9.xxx LL	BL	R4	4x2/2
			9.xxx LL
L34		8/9t	8.xxx LL	BL	R6	4x2/2
L34		8/9t	9.xxx LL	BL	R6	4x2/2
			9.xxx LL
L35		10t	10.xxx LL	BL	R4	4x2/2
L36		10t	10.xxx LL	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 ﬁrst 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)

Table 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		15t	15.xxx LL	BL	R6	4x2/2
L84		20t	20.xxx LNL	BLL	R6	6x2-4
		20t	20.xxx LNL	BLL	R6	6x2-4
L86		15t	15.xxx LLL	LL	R6	4x2/2
L86		20t	20.xxx LNLL	LLL	R6	6x2-4
		20t	20.xxx LNLL	LLL	R6	6x2-4
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
Table 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)

Table 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	6x2/2
T05		23t	23.xxx FNLL	LLL	R5	6x2-4
						6x2-4
T06		26t	26.xxx FNL	BLL	R5	6x2/2
T06		26t	26.xxx FNL	BLL	R5	6x2-4
						6x2-4
T07		26t	26.xxx FNLL	LLL	R5	6x2/2
T07		26t	26.xxx FNLL	LLL	R5	6x2-4
						6x2-4
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	6x2/2
T35		23t	23.xxx FNLL	LLL	R6	6x2-4
						6x2-4
T36		26t	26.xxx FNL	BLL	R6	6x2/2
T36		26t	26.xxx FNL	BLL	R6	6x2-4
						6x2-4
T37		26t	26.xxx FNLL	LLL	R6	6x2/2
T37		26t	26.xxx FNLL	LLL	R6	6x2-4
						6x2-4
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

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

Table 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	R6	8x8/4
E41		41t	41.xxx VFA	BBLL	R6	8x4/4
				BBLL		8x4/4
E42		26t	26.xxx FVL	BLL	R6	6x2/4
E47		28t	28.xxx FAN	BBB	R5	6x4-4
E47		28t	28.xxx DFA	BBB	R5	6x6-4
			28.xxx DFA			6x6-4
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	6x2-4
E53		26t	26.xxx FNL	BLL	R5	6x4-4
						6x4-4
E54		26t	26.xxx FN	BBB	R5	6x2/2
						8x2/4
E55		32t	32.xxx VFL	BBLL	R5	6x2-6
						8x4/4
E56		26t	26.xxx FAVL	BLL	R5	6x4/4
						8x8/4
E58		41/50t	41.xxx VFA	BBBB	R5	8x6/4
						8x4/4
E59		33t	33.xxx DFL	BLL	R5	6x2/2
E59		33t	33.xxx DFL	BLL	R5	6x4/2
						6x4/2
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	6x2-4
E63		26t	26.xxx FNL	BLL	R6	6x4-4
						6x4-4
E64		26t	26.xxx FN	BBB	R6	6x2/2
						8x2/4
E65		32t	32.xxx VFL	BBLL	R6	8x2-6
						8x4/4
E66		26t	26.xxx FAVL	BLL	R6	6x4/4
E67		28t	28.xxx FANL	BLL	R6	6x4-4
E67		28t	28.xxx FNAL	BLL	R6	6x6-4
			28.xxx FNAL			6x6-4
						8x8/4
E68		41/50t	41.xxx VFA	BBBB	R6	8x6/4
						8x4/4
E69		33t	33.xxx DFL	BLL	R6	6x2/2
E69		33t	33.xxx DFL	BLL	R6	6x4/2
						6x4/2
E72		33t	33.xxx DFAP	BHH	R6	6x6-4
E73		32/35t	32.xxx FVNL	BLLL	R6	8x2/4
E73		32/35t	32.xxx FVNL	BLLL	R6	8x2-6
						8x2-6
E74		42t	42.xxx VFP	BBHH	R6	8x4-6
E75		41t	41.xxx DFVL	BLBB	R6	8x4/4
E75		41t	41.xxx DFVL	BLLL	R6	8x4/4
				BLLL

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

Table 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	40.xxx DFA	BBB	V10	6x6/2
E94		40t	40.xxx DFAL	BLL	V10	6x6/2
			40.xxx DFAL	BLL
E95		41t	41.xxx DFVL	BLBB	V10	8x4/4
E95		41t	41.xxx DFVL	BLLL	V10	8x4/4
				BLLL
E98		50t	50.xxx VFA	BBBB	V10	8x8/4
E99		33t	33.xxx DF	BBB	V10	6x4/2
E99		33t	33.xxx DFL	BLL	V10	6x4/2
			33.xxx DFL	BLL

2.5 Engine designations
Table 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

Intercooling

F= Front installation, engine vertical

H= Rear installation, engine vertical (bus)

Table 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)

3.General

3.1Legal 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.

3.1.1Preconditions

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. 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)

3.2Responsibility

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.

3.3Quality 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)

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 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

„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.

3.4Approval

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.

3.5Submission 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 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)

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.

3.6Warranty

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)

3.7Liability

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.

3.8Type 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 certiﬁcation)

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)

3.9Safety

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.

3.9.1Functional 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)

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.

3.9.2Manuals 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)

3.9.3Manuals 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.

3.10Limitation 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 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).

3.11Special-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)

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).

3.12Change 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)

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)

3.13Increasing 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.

3.14Increasing 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)

3.15Increasing 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 ofﬁcial 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

3.16Reducing 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 modiﬁcations are required.

3.17Deﬁnitions, 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® documents:

•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).

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

3.17.1Axle 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

G G

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

Formula 1: Difference in wheel load

∆G ≤ 0,04 • Gtat

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 Gtat = 11.000kg

Therefore, the permissible wheel load difference is:

∆G = 0,04 · Gtat = 0,04 · 11.000kg ∆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.

3.18Minimum 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.

Table 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	Wheel		GG [t]	With SDAH	With SDAH	With SDAH	Triple SDAH	Other rear load
No. of axles	formula			ZAA	ZAA	ZAA	ZAA	e.g. crane
					GG ≤ 11t	GG ≤ 18t	GG > 18t
All 2-axle	4x2, 4x4		≤ 10	25%	30%	35%	not perm.	30%
vehicles	4x2, 4x4		≤ 15	25%	30%	30%	not perm.	30%
	4x2, 4x4		> 15	25%	25%	25%	not perm.	30%
							TGA and F2000
More than 2	6x2, 6x4,		> 19	20%	25%*	25%*	30%	25%
axles	6x6
	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.

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

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