MAN TGA Service Manual

4.6 (42)

Guidelines to ﬁtting bodies

TRUCKNOLOGY® GENERATION A (TGA)

Edition 2011 Version 1.0

P U B L I S H E R

MAN Truck & Bus AG

(mentioned in the text below “MAN“)

ESC Department

Engineering Services

Consultation

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

D - 8 0 9 9 5 M u n i c h

E-Mail: esc@man.eu

Fax:

+ 49 (0) 89 1580 4264

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

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

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

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

TRUCKNOLOGY® GENERATION A (TGA)


1.	Applicability and legal agreements			1
1.	Applicability and legal agreements			1
	1.1	Applicability		1
	1.2	Legal agreements and approval procedure		1
	1.2	Legal agreements and approval procedure		1
		1.2.1	Preconditions	1
		1.2.1	Preconditions	1
		1.2.2	Responsibility	2
		1.2.2	Responsibility	2
		1.2.3	Quality assurance	2
		1.2.3	Quality assurance	2
		1.2.4	Approval	3
		1.2.4	Approval	3
		1.2.5	Submission of documents	3
		1.2.6	Liability for defects	4
		1.2.7	Product liability	5
		1.2.8	Safety	5
		1.2.8	Safety	5
		1.2.9	Manuals from body and conversion companies	6
		1.2.9	Manuals from body and conversion companies	6
		1.2.10	Limitation of liability for accessories/spare parts	7
		1.2.10	Limitation of liability for accessories/spare parts	7
2.	Product designations			7
	2.1	Vehicle designation and wheel formula		7
		2.1.1	Door designation	7
		2.1.1	Door designation	7
		2.1.2	Variant descriptor	7
		2.1.3	Wheel formula	8
		2.1.4	Sufﬁ x	9
	2.2	Model number, vehicle identiﬁcation number, vehicle number, basic vehicle number		10
	2.2			10
	2.3	Use of logos		13
	2.4	Cabs		14
	2.4	Cabs		14
	2.5	Engine variants		16
3.	General			17
	3.1	Axle overload, one-sided loading		17
	3.2	Minimum front axle load		19
	3.3	Wheels, rolling circumference		20
	3.4	Permissible overhang		20
	3.5	Theoretical wheelbase, overhang, theoretical axle centreline		21
	3.6	Calculating the axle load and weighing procedure		23
	3.7	Checking and adjustment procedures once body has been ﬁ tted		24
	3.8	Notes on MAN Hydrodrive®		25
	3.8	Notes on MAN Hydrodrive®		25

TRUCKNOLOGY® GENERATION A (TGA)


4.	Modifying the chassis			25
	4.1	Frame material		25
	4.2	Corrosion protection		30

	4.3	Drill holes, riveted joints and screw connections on the frame		30
	4.4	Modifying the frame		33
		4.4.1	Welding the frame	33
		4.4.2	Modifying the frame overhang	35
		4.4.3	Modiﬁ cations to the wheelbase	37

	4.5	Retroﬁ tting additional equipment add-on components or accessories		43
	4.5.1	Retroﬁ tting additional or larger fuel tanks after factory delivery		44
	4.6	Propshafts		45

		4.6.1	Single joint	45

		4.6.2	Jointed shaft with two joints	46

		4.6.3	Three-dimensional propshaft layout	47

			4.6.3.1 Propshaft train	48

			4.6.3.2 Forces in the propshaft system	48

		4.6.4	Modifying the propshaft layout in the driveline of MAN chassis	49

	4.7	Modifying the wheel formula		49

	4.8	Coupling devices		51

		4.8.1	Basics	51

		4.8.2	Trailer coupling, D value	52

	4.9	Tractor units and converting the vehicle type - truck / tractor		52

		4.9.1	Articulated vehicles	52

		4.9.2	Converting trucks into tractor units or tractor units into trucks	55

	4.10	Modifying the cab		55

		4.10.1	General	55

		4.10.2	Spoilers, roof extensions, roofwalk	55

		4.10.3	Roof sleeper cabs	58

	4.11	Add-on frame components		59

		4.11.1	Rear underride guard	59

		4.11.2	FUP - front underride protection	61

		4.11.3	Sideguards	62

	4.12	Modiﬁ cations to engine systems		64

		4.12.1	Modiﬁ cations to the air intake and exhaust gas routing for engines up to and	64

			including Euro4 with On Board Diagnosis	64

		4.12.2	Additional requirements if changes are made to the AdBlue® system/exhaust	66

			system on Euro5 vehicles	66

		4.12.3	Engine cooling	74

		4.12.4	Engine encapsulation, noise insulation	74

	4.13	Fitting other manual gearboxes, automatic transmissions and transfer boxes		74

TRUCKNOLOGY® GENERATION A (TGA)


5.	Bodies			74
	5.1	General		74
	5.2	Corrosion protection		76
	5.2	Corrosion protection		76
	5.3	Subframes		76
	5.3	Subframes		76
		5.3.1	General	76
		5.3.1	General	76
		5.3.2	Permissible materials, yield points	77
		5.3.2	Permissible materials, yield points	77
		5.3.3	Subframe design	79
		5.3.3	Subframe design	79
		5.3.4	Attaching subframes and bodies	80
		5.3.4	Attaching subframes and bodies	80
		5.3.5	Screw connections and riveted joints	81
		5.3.5	Screw connections and riveted joints	81
		5.3.6	Flexible connection	84
		5.3.6	Flexible connection	84
		5.3.7	Rigid connection	87
		5.3.7	Rigid connection	87
	5.4	Bodies		87
	5.4	Bodies		87
		5.4.1	Testing of bodies	87
		5.4.1	Testing of bodies	87
		5.4.2	Platform and box bodies	88
		5.4.2	Platform and box bodies	88
		5.4.3	Tail-lifts	96
		5.4.3	Tail-lifts	96
		5.4.4	Interchangeable containers	97
		5.4.4	Interchangeable containers	97
		5.4.5	Self-supporting bodies without subframe	98
		5.4.5	Self-supporting bodies without subframe	98
		5.4.6	Single-pivot body	98
		5.4.6	Single-pivot body	98
		5.4.7	Tank and container bodies	101
		5.4.7	Tank and container bodies	101
		5.4.8	Tippers	103
		5.4.8	Tippers	103
		5.4.9	Set-down, sliding set-down and sliding roll-off tippers	104
		5.4.9	Set-down, sliding set-down and sliding roll-off tippers	104
		5.4.10	Propping air-sprung vehicles	105
		5.4.10	Propping air-sprung vehicles	105
		5.4.11	Loading cranes	106
		5.4.12	Cable winches	116
		5.4.13	Transport mixers	116
		5.4.13	Transport mixers	116
		5.4.14	Car transporter	117

TRUCKNOLOGY® GENERATION A (TGA)

III


6.	Electrics, electronics, wiring			118
	6.1	General		118
	6.1	General		118
	6.2	Routing cables, earth cable		118
	6.2	Routing cables, earth cable		118
	6.3	Handling batteries		118
	6.3	Handling batteries		118
		6.3.1	Handling and maintaining the batteries	118
		6.3.2	Handling and maintaining batteries with PAG technology		119
	6.4	Additional wiring diagrams and wiring harness drawings			120
	6.5	Fuses, additional power consumers			120
	6.6	Lighting installations			123
	6.6	Lighting installations			123
	6.7	Electromagnetic compatibility			123
	6.8	Radio equipment and aerials			124
	6.9	Interfaces on the vehicle, preparations for the body			126
	6.9	Interfaces on the vehicle, preparations for the body			126
		6.9.1	Electrical connections for tail-lifts		126
		6.9.1	Electrical connections for tail-lifts		126
		6.9.2	Start-stop control on frame end		126
		6.9.2	Start-stop control on frame end		126
	6.10	Electronics			127
		6.10.1	Display and instrumentation concept		127
		6.10.2	Diagnostics concept and parameterisation using MAN-cats®		127
		6.10.2	Diagnostics concept and parameterisation using MAN-cats®		127
		6.10.3	Parameterisation of the vehicle electronics		127

TRUCKNOLOGY® GENERATION A (TGA)

7.	Power take-off			(See separate booklet)	127
8.	Brakes, lines				128
	8.1	ALB, EBS braking system			128
	8.2	Brake and compressed air lines			128
		8.2.1	Basic principles		128
		8.2.1	Basic principles		128
		8.2.2	Voss 232 system plug connectors		129
		8.2.3	Installing and attaching lines		130
		8.2.4	Compressed air loss		132
		8.2.4	Compressed air loss		132
	8.3	Connecting additional air consumers			132
	8.3	Connecting additional air consumers			132
	8.4	Retroﬁ tting continuous brakes not manufactured by MAN			134
9.	Calculations				134
9.	Calculations				134
	9.1	Speed			134
	9.1	Speed			134
	9.2	Efﬁ ciency			135
	9.2	Efﬁ ciency			135
	9.3	Tractive force			136
	9.3	Tractive force			136
	9.4	Gradeability			137
	9.4	Gradeability			137
		9.4.1	Distance travelled on uphill or downhill gradients		137
		9.4.2	Angle of uphill or downhill gradient		137
		9.4.3	Calculating the gradeability		138
	9.5	Torque			142
	9.6	Power output				143
	9.7	Rotational speeds for power take-offs at the transfer case			145
	9.8	Driving resistances			146
	9.9	Turning circle			149
	9.10	Axle load calculation			151
		9.10.1	Performing an axle load calculation		151
		9.10.2	Calculation of weight with trailing axle lifted		154
	9.11	Support length for bodies without subframes			156
	9.12	Coupling devices			157
		9.12.1	Trailer coupling		157
		9.12.2	Rigid drawbar trailers / central axle trailers		157
		9.12.3	Fifth-wheel coupling		159

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

They are of no consequence to the reader.

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

TRUCKNOLOGY® GENERATION A (TGA)

1.Applicability and legal agreements

1.1Applicability

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

1.2Legal agreements and approval procedure

1.2.1Preconditions

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

•laws and decrees

•accident prevention regulations

•operating instructions

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

Standards are binding when they form part of regulations.

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

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

to experience.

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

References to

•legal stipulations

•accident prevention regulations

•decrees from professional associations

•work regulations

•other guidelines and sources of information

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

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

the lowest possible fuel consumption.

TRUCKNOLOGY® GENERATION A (TGA)

1.2.2Responsibility

The responsibility for proper

•design

•production

•installation of bodies

•modiﬁ cation to the chassis

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

•the customer

•the user

•its own personnel

•the vehicle manufacturer

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

The company is responsible for seeing that the vehicle’s

•operational safety

•trafﬁ c safety

•maintenance possibilities and

•handling characteristics

do not exhibit any disadvantageous properties.

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

•the design

•the production of bodies

•the installation of bodies

•the modiﬁ cation of chassis

•instructions and

•operating instructions.

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

1.2.3Quality assurance

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

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

TRUCKNOLOGY® GENERATION A (TGA)

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

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

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

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

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

Documents:

VDA Volume 8

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

1.2.4Approval

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

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

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

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

•Function

•Design

•Equipment of the body or the modiﬁ cation.

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

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

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

the interim period have to be taken into account.

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

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

1.2.5Submission of documents

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

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

•Documents should be submitted in duplicate

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

•All the technical data and documents must be submitted.

TRUCKNOLOGY® GENERATION A (TGA)

The following information should be included:

•Vehicle model (see Chapter 2.2 for model code) with

-cab design

-wheelbase

-frame overhang

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

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

•Loads and their load application points:

-Forces from the body

-Axle load calculation

•Special conditions of use:

•Subframe:

-Material and cross-sectional data

-Dimensions

-Type of section

-Arrangement of cross members in the subframe

-Special features of the subframe design

-Cross-section modiﬁ cations

-Additional reinforcements

-Upsweeps, etc.

•Means of connection:

-Positioning (in relation to the chassis)

-Type

-Size

-Number.

The following are not sufﬁ cient for inspection or approval:

•Parts lists

•Brochures

•Photographs

•Other not binding information.

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

1.2.6Liability for defects

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

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

•This Guide was not observed

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

•The damage to the chassis has been caused by

-the body

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

-the modiﬁ cation to the chassis

-improper use.

TRUCKNOLOGY® GENERATION A (TGA)

1.2.7Product liability

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

Product liability regulates:

•The liability of the manufacturer for its product or component

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

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

•The company did not observe this Guide

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

-design

-manufacture

-installation

-instructions

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

1.2.8Safety

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

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

•Provide comprehensible, sufﬁ cient operating instructions

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

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

•Provide full toxicological information

•Provide full environmental information.

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

•Active safety = prevention of accidents. This includes:

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

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

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

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

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

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

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

TRUCKNOLOGY® GENERATION A (TGA)

Climatic and environmental conditions have effects on:

•Operational safety

•Readiness for use

•Operational performance

•Service life

•Cost-effectiveness.

Climatic and environmental conditions are, for example:

•The effects of temperature

•Humidity

•Aggressive substances

•Sand and dust

•Radiation.

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

1.2.9Manuals from body and conversion companies

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

not able to:

•Handle the product safely and properly

•Use it rationally and effortlessly

•Maintain it properly

•Master all of its functions.

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

•Clarity

•Completeness

•Accuracy

•Comprehensibility

•Product-speciﬁ c safety instructions.

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

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

•Complaints and annoyance

•Faults and damage, which are normally blamed on the chassis

•Unexpected and unnecessary additional cost through repairs and time lost

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

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

TRUCKNOLOGY® GENERATION A (TGA)

1.2.10Limitation of liability for accessories/spare parts

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

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

2.Product designations

2.1Vehicle designation and wheel formula

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

-Door designation

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

-Model code.

2.1.1Door designation

The door designation comprises:

Model range + permissible weight + engine power

TGA 18.400

Model range	+ Permissible weight	+ Engine power
T G A	1 8	. 4 0 0

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

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

2.1.2Variant descriptor

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

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

TGA 25.480 6x2-2 LL-U

Model range

+ Permissible weight

+ Engine power

T G A	2 5	. 4 8 0	6 x 2 - 2	L L - U
			Wheel formula	Sufﬁ x

TRUCKNOLOGY® GENERATION A (TGA)

2.1.3Wheel formula

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

The following two examples illustrate the wheel formula:

Table 1: Wheel formula examples

6 x 2 - 4

6 x 2 / 4

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

2= Number of driven wheels

-= Trailing axle behind the rear drive-axle assembly

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

4= Number of steered wheels

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

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

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

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

Currently the following wheel formulae are available ex-works:

Table 2: TGA wheel formulae

4x2 Two-axle vehicle with one drive axle

4x4 Two-axle vehicle with two drive axles “All-wheel drive”

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

6x2/2 Three-axle vehicle with non-steered “Pusher” leading axle

6x2/4 Three-axle vehicle with steered leading axle

6x2-2 Three-axle vehicle with non-steered trailing axle

6x2-4 Three-axle vehicle with steered trailing axle

6x4 Three-axle vehicle with two driven non-steered rear axles

6x4/4 Three-axle vehicle with 2 driven axles (ﬁ rst and last axles), steered leading axle

6x4-4 Three-axle vehicle with 2 driven axles, (ﬁ rst and second axles), steered trailing axle

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

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

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

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

TRUCKNOLOGY® GENERATION A (TGA)

Table 2: TGA wheel formulae (continuation)

6x6 Three-axle vehicle with all-wheel drive

6x6-4 Three-axle vehicle with all-wheel drive, steered and driven trailing axle

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

8x2-4 Four-axle vehicle with one drive axle, two steered front axles, non steered trailing axle or four-axle vehicle with three rear axles with front and trailing axles steered

8x2-6 Four-axle vehicle with one drive axle, two steered front axles, steered trailing axle

8x4 Four-axle vehicle with two steered front axles and two driven rear axles

8x4/4 Four-axle vehicle with one front axle, one steered leading axle and two driven rear axles

8x4-4 Four-axle vehicle with one front axle, two driven rear axles and one steered trailing axle

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

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

8x6 Four-axle vehicle “All wheel drive” with two front axles (2nd driven) and two driven rear axles

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

8x8 Four-axle vehicle “All wheel drive” with two front axles and two rear axles, all driven

2.1.4Sufﬁx

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

	T G A 2 5 . 4 8 0 6 x 2 - 2	LL-U
		Sufﬁ x

Types of suspension (Digits 1 and 2 of sufﬁ x)
Table 3:	Types of suspension

BB	Leaf suspension on front axle(s), leaf suspension on rear axle(s)
BL	Leaf suspension on front axle(s), air suspension on rear axle(s)
LL	Air suspension on front axle(s), air suspension on rear axle(s)
BH	Leaf suspension on front axle(s), hydropneumatic on rear axle(s)

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

Example for semitrailer tractor:

T G A 3 3 . 4 4 0 6 x 6	BBS
	S = Semitrailer tractor

TRUCKNOLOGY® GENERATION A (TGA)

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

Example for special product features:

	T G A 1 8 . 3 5 0 4 x 2 B L S	-TS
		-TS = Weight optimised version for silo tanker

Table 4:	Designations for special designs produced to-date (to be supplemented with further designs)

-U	For low design ‘Ultra’ e.g.: TGA 18.410 4x2 LLS-U
-TS	Weight optimised version for silo tanker, e.g.: TGA 18.400 4x2 BLS-TS
-WW	“World wide” variant, eligible for licensing outside Europe only, e.g. TGA 40.460 6x6 BB-WW
-LE	“Low entry” cab with lowered entry, e.g.: TGA 28.310 6x2-4 LL-LE
-CKD	“Completely knocked down”, for assembly in MAN factory of the recipient country, e.g.: TGA 40.480 6x4-4 WW-CKD

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

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

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

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

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

Vehicle designation	Model number	Vehicle identiﬁ cation number	Basic vehicle	Vehicle number
	Model code	(VIN)	number
TGA 18.440 4x2 BLS	H06	WMAH06ZZ14M000479	LH06AG53	H060057
TGA 26.410 6x2-4 LL	H21	WMAH21ZZ94G144924	LH21E 05	H210058
TGA 33.540 6x4 BB	H26	WMAH26ZZ75M350354	LH26LR04	H261158

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

TRUCKNOLOGY® GENERATION A (TGA)

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

Model number	Tonnage	Designation , xxx stands for	Engine	Suspension
		various engine powers
H01	18 t	TGA 18.xxx 4x2 BLS-TS	D28 R6	BL
H02	18 t	TGA 18.xxx 4x2 BB	D28 R6	BB
H03	18 t	TGA 18.xxx 4x2 BB	D20/D26 R6	BB
H05	18 t	TGA 18.xxx 4x2 BL	D28 R6	BL
H06	18 t	TGA 18.xxx 4x2 BL	D20/D26 R6	BL
H07	18 t	ECT 18.ISM 4x2 BL	ISMe	BL
H08	18 t	TGA 18.xxx 4x2 BLS-TS	D20/D26 R6	BL
H09	18 t	TGA 18.xxx 4x2 LL	D28 R6	LL
H10	18 t	TGA 18.xxx 4x2 LL	D20/D26 R6	LL
H11	40 t	TGA 40.xxx 6x4 BB-WW-CKD	D20/D26 R6	BBB
H12	18 t	TGA 18.xxx 4x2 LLS-U	D28 R6	LL
H13	18 t	TGA 18.xxx 4x2 LLS-U	D20/D26 R6	LL
H14	18 t	TGA 18.xxx 4x2 LL-U	D28 R6	LL
H15	18 t	TGA 18.xxx 4x2 LL-U	DD20/D26 R6	LL
H16	26 t	TGA 26.xxx 6x2-4 BL	D08 R6	BLL
H17	26 t	TGA 26.xxx 6x2-2, 6x2-4 BL	D28 R6	BLL
H18	26 t	TGA 26.xxx 6x2-2, 6x2-4 BL	D20/D26 R6	BLL
H19	26 t	TGA 26.xxx 6x2-4 LL	D08 R6	LLL
H20	26 t	TGA 26.xxx 6x2-2, 6x2-4 LL	D28 R6	LLL
H21	26 t	TGA 26.xxx 6x2-2, 6x2-4 LL	D20/D26 R6	LLL
H22	18 t	TGA 18.xxx 4x4H BL	D20/D26 R6	BL
H23	26 t	TGA 26.xxx 6x2/2, 6x2/4 BL	D28 R6	BLL
H24	26 t	TGA 26.xxx 6x2/2, 6x2/4 BL	D20/D26 R6	BLL
H25	26/33 t	TGA 26/33.xxx 6x4 BB	D28 R6	BBB
H26	26/33 t	TGA 26/33.xxx 6x4 BB	D20/D26 R6	BBB
H27	26 t	ECT 26.ISM 6x2-2, 6x2-4 BL	ISMe	BLL
H28	33 t	TGA 33.xxx 6x4 BB-WW	D28 R6	BBB
H29	26/33 t	TGA 26/33.xxx 6x4 BL	D28 R6	BLL
H30	26/33 t	TGA 26/33.xxx 6x4 BL	D20/D26 R6	BLL
H31	26 t	ECT 26.ISM 6x2-2 LL	ISMe	LLL
H32	26 t	ECT 26.ISM 6x2/2 BL	ISMe	BLL
H33	40 t	TGA 40.xxx 6x4 BB-WW	D28 R6	BBB
H34	40 t	TGA 40.xxx 6x4 BB-WW	D20/D26 R6	BBB
H35	26 t	TGA 26.xxx 6x4H-2 BL, 6x4H-4 BL	D20/D26 R6	BLL
H36	35 t	TGA 35.xxx 8x4 BB	D28 R6	BBBB
H37	35 t	TGA 35.xxx 8x4 BB	D20/D26 R6	BBBB

TRUCKNOLOGY® GENERATION A (TGA)

Model number	Tonnage	Designation , xxx stands for	Engine	Suspension
		various engine powers
H38	41 t	TGA 41.xxx 8x4 BB	D28 R6	BBBB
H39	41 t	TGA 41.xxx 8x4 BB	D20/D26 R6	BBBB
H40	35 t	TGA 35.xxx 8x4 BL	D28 R6	BBLL
H41	35 t	TGA 35.xxx 8x4 BL	D20/D26 R6	BBLL
H42	26 t	TGA 26.xxx 6x4H/2 BL, 6x4H/4 BL	D20/D26 R6	BLL
H43	19 t	TGA 19.xxx 4x2 BBS-WW	D28 R6	BB
H44	25 t	TGA 25.xxx 6x2-2 LL-U	D28 R6	LLL
H45	25 t	TGA 25.xxx 6x2-2 LL-U	D20/D26 R6	LLL
H46	41 t	TGA 41.xxx 8x4 BB-WW	D28 R6	BBBB
H47	26/33 t	TGA 26/33.xxx 6x6H BB	D20/D26 R6	BBB
H48	32 t	TGA 32.xxx 8x4 BB	D28 R6	BBBB
H49	32 t	TGA 32.xxx 8x4 BB	D20/D26 R6	BBBB
H50	35 t	TGA 35.xxx 8x6H BB	D20/D26 R6	BBBB
H51	18 t	TGA 18.xxx 4x4 BB	D28 R6	BB
H52	18 t	TGA 18.xxx 4x4 BB	D20/D26 R6	BB
H54	33 t	TGA 33.xxx 6x6 BB-WW	D28 R6	BBB
H55	26/33 t	TGA 26/33.xxx 6x6 BB	D28 R6	BBB
H56	26/33 t	TGA 26/33.xxx 6x6 BB	D20/D26 R6	BBB
H57	40 t	TGA 40.xxx 6x6 BB-WW	D28 R6	BBB
H58	40 t	TGA 40.xxx 6x6 BB-WW	D20/D26 R6	BBB
H59	35 t	TGA 35.xxx 8x6H BL	D20/D26 R6	BBLL
H60	19 t	TGA 19.xxx 4x2 BBS-WW-CKD	D28 R6	BB
H61	18 t	TGA 18.xxx 4x2 BLS-WW-CKD	D28 R6	BL
H62	33 t	TGA 33.xxx 6x4 BB-WW-CKD	D28 R6	BBB
H63	26 t	TGA 26.xxx 6x4 BL-WW-CKD	D28 R6	BLL
H64	19 t	TGA 19.xxx 4x2 BBS-WW-CKD	D20/D26 R6	BB
H65	18 t	TGA 18.xxx 4x2 BLS-WW-CKD	D20/D26 R6	BL
H66	33 t	TGA 33.xxx 6x4 BB-WW-CKD	D20/D26 R6	BBB
H67	26 t	TGA 26.xxx 6x4 BL-WW-CKD	D20/D26 R6	BLL
H68	40 t	TGA 40.xxx 6x4 BB-WW-CKD	D28 R6	BBB
H69	39 t	TGA 39.xxx 8x2-4 BL	D20/D26 R6	BBLL
H70	18 t	TGA 18.xxx 4x4 BL	D28 R6	BL
H71	28 t	TGA 28.xxx 6x2-4 BL	D28 R6	BLLLLL
		TGA 28.xxx 6x2-4 LL
H72	26/33 t	TGA 26/33.xxx 6x6 BL	D28 R6	BLL
H73	35/41 t	TGA 35/41.xxx 8x6 BB	D28 R6	BBBB
H74	28 t	TGA 28.xxx 6x2-4 BL	D20/D26 R6	BLL
H75	28 t	TGA 28.xxx 6x2-4 LL	D20/D26 R6	LLL
H76	35/41 t	TGA 35/41.xxx 8x8 BB	D28 R6	BBBB
H77	28 t	TGA 28.xxx 6x4-4 BL	D20/D26 R6	BLL
H80	18 t	TGA 18.xxx 4x4 BL	D20/D26 R6	BL

TRUCKNOLOGY® GENERATION A (TGA)

Model number	Tonnage	Designation , xxx stands for	Engine	Suspension
		various engine powers
H81	28 t	TGA 28.xxx 6x4-4 BL	D28 R6	BLL
H82	26/33 t	TGA 26/33.xxx 6x6 BL	D20/D26 R6	BLL
H83	28 t	TGA 28.xxx 6x6-4 BL	D20/D26 R6	BLL
H84	28 t	TGA 28.xxx 6x4-4 BL	D20/D26 R6	BLL
H85	28 t	TGA 28.xxx 6x2-2 LL	D20/D26 R6	LLL
H86	28 t	TGA 28.xxx 6x2-2 BL	D28 R6	BLL
H87	28 t	TGA 28.xxx 6x2-2 LL	D28 R6	LLL
H88	35 t	TGA 35.xxx 8x2-4, 8x2-6 BL	D28 R6	BBLL
H89	28 t	TGA 28.xxx 6x2-2 BL	D20/D26 R6	BLL
H90	35 t	TGA 35.xxx 8x2-4, 8x2-6 BL	D20/D26 R6	BBLL
H91	35 t	TGA 35.xxx 8x4-4 BL	D28 R6	BLLL
H92	35 t	TGA 35.xxx 8x4-4 BL	D20/D26 R6	BLLL
H93	35/41 t	TGA 35/41.xxx 8x6 BB	D20/D26 R6	BBBB
H94	41 t	TGA 41.xxx 8x4/4 BB	D28 R6	BLBB
		TGA 41.xxx 8x4/4 BL		BLLL
H95	41 t	TGA 41.xxx 8x4/4 BB	D28 V10	BLBB
		TGA 41.xxx 8x4/4 BL		BLLL
H96	35/41 t	TGA 35/41.xxx 8x8 BB	D20/D26 R6	BBBB
H97	18 t	TGA 18.xxx 4x2 LL-LE	D20/D26 R6	LL
H98	26 t	TGA 26.xxx 6x2/4 LL-LE	D20/D26 R6	LLL
H99	28 t	TGA 28.xxx 6x2-4 LL-LE	D20/D26 R6	LLL
HH1	26/33 t	TGA 26/33.xxx 6x6H BL	D20/D26 R6	BLL
HH2	28 t	TGA 28.xxx 6x4H-4	D20/D26 R6	BLL
HH4	35 t	TGA 35.xxx 8x4H-4, 8x4H-6 BL	D20/D26 R6	BBLL
HV1	26 t	TGA 26.xxx 6X2-2, 6X2-4 BL-WW	D20/D26 R6	BLL
HV2	26/33 t	TGA 26/33.xxx 6X4 BL-WW	D20/D26 R6	BLL
HV3	39 t	TGA 39.xxx 8X2-4 BL-WW	D20 R6	BBLL
HV4	28 t	TGA 28.xxx 6X2-2 BL-WW	D20/D26 R6	BLL
HV5	18 t	TGA 18.xxx 4X4 BB-WW	D20 R6	BB
HV6	35/41 t	TGA 35/41.xxx 8X8 BB-WW	D20 R6	BBBB
HV7	28 t	TGA 28.xxx 6X2-2 BL-WW-CKD	D20/D26 R6	BLL
HV8	32 t	TGA 32.xxx 8X4 BB-WW	D20 R6	BBBB
HW1	19 t	TGA 19.xxx 4x2 BBS-WW	D20/D26 R6	BB
HW2	33 t	TGA 33.xxx 6x4 BB-WW	D20/D26 R6	BBB
HW3	41 t	TGA 41.xxx 8x4 BB-WW	D20/D26 R6	BBBB
HW4	33 t	TGA 33.xxx 6x6 BB-WW	D20/D26 R6	BBB
HW5	19 t	TGA 19.xxx 4x2 BLS-WW-CKD	D20/D26 R6	BL
HW6	41 t	TGA 41.xxx 8x4 BB-WW-CKD	D20/D26 R6	BBBB
HW7	19 t	TGA 19.xxx 4x2 BLS-WW	D20/D26 R6	BL
HW8	33 t	TGA 33.xxx 6x4 BBS-WW	D20/D26 R6	BBB
HW9	33 t	TGA 33.xxx 6x4 BBS-WW-CKD	D20/D26 R6	BBB

TRUCKNOLOGY® GENERATION A (TGA)

2.3Use of logos

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

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

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

TRUCKNOLOGY® GENERATION A (TGA)

2.4Cabs

There are 6 different Trucknology® Generation A cabs:

Table 7:	Trucknology® Generation A cabs
	Description		Dimensions*			Views
Name	Technical	Length	Width	High roof	Side	Front
	description
M	LHD	1.880	2.240
	F99L15S
	RHD
	F99R15S

L	LHD	2.280	2.240
	F99L32S
	RHD
	F99R32S

LX	LHD	2.280	2.240	yes
	F99L37S
	RHD
	F99R37S

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

TRUCKNOLOGY® GENERATION A (TGA)

	Description		Dimensions*			Views
Name	Technical	Length	Width	High roof	Side	Front
	description
XL	LHD	2.280	2.440
	F99L40S
	RHD
	F99R40S

XLX	LHD	2.280	2.440	yes, low
	F99 L47 S
	RHD
	F99 R47 S

XXL	LHD	2.280	2.440	yes
	F99L41S
	RHD
	F99R41S

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

TRUCKNOLOGY® GENERATION A (TGA)

2.5Engine variants

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

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

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

Vehicle	Emission	Power [kW]	OBD	EGR	Exhaust gas	Max. torque	Engine	Engine
designation	class	at [rpm]	generation		after treatment	[Nm] / at [rpm]	type	designation

xx.280		206 kW / 2.400				1.100 at 1.200 - 1.800 rpm		D0836LF41

xx.330		240 kW / 2.400				1.250 at 1.200 - 1.800 rpm		D0836LF44

xx.310		228 kW / 1.900				1.500 at 900 - 1.300 rpm		D2866LF26
xx.310		228 kW / 1.900				1.550 at 1.000 - 1.300 rpm		D2066LF04

xx.360		265 kW / 1.900				1.700 at 900 - 1.400 rpm		D2866LF27
xx.350		257 kW / 1.900				1.750 at 1.000 - 1.300 rpm		D2066LF03

xx.410		301 kW / 1.900				1.850 at 900 - 1.300 rpm	R6	D2866LF28

xx.390		287 kW / 1.900				1.900 at 1.000 - 1.300 rpm		D2066LF02

xx.430	Euro 3	316 kW / 1.900			None	2.100 at 1.000 - 1.300 rpm		D2066LF01

xx.460		338 kW / 1.900				2.100 at 900 - 1.300 rpm		D2876LF04
xx.460		338 kW / 1.900				2.100 at 900 - 1.300 rpm		D2876LF04
xx.510		375 kW / 1.900	No OBD			2.300 at 1.000 - 1.300 rpm		D2876LF05

xx.480		353 kW / 1.900				2.300 at 1.000 - 1.400 rpm		D2876LF12
xx.480		353 kW / 1.900				2.300 at 1.000 - 1.400 rpm		D2876LF12
xx.530		390 kW / 1.900				2.400 at 1.000 - 1.400 rpm		D2876LF13

xx.660		485 kW / 1.900		With		2.700 at 1.000 - 1.600 rpm	V10	D2840LF25

xx.360		265 kW / 1.900				1.800 at 1.000 - 1.400 rpm		D2066LF48
xx.360		265 kW / 1.900		AGR		1.800 at 1.000 - 1.400 rpm		D2066LF48

xx.400		294 kW / 1.900				1.900 at 1.000 - 1.400 rpm		D2066LF49
xx.400		294 kW / 1.900				1.900 at 1.000 - 1.400 rpm		D2066LF49

xx.440		324 kW / 1.900				2.100 at 1.000 - 1.400 rpm		D2066LF50
xx.480		353 kW / 1.900				2.300 at 1.050 - 1.400 rpm		D2676LF31

xx.310		228 kW / 1.900				1.550 at 1.000 - 1.400 rpm		D2066LF14
xx.350		257 kW / 1.900				1.750 at 1.000 - 1.400 rpm		D2066LF13

xx.390		287 kW / 1.900				1.900 at 1.000 - 1.400 rpm		D2066LF12
xx.430		316 kW / 1.900				2.100 at 1.000 - 1.400 rpm	R6	D2066LF11

xx.320		235 kW / 1.900				1.600 at 1.000 - 1.400 rpm		D2066LF35
	Euro 4				PM-Kat®
xx.360	Euro 4	265 kW / 1.900			PM-Kat®	1.800 at 1.000 - 1.400 rpm		D2066LF33
xx.400		294 kW / 1.900	OBD 1			1.900 at 1.000 - 1.400 rpm		D2066LF32

xx.440		324 kW / 1.900				2.100 at 1.000 - 1.400 rpm		D2066LF31
xx.480		353 kW / 1.900				2.300 at 1.050 - 1.400 rpm		D2676LF01

xx.320		235 kW / 1.900	OBD 1 +			1.600 at 1.000 - 1.400 rpm		D2066LF39
			NOX control

TRUCKNOLOGY® GENERATION A (TGA)

Vehicle	Emission	Power [kW]	OBD	EGR	Exhaust gas	Max. torque	Engine	Engine
designation	class	at [rpm]	generation		after treatment	[Nm] / at [rpm]	type	designation

xx.360	Euro 4	265 kW / 1.900	OBD 1 +	With	PM-Kat®	1.800 at 1.000 - 1.400 rpm		D2066LF38
xx.400		294 kW / 1.900	NOX control	EGR		1.900 at 1.000 - 1.400 rpm		D2066LF37

xx.440		324 kW / 1.900				2.100 at 1.000 - 1.400 rpm		D2066LF36
xx.480		353 kW / 1.900				2.300 at 1.050 - 1.400 rpm		D2676LF05

xx.400		294 kW / 1.900	NO OBD			1.900 at 1.000 - 1.400 rpm		D2066LF22

xx.440		321 kW / 1.900				2.100 at 1.000 - 1.400 rpm		D2066LF21
xx.440		321 kW / 1.900				2.100 at 1.000 - 1.400 rpm		D2066LF21

xx.400		294 kW / 1.900				1.900 at 1.000 - 1.400 rpm		D2066LF24

xx.440		324 kW / 1.900	OBD 1			2.100 at 1.000 - 1.400 rpm		D2066LF23

xx.480		353 kW / 1.900				2.300 at 1.050 - 1.400 rpm		D2676LF12
xx.480		353 kW / 1.900				2.300 at 1.050 - 1.400 rpm		D2676LF12

xx.540		397 kW / 1.900				2.500 at 1.050 - 1.350 rpm		D2676LF11
xx.320		235 kW / 1.900				1.600 at 1.000 - 1.400 rpm	R6	D2066LF28

xx.360		265 kW / 1.900				1.800 at 1.000 - 1.400 rpm		D2066LF27
xx.360		265 kW / 1.900				1.800 at 1.000 - 1.400 rpm		D2066LF27
xx.400	Euro 5	294 kW / 1.900		No	SCR	1.900 at 1.000 - 1.400 rpm		D2066LF26
xx.440	Euro 5	324 kW / 1.900		EGR	SCR	2.100 at 1.000 - 1.400 rpm		D2066LF25
xx.440		324 kW / 1.900		EGR		2.100 at 1.000 - 1.400 rpm		D2066LF25

xx.480		353 kW / 1.900				2.300 at 1.050 - 1.400 rpm		D2676LF14

xx.540		397 kW / 1.900	OBD 1 +			2.500 at 1.050 - 1.350 rpm		D2676LF13
xx.320*		235 kW / 1.900	NOX control			1.600 at 1.000 - 1.400 rpm		D2066LF20
xx.360*		265 kW / 1.900				1.800 at 1.000 - 1.400 rpm		D2066LF19

xx.400*		294 kW / 1.900				1.900 at 1.000 - 1.400 rpm		D2066LF18
xx.440*		324 kW / 1.900				2.100 at 1.000 - 1.400 rpm		D2066LF17

xx.480*		353 kW / 1.900				2.300 at 1.050 - 1.400 rpm		D2676LF16
xx.540*		397 kW / 1.900				2.500 at 1.050 - 1.350 rpm		D2676LF15

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

3.General

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

•Dimensions

•Weights

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

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

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

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

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

TRUCKNOLOGY® GENERATION A (TGA)

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

•Under no circumstances may the permissible axle weights be exceeded

•A sufﬁ cient minimum front axle load is achieved

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

•The permissible overhang (vehicle overhang) is not exceeded.

3.1Axle overload, one-sided loading

Fig. 1: Overloading the front axle ESC-052

Fig. 2: Difference in wheel load ESC-126

G G

Formula 1: Difference in wheel load

∆G ≤ 0,05 • Gtat

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

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

TRUCKNOLOGY® GENERATION A (TGA)

Example:

Actual axle load Gtat = 11.000kg

Therefore, the permissible wheel load difference is:

∆G	=	0,05 Gtat = 0,05 · 11.000 kg
∆G	=	550 kg

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

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

3.2Minimum front axle load

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

Fig. 3: Minimum front axle loading ESC-051

TRUCKNOLOGY® GENERATION A (TGA)

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

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

SDAH = Rigid drawbar trailer ZAA = Centre-axle trailer

GVW = Gross vehicle weight (vehicle/trailer)

Number of axles	Wheel formula	Without SDAH	With SDAH /ZAA	Tridem SDAH /ZAA	Other rear load
		/ZAA	GG ≤ 18 t	GG > 18 t	e.g. crane
Two-axle vehicle	4x2, 4x4H	25 %	25 %	30 %	30 %
	4x4
More than 2 axles	6x2/2, 6x2/4	20 %*	25 %*	30 %*	25 %*
Three axle vehicles with lifting	6x2-2, 6x2-4
leading or trailing axles must be	6x4, 6x4-4
treated as having two axles when	6x4H/2, 6x4H/4
the lifting axles are raised. In this	6x4H-2, 6x4H-4
condition the higher minimum	6x6, 6x6H
front axle load for two axle vehi-	8x2-4, 8x2-6
cles applies.	8x4, 8x4/4,
	8x4-4
	8x4H-6, 8x6,
	8x6H, 8x8

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

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

•loading cranes

•tail lifts

•fork lift trucks.

3.3Wheels, rolling circumference

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

3.4Permissible overhang

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

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

-Two-axle vehicles 65 %

-all other vehicles 70 %.

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

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

TRUCKNOLOGY® GENERATION A (TGA)

3.5Theoretical wheelbase, overhang, theoretical axle centreline

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

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

Theoretical rear axle centreline

l12= lt ut

G G		G G
permissible1zul1		permissible2zul2

Formula 2: Theoretical wheelbase for a two-axle vehicle

lt = l12

Formula 3: Permissible overhang for a two-axle vehicle

Ut ≤ 0,65 • lt

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

Theoretical rear axle centreline

		l12		l23
G	Gzul1
G	Gzul1		G G		G G
	permissible1		G G		G G
		lt	permissible2zul2		permissible3zul3	ut
		lt				ut

TRUCKNOLOGY® GENERATION A (TGA)

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

lt = l12 + 0,5 • l23

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

Ut ≤ 0,70 • lt

Fig. 6: Theoretical wheelbase and overhang for a three-axle vehicle with two rear axles and different rear axle loads (e.g. in the MAN vehicle range all 6x2’s) ESC-048

Theoretical rear axle centreline

		l12		l23
G	G
G	G		G G		GG
	permissible1zul1		G G		GG
		lt	permissible2zul2		permissible3zul3
		lt			ut

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

G permissible3 • l23

lt = l12 +

G permissible2 + G permissible3

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

Ut ≤ 0,70 • lt

TRUCKNOLOGY® GENERATION A (TGA)

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