MAN TGL, TGM. Operator Manual
MAN GUIDELINES TO
FITTING BODIES
Series TGL/TGM
Edition 2018 V2.0
P U B L I S H E R
MAN Truck & Bus AG
(hereinafter referred to as MAN)
Engineering Vehicle Truck
Application Engineering
Dachauer Str. 667
D-80995 Munich
E-Mail: info.manted@man.eu
Fax: + 49 (0) 89 1580 4264
www.manted.de
This English version is a translation.
In case of doubt or conict the valid German language original will govern.
We reserve the right to make technical modications in the course of further development.
© 2018 MAN Truck & Bus AG
Not to be reprinted, duplicated by any means whatsoever or translated – in whole or in part – without the prior
written consent of MAN Truck & Bus AG. All rights, especially those deriving from copyright law, are expressly
reserved by MAN.
®
Trucknology
If names constitute trademarks, they are also recognised as protected by the relevant owner without use of
the appropriate symbols (® ™).
Edition 2018 V2.0 MAN Guide to fitting bodies TGL/TGM
and MANTED® are registered trademarks of MAN Truck & Bus AG.
Content
I. Applicability and legal agreements ............................................... 1
1.0 General ..............................................................................................2
2.0 Legal agreements ..............................................................................2
2.1 Requirements .................................................................................... 2
2.2 Responsibility .................................................................................... 3
2.3 Registration of the vehicle ................................................................. 4
3.0 Liability .............................................................................................. 7
3.1 Liability for material defects .............................................................. 7
3.2 Product liability ..................................................................................7
3.3 Limitation of liability for accessories/spare parts ..............................8
3.4 Operational and road safety ..............................................................8
3.5 Instructions from body-building and conversion companies ............9
4.0 Quality assurance ............................................................................10
5.0 Approvals ........................................................................................11
5.1 Body approval ................................................................................. 11
5.2 Manufacturer Conrmation .............................................................13
5.3 Trademarks......................................................................................14
MAN Guide to fitting bodies TGL/TGM Edition 2018 V2.0 I
Contents
II. Product identication ................................................................... 17
1.0 General ............................................................................................18
2.0 Terms ...............................................................................................18
2.1 Model range .................................................................................... 18
2.2 Model number ................................................................................. 18
2.3 Tonnage class .................................................................................20
2.4 Power rating .................................................................................... 20
2.5 Type of suspension .........................................................................20
2.6 Wheel conguration ........................................................................21
2.7 Sufx ...............................................................................................22
2.8 Cabs ................................................................................................ 23
3.0 Door designation .............................................................................25
4.0 Variant descriptor ............................................................................ 25
5.0 Base vehicle number .......................................................................26
6.0 Vehicle identication number and vehicle production number ....... 26
II Edition 2018 V2.0 MAN Guide to fitting bodies TGL/TGM
Contents
III. Chassis ........................................................................................... 29
1.0 General ............................................................................................30
1.1 Obtaining technical vehicle data ..................................................... 30
1.2 Standards, guidelines, regulations, tolerances ...............................30
1.3 Quality of execution ........................................................................31
1.3.1 Corrosion protection .......................................................................31
1.3.2 Welding work on the vehicle ...........................................................31
1.3.3 Drill holes, riveted and bolted connections ..................................... 35
1.4 Fire-protection measures for vehicle bodies and modications ..... 38
1.4.1 General ............................................................................................38
1.4.2 Statutory requirements ....................................................................38
1.4.3 Measures in the vicinity of the engine and exhaust system ...........39
1.4.4 Measures on the air intake system .................................................39
1.4.5 Electric wiring/ttings ......................................................................40
2.0 Overall vehicle ................................................................................. 41
2.1 General ............................................................................................41
2.2 Terms, dimensions and weights ...................................................... 41
2.2.1 Theoretical wheelbase ....................................................................41
2.2.2 Theoretical and permitted overhang lengths ..................................43
2.2.3 Permissible axle load ......................................................................44
2.2.4 Permissible gross weight ................................................................44
2.2.5 Permissible gross train weight ........................................................ 45
2.2.6 Axle overload ..................................................................................46
2.2.7 Wheel-load difference .....................................................................47
2.2.8 Minimum front-axle load .................................................................49
2.2.9 Calculating the axle load and weighing procedure ......................... 51
2.2.10 Rolling circumference and difference in rolling circumference .......51
2.3 Modications to the overall vehicle ................................................. 52
2.3.1 Modications to the wheelbase ...................................................... 52
2.3.2 Modifying the frame overhang ........................................................ 58
2.3.3 Modifying the wheel conguration .................................................. 62
2.3.4 Changing the tyre type ....................................................................63
2.3.5 Changing the vehicle type and interchangeable operation as
semitrailer .......................................................................................63
tractor/truck ....................................................................................63
2.3.6 Retrotting additional units, attachments and accessories ............ 64
2.4 Homologated vehicle components / vehicle components
relevant to safety .............................................................................65
3.0 Cab ..................................................................................................66
MAN Guide to fitting bodies TGL/TGM Edition 2018 V2.0 III
Contents
3.1 General ............................................................................................66
3.2 Cabs ................................................................................................ 67
3.3 Spoilers, roof extensions, roofwalk ................................................. 68
3.4 Roof sleeper cabs ........................................................................... 71
3.5 Fastening of warning plates to the front ap .................................. 74
4.0 Chassis frame .................................................................................75
4.1 General ............................................................................................75
4.2 Frame materials...............................................................................75
4.3 Frame proles .................................................................................76
5.0 Frame attachments ......................................................................... 77
5.1 General ............................................................................................77
5.2 Front underride protection ..............................................................78
5.3 Side underride protection ...............................................................79
5.4 Rear underride protection ............................................................... 83
5.5 Fuel tanks ........................................................................................85
5.5.1 Mounting fuel tanks .........................................................................87
5.5.2 Modications to fuel lines ............................................................... 88
5.6 Coupling devices.............................................................................91
5.7 Front-mounted attachments ...........................................................92
6.0 Engine and driveline ........................................................................94
6.1 General ............................................................................................94
6.2 Engine versions ............................................................................... 95
6.2.1 Type codes for MAN engines .......................................................... 96
6.3 Engine environment ........................................................................97
6.3.1 Modications to the engine ............................................................. 97
6.3.2 Modication to the air intake ........................................................... 97
6.3.3 Modications to the engine cooling system ................................. 103
6.3.4 Modications to engine encapsulation, noise insulation .............. 105
6.3.5 Compressed-air supply .................................................................105
6.3.5.1 Basic principles ............................................................................. 105
6.3.5.2 Routing lines .................................................................................105
6.3.5.3 Connecting auxiliary consumers ................................................... 108
6.3.5.4 Loss of compressed-air pressure .................................................109
6.3.5.5 External air supply ......................................................................... 110
6.4 Exhaust system ............................................................................. 113
6.4.1 Modications to the exhaust routing ............................................113
6.4.2 AdBlue-System ............................................................................. 121
6.4.2.1 Basic principles and structure of the AdBlue system ................... 121
6.4.2.2 AdBlue line set ..............................................................................125
IV Edition 2018 V2.0 MAN Guide to fitting bodies TGL/TGM
Contents
6.4.2.3 AdBlue tank ...................................................................................135
6.4.2.4 AdBlue supply module .................................................................. 138
6.4.2.5 AdBlue cable harness ................................................................... 140
6.4.2.6 Parts list ........................................................................................159
6.5 Gearbox and propshafts ...............................................................163
6.5.1 Basic principles ............................................................................. 163
6.5.2 Propshaft congurations ............................................................... 164
6.5.3 Forces in the propshaft system .....................................................168
6.5.4 Modifying the propshaft conguration .......................................... 168
6.5.5 Fitting other manual or automatic gearboxes and transfer cases 169
6.6 PTOs .............................................................................................169
6.7 Brake system ................................................................................170
6.7.1 Basic principles ............................................................................. 170
6.7.2 Installing and fastening brake lines ............................................... 170
6.7.3 ALB, EBS brake system ................................................................ 170
6.7.4 Retrotting continuous brakes ...................................................... 170
7.0 Running gear .................................................................................171
7.1 General ..........................................................................................171
7.2 Modications to the running gear ................................................. 172
7.3 Equipment-related notes ...............................................................172
8.0 Electrical/electronic system (on-board network) ...........................173
8.1 General ..........................................................................................173
8.1.1 Electromagnetic compatibility .......................................................174
8.1.2 Static discharge ............................................................................174
8.1.3 Radio equipment and aerials ........................................................ 174
8.1.4 Diagnostics concept and parameterisation using MAN-cats ....... 177
8.2 Cables ........................................................................................... 178
8.2.1 Routing cables ..............................................................................178
8.2.2 Ground cable.................................................................................179
8.2.3 Wiring harnesses for wheelbase extensions ................................. 179
8.2.4 Cable harnesses for rear position lamps, additional rear
position lamps, trailer sockets, side marker lamps and
supplementary ABS sockets ......................................................... 183
8.2.5 Supplementary wiring diagrams and cable-harness drawings ..... 188
8.2.6 Battery cable ................................................................................. 188
8.3 Interfaces on the vehicle, preparations for the body ....................189
8.3.1 Tapping into the engine-on (D+) signal ......................................... 190
8.3.2 Electrical interface for liftgate........................................................190
8.3.3 Engine-Start-stop system ............................................................. 193
8.3.4 Tapping into the speed signal ....................................................... 193
MAN Guide to fitting bodies TGL/TGM Edition 2018 V2.0 V
Contents
8.3.5 Tapping into the reverse gear signal .............................................194
8.3.6 Interfaces for intermediate speed control with VMC/PTM and
CSM (ISC interfaces) .....................................................................194
8.3.7 Interface for reversing-camera preparation ..................................197
8.4 Additional consumers ...................................................................203
8.4.1 Notes on charging balance ...........................................................208
8.5 Batteries ........................................................................................ 210
8.5.1 Handling and maintaining batteries .............................................. 210
8.5.2 Handling and care of maintenance-free batteries ........................211
8.6 Lighting installations .....................................................................212
8.7 Display and instrumentation concept ........................................... 213
8.8 Safety and assistance systems ..................................................... 214
8.8.1 Yaw-rate sensor ............................................................................ 214
8.8.2 Radar sensor ................................................................................. 216
8.8.3 Multi-functional camera ................................................................219
8.9 Electrical Boxes on the chassis frame .......................................... 222
VI Edition 2018 V2.0 MAN Guide to fitting bodies TGL/TGM
Contents
IV. Body..............................................................................................225
1.0 General requirements .................................................................... 226
1.1. Requirements ................................................................................ 226
1.2 Accessibility and clearance ...........................................................226
1.3 Handling characteristics and driving resistances .........................228
1.4 Vibration ........................................................................................229
1.5 Special feature of vehicles with lifting axles..................................229
1.6 Vehicles with outriggers ................................................................230
1.6.1 Outrigger operation with the wheels in contact with the ground .. 230
1.6.2 Outrigger operation with the wheels not in contact with
the ground ..................................................................................... 231
1.7 Tolerances ..................................................................................... 231
1.8 Assembly .......................................................................................231
1.9 Corrosion protection of bodywork ................................................232
1.10 Standards, directives and regulations ...........................................233
1.10.1 Machinery Directive (2006/42/EC).................................................233
1.10.2 Securing of cargo .......................................................................... 235
1.10.3 Contour markings .........................................................................235
1.10.4 Radio Equipment Directive 2014/53/EU .......................................236
2.0 Body and auxiliary-frame design .................................................. 239
2.1 General requirements .................................................................... 239
2.2 Body with auxiliary frame .............................................................. 241
2.2.1 Permissible materials .................................................................... 241
2.2.2 Auxiliary-frame design ..................................................................241
2.2.3 Connection to chassis frame ........................................................ 244
2.2.4 Equipment-specic notes and restrictions ...................................245
2.3 Body without auxiliary frame .........................................................249
2.4 Attaching auxiliary frames and bodies .......................................... 251
2.5 Bolt connections and riveted joints ............................................... 252
2.6 Flexible connection ....................................................................... 254
2.6.1 General requirements for exible body fasteners .........................254
2.6.2 Implementations of exible body fasteners .................................. 256
2.7 Rigid connection ........................................................................... 261
3.0 Bodies ........................................................................................... 264
3.1 Semitrailer tractors ........................................................................264
3.1.1 Chassis and equipment ................................................................264
3.1.2 Requirements for bodies ...............................................................264
3.2 Platform and box bodies ...............................................................266
3.3 Swap body ttings ........................................................................267
MAN Guide to fitting bodies TGL/TGM Edition 2018 V2.0 VII
Contents
3.3.1 Chassis and equipment ................................................................267
3.3.2 Requirements to be met by the body ...........................................267
3.4 Liftgates ........................................................................................268
3.5 Tank and container bodies ............................................................ 279
3.5.1 Chassis and equipment ................................................................279
3.5.2 Requirements to be met by the body ...........................................279
3.6 Refuse-collector body ...................................................................282
3.6.1 Chassis and equipment ................................................................282
3.6.2 Requirements to be met by the body ...........................................282
3.7 Tippers ..........................................................................................283
3.7.1 Chassis and equipment ................................................................283
3.7.2 Requirements to be met by the body ..........................................284
3.8 Set-down and roll-off skip loaders ................................................286
3.9 Loading crane ...............................................................................287
3.9.1 Chassis and equipment ................................................................287
3.9.2 Requirements to be met by the body ...........................................289
3.9.3 Requirements to be met by auxiliary frames for loading cranes ...291
3.10 Transport mixers ........................................................................... 298
3.10.1 Chassis and equipment ................................................................298
3.10.2 Requirements to be met by the body ...........................................299
3.11 Cable winch ..................................................................................300
3.12 Single-pivot body .......................................................................... 300
VIII Edition 2018 V2.0 MAN Guide to fitting bodies TGL/TGM
Contents
V. Calculations ................................................................................. 303
1.0 General ..........................................................................................304
1.1 Speed ............................................................................................ 304
1.2 Efciency .......................................................................................306
1.3 Tractive force .................................................................................308
1.4 Gradeability ................................................................................... 309
1.4.1 Distance travelled on uphill or downhill gradients ........................ 309
1.4.2 Angle of uphill or downhill gradient ............................................... 310
1.4.3 Calculating the gradeability ........................................................... 311
1.5 Torque ...........................................................................................315
1.6 Power output .................................................................................317
1.7 Rotational speeds for power take-offs on the transfer case .........319
1.8 Driving resistances ........................................................................ 320
1.9 Turning circle ................................................................................. 323
1.10 Axle-load calculation .....................................................................326
1.10.1 Performing an axle-load calculation ............................................. 326
1.10.2 Calculation of weight with trailing axle lifted ................................. 333
1.11 Support length for body without auxiliary frame ........................... 335
1.12 Coupling devices...........................................................................336
1.12.1 Trailer coupling for steerable drawbar trailer (D value) .................. 336
1.12.2 Trailer coupling for rigid drawbar trailer/ center-axle trailer
(D
value, V value) .........................................................................337
C
1.12.3 Trailer coupling for semi-trailer (D value) ....................................... 339
1.13 Theoretical wheelbase and permissible overhang length ............. 341
If not otherwise specied: all dimensions are in mm, all weights and loads are in kg.
MAN Guide to fitting bodies TGL/TGM Edition 2018 V2.0 IX
NOTICE
X Edition 2018 V2.0 MAN Guide to fitting bodies TGL/TGM
These Guidelines to tting bodies aimed at professional bodybuilder.
Therefore, in this guideline, background knowledge is assumed.
It should be noted that some work may only be carried out by suitably qualied personnel in order to avoid the risk
of injury and to achieve the necessary quality for construction work.
Notational conventions
In this guideline the following notational conventions are used:
Information
This notice points out further information to you.
Important notice
This notice draws your attention to possible damage to the vehicle.
Environmental notice
An environmental notice provides you with tips for environmental protection.
Warning notice
A hazard warning notice points out possible risks of accident or injury to you and others.
MAN Guide to fitting bodies TGL/TGM Edition 2018 V2.0 XI
NOTICE
XII Edition 2018 V2.0 MAN Guide to fitting bodies TGL/TGM
I. Applicability and legal agreements
MAN Guide to fitting bodies TGL/TGM Edition 2018 V2.0 1
I. Applicability and legal agreements
1.0 General
The statements in these MAN guidelines to tting bodies are binding. Exceptions may only be approved by MAN
following a written request and provided such exceptions are technically feasible (for address see “Publisher”).
2.0 Legal agreements
2.1 Requirements
In addition to these guidelines to tting bodies the executing company must observe all of the following that apply
to the operation and bodywork of the vehicle:
• Legislation, rules and regulations
• Accident-prevention regulations
• Operating instructions
observed.
Standards are technical standards and thus contain minimum requirements. Failure to observe such minimum
requirements is a negligent act. Standards are binding if they are part of rules and regulations.
Information received from MAN in answer to telephone enquiries is non-binding unless conrmed in writing.
Enquiries must be directed to the MAN department responsible.
Information is based on conditions of use such as are typical in Europe. Dimensions, weights and other basic values
deviating therefrom must consequently be taken into account for the engineering design and attachment of
bodywork and the design of the auxiliary frame. The executing company must ensure that the entire vehicle is able
to sustain the conditions of use to be expected.
Various manufacturers have worked out specications for certain units, e.g. loading cranes, liftgates, cable winches
and so on. These are also to be observed if they contain requirements extra to the MAN guidelines to tting bodies.
Mentions of:
• Legal regulations
• Accident-prevention regulations
• Regulations issued by professional associations
• Standard operating procedures
• Other guidelines and sources
are by no means complete and are only for purposes of information. They are no replacement for due diligence on
the part of the particular company.
2 Edition 2018 V2.0 MAN Guide to fitting bodies TGL/TGM
I. Applicability and legal agreements
2.2 Responsibility
Responsibility for professional
• Engineering Design
• Production
• tting of bodywork,
• modications to chassis
is always, and in full, that of the company producing or assembling the bodywork or carrying out the modication
(manufacturer’s liability). This also applies when MAN has expressly granted approval of the bodywork or
modication. Written approval of bodywork or modications by MAN does not release the bodywork
manufacturer from their responsibility for the product.
Should the executing company detect an error in the planning stage or in the intentions of the
• customers
• user
• its own personnel
• vehicle manufacturer
they will draw the attention of the particular party to it.
The company is responsible for ensuring that the
• Operational safety
• Road safety
• serviceability,
• Driving characteristics
of the vehicle are not negatively affected in any way.
In terms of road safety the company must construe and base:
• Engineering Design
• production of bodywork,
• tting of bodywork,
• modications to chassis
• instructions,
• Operating instructions
by the latest state of the art and recognized rules of the discipline. More difcult operating conditions are in addition
to be taken into consideration.
MAN Guide to fitting bodies TGL/TGM Edition 2018 V2.0 3
I. Applicability and legal agreements
2.3 Registration of the vehicle
National laws and technical regulations with respect to the registration of modied vehicles are to be complied
with. Modication work carried out in on the chassis must be submitted to a Technical Service for assessment.
The executing company remains responsible even subsequent to the registration of the vehicle in the event of the
competent authorities having issued the vehicle registration in ignorance of the operational safety of the product.
EU multi-stage type-approval procedure as per Annex XVII 2007/46/EC
Process
Within the framework of the multi-stage process pursuant to Annex XVII of Directive 2007/46/EC, each manufacturer
shall bear independent responsibility for approval and conformity of production of all systems, components or
independent technical units that it manufactures or adds in an earlier stage of manufacturing.
The body manufacturer is the manufacturer of the second or additional production stage pursuant to 2007/46/EC.
Responsibilities
As a basic principle, the body builder is responsible for:
• modications it carried out on the base vehicle.
• objects granted approval at an earlier stage if, due to modications to the base vehicle, the approvals
granted are no longer applicable to this vehicle.
• ensuring that the modication carried out complies with the respective national/international statutory
regulations, in particular those of the destination country.
• submitting the modications it carried out to a technical service for assessment.
• documenting compliance with statutory regulations in appropriate form (test report and/or permit or
documents meeting the legal requirements of the destination country).
As a basic principle, MAN as manufacturer of the base vehicle is responsible for:
• providing the body builder with the homologation documentation (EU/EEC approvals) available for
the scope of delivery of the base vehicles in electronic form on request.
Identication of the vehicles
The respective vehicle shall receive a vehicle identication number (“VIN”), which identies MAN as manufacturer
of the incomplete base vehicle.
As a basic principle, the requirements laid down in Annex XVII to 2007/46/EU and the published associated
procedural instructions apply.
Conformity of production (COP)
As a basic principle, the requirements laid down in individual EU Directives and Annex X to 2007/46/EU as well as
the requirements laid down in Annex 2 to the EEC Agreement of 1958 apply.
Provision of documentation for registration/following stage
In accordance with Annex XVII to 2007/46/EU, MAN as manufacturer of the base vehicle provides the body builder
or builders the available EU/EEC system approvals and the Certicate of Conformity (CoC)1) for the base vehicle in
electronic form.
1)
Only in cases where the vehicle is EU-compliant and a Certicate of Conformity (CoC) has been printed by
the plant.
4 Edition 2018 V2.0 MAN Guide to fitting bodies TGL/TGM
I. Applicability and legal agreements
Case I: Registration in Germany
In the case of MAN acting as general contractor (“single-invoice transaction”) the body builder/s as later-stage manufacturer/s undertake/s to provide the following documentation in electronic form:
a) The individual supplier conditions provide for an acceptance/approval and registration process
by the vehicle manufacturer (MAN).
1. In the case of an existing and valid whole vehicle type-approval in accordance
with 2007/46/EC for the manufacturing stages, a CoC. On request, existing EC/EEC system
approvals or technical reports must be submitted.
2. Alternatively to 1, the test reports and approval documentation required for national
individual approval procedures in accordance with Section 13 of the EC vehicle
approval Directive.
The latest time for submitting the above stated documentation in printable form is the day the
completed vehicle is returned to the contractually agreed place of delivery.
The documentation shall be sent to the following e-mail address documents@de.man-mn.com.
In cases where MAN receives a CoC from the bodybuilder, then original certicates may only
be generated by MAN on behalf of the bodybuilder.
b) The acceptance/approval and registration process is to be carried out by the contract partner or
by the manufacturer of the nal completion stage of the vehicle.
1. None.The registration process is the responsibility of the contract partner or the
manufacturer of the nal completion stage of the vehicle.
In all other cases the acceptance/approval and registration process is to be carried out by the manufacturer of the
nal completion stage of the vehicle or by the corresponding contract partner.
Case II: Registration outside Germany but inside the area of application of Directive 2007/46/EC
If MAN serves as general contractor then the bodybuilder is under an obligation, as the nal stage manufacturer, to
provide in electronic form, all the necessary approval/registration documentation for all modications made during
the subsequent manufacturing stages of the respective responsible sales organisation or importer which exceed
the scope of the basic vehicle.
Irrespective of any general contractor status of the importers, the acceptance/approval and registration process is
to be carried out by the manufacturer of the nal completion stage of the vehicle or by the corresponding contract
partner.
The importer in the respective country or the corresponding contract partner has the authority and responsibility for
the registration process.
MAN does not supply any national data for registration purposes exceeding that for incomplete vehicles set forth in
Annex IX to Directive 2007/46/EG in its current form and as amended from time to time. This also applies in
particular to national model codes and encrypted basic technical data.
MAN as a manufacturer reserves the right – following corresponding feasibility studies and economic
implementation – and after reaching corresponding specically applicable agreements with national sales
organisations and importers, to provide data for national registration which exceeds the scope of that set forth
above (e.g. vehicle’s manufacturing plates etc.). Enquiries in this regard shall be sent to the following e-mail address
documents@de.man-mn.com.
MAN Guide to fitting bodies TGL/TGM Edition 2018 V2.0 5
I. Applicability and legal agreements
Non-disclosure agreement
The bodybuilder may not forward the approval documentation provided by MAN to any third parties without
obtaining prior, express permission from MAN.
The forwarding of documentation that is directly associated with the registration of the vehicle in question
to persons of the institutions listed below is excepted:
• MAN Sales partners
• Technical vehicle inspection centers or testing organisations
• Approval authorities
• Registration authorities or licensing centers acting for the government
Note on type approval / homologation for TiB, CiB, BiB, CKD, SKD and PKD vehicles
Where:
• TiB stands for “truck in the box”
• CiB stands for “chassis in the box”
• BiB stands for “bus in the box”
• CKD stands for “completely knocked down”
• SKD stands for “semi knocked down”
• PKD stands for “partly knocked down”
For these versions MAN is not considered to be the manufacturer within the meaning of Directive 2007/46/EC –
therefore, the responsibility for the homologation and registration process lies with the manufacturer of
these vehicles.
In principle, the substance of the contracts respectively concluded with MAN shall apply.
In principle, MAN does not provide registration-related data for completed vehicles. Exceptions include
homologation documentation for components subject to approval such as the engine, which MAN provides
in electronic form.
However, this does not exclude MAN as a manufacturer reserving the right – following corresponding feasibility
studies and economic implementation – and after reaching corresponding specically applicable agreements with
national sales organisations and importers, to provide data for national registration which exceeds the scope of that
set forth above (e.g. vehicle’s manufacturing plates etc.). Enquiries in this regard shall be sent to
MAN’s Homologation Department.
6 Edition 2018 V2.0 MAN Guide to fitting bodies TGL/TGM
I. Applicability and legal agreements
3.0 Liability
3.1 Liability for material defects
Claims on liability for defects only exist within the contract of sale between the purchaser and the seller. The liability
for defects consequently rests with the seller of the article of sale. Claims may not be made of MAN if the reported
defect results from the following:
• Non-adherence to these body guidelines
• Selection of a chassis unsuitable for the intended purpose of the vehicle
• Damage to the chassis caused by:
- the body,
- the nature/execution of body installation,
- modication to the chassis,
- incorrect operation.
3.2 Product liability
Defects in workmanship detected by MAN are to be corrected. In as much as this is legally admissible, MAN will
bear no liability, in particular for consequential damages.
Product liability regulates:
• The liability of the manufacturer for their product or component of a product.
• The claim to compensation from the manufacturer of an integrated component of a product made by the
manufacturer claimed upon if the occurring damage results from a defect of this component of a product.
The company that executes the bodywork or modication to the chassis shall indemnify MAN from any claims for
liability made by its customers or other third parties, in as much as any damage results from the following:
• The company having failed to comply with the guidelines to tting bodies valid at the time.
• The bodywork or chassis modication has caused damage through faulty
- Engineering Design
- Manufacture
- Assembly
- instructions.
• The set principles were not complied with in any other way.
MAN Guide to fitting bodies TGL/TGM Edition 2018 V2.0 7
I. Applicability and legal agreements
3.3 Limitation of liability for accessories/spare parts
Warning notice
Accessories and spare parts not manufactured by MAN or approved for use in its products can impair the
operational and road safety of the vehicle and lead to dangerous 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. Excepted from the aforementioned are
cases in which MAN Truck & Bus AG (or the seller) itself offers the accessory for sale or ts it to the vehicle (or the
subject of the contract).
3.4 Operational and road safety
In order to ensure operational and road safety or to maintain the validity of any claims under the guarantee, the
bodybuilder must observe the instructions given in these guidelines to tting bodies exactly. MAN shall not be liable
for non-compliance.
Warning notice
Before commencing work on the body, making modications or starting installation work, the bodybuilder must
also have knowledge of the sections of the operator‘s manual that relate to the work he is completing. It will
otherwise be impossible to recognise risks and other persons may be endangered.
MAN cannot be liable for reliability, safety and suitability under the following circumstances.
• Bodies are not constructed and tted in accordance with these guidelines to tting bodies
• MAN Genuine Parts or approved parts and modications are replaced with other parts
• Unauthorised modications are made to the vehicle
Approvals by third parties, for example Technical Inspection Agencies or approvals from public authorities, shall not
be considered sufcient for precluding safety risks.
Companies handling and working on the vehicle are liable for any damages that result from decient functional and
operational safety or inadequate operating manuals. MAN consequently requires of the bodybuilder or modier:
• maximum state-of-the-art safety standards,
• comprehensible and adequately detailed operating instructions,
• easily visible, permanently afxed plates at points posing a risk to operators and/or third persons,
• adherence to necessary protective measures (e.g. against re and explosion risks),
• full details relating to toxicology,
• full details relating to ecology.
Safety has priority! Make use of all technical possibilities to avoid and eliminate insecure operation.
This applies equally to:
• Active safety = prevention of accidents. This includes:
- driving safety as a result of the overall concept of the vehicle with its bodywork
- conditional safety produced by minimal physical stress on occupants through vibration, noise,
climate, etc.
- assured perception, especially correct design of lighting ttings, warning devices, sufcient direct
and indirect visibility
- operational safety, including optimum operability of all devices and ttings, and those of
the bodywork
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• Passive safety = avoidance and containment of accident consequences. This includes:
- outer safety, e.g. design of the exterior of the vehicle/bodywork in terms of deformation, tting
of protective devices
- inner safety, including protection of the occupants of vehicles, but also cabs installed by
bodywork producers
Climatic and environmental conditions affect:
• Operational safety
• readiness for use,
• in-service performance,
• Service life
• cost-effectiveness,
Climatic and environmental inuences are, for example:
• effects of temperature
• Humidity
• aggressive substances,
• sand and dust,
• radiation.
Ensure sufcient clearance of all parts involved in movement, including all cables and leads. The operating manuals
for MAN vehicles provide information on the maintenance points on the vehicle. Regardless of the kind of bodywork,
ensure good access to these maintenance points in all cases. Maintenance must be possible unhindered by having
to remove any parts. Ensure adequate ventilation and/or cooling of sub-assemblies.
3.5 Instructions from body-building and conversion companies
In the event of a body atng added or modications to the vehicle atng carried out by a conversion company, the
operator of the vehicle is also entitled to receive the operating instructions. All the benets of a product are of no
use if the customer is unable to:
• handle it safely and true to its purpose,
• use it rationally and effortlessly,
• correctly service and maintain it,
• work with it expertly in all its functions.
Every bodybuilder and modier shall consequently ensure that their technical manuals exhibit:
• Comprehensibility
• Complete
• Accuracy
• Traceability
• Product-specic notes on safety
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A poor or incomplete operating manual means considerable risk factors for the user. Possible consequences are:
• reduced value because product advantages go unrecognized;
• complaints, irritation and annoyance;
• failures and damage that are usually attributed to the chassis,
• unexpected and unnecessary extra costs through repairs and loss of time;
• a negative image and thus less inclination to purchase from the same source again.
Operating personnel is to be instructed in operation and maintenance for the particular vehicle body or modication.
Instruction must also include possible effects on the static and dynamic performance of the vehicle.
4.0 Quality assurance
To satisfy the high quality demands of our customers and comply with international product/producer liability,
continuous quality inspection is also needed to conduct retrots and in the production/tting of bodywork.
This calls for a properly functioning quality-assurance system.
The bodybuilder is advised to set up and provide evidence of a quality management system complying with general
requirements and accepted rules (e.g. EN ISO 9000 ff or VDA Vol. 8).
If MAN is the contracting body for the bodywork or modication, it will demand evidence of qualication. MAN Truck
& Bus AG reserves the right to conduct its own VDA Vol. 8 system audit of a supplier or appropriate examinations
of processes. VDA Vol. 8 is harmonised with the bodywork manufacturer associations ZKF (federal association of
bodywork and vehicle engineering), BVM (federal association of the metalworking trade) as well as with the ZDH
(federal association of skilled crafts).
Publications:
VDA Vol. 8: Aids to quality assurance for trailer, body and container manufacturers can be obtained from
the German Association of the Automotive Industry (VDA).
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5.0 Approvals
The “Approvals” section contains information on the approval of bodies and manufacturer’s conrmation.
The prerequisites, basic principles to be complied with when submitting applications and the options for obtaining
applications are described.
5.1 Body approval
General information
Body approval from MAN is not required if the bodies or modications are carried out in accordance with these
guidelines to tting bodies.
If MAN approves a body, this approval applies, in the case of bodies,
• to their basic compatibility with the respective chassis,
• to interfaces with the body (e.g. dimensioning and fastening the auxiliary frame).
The endorsement of approval entered by MAN in the submitted technical documents does not cover inspection of the:
• Function
• Engineering Design
• equipment of the body or the modication.
The endorsement of approval only concerns measures or parts to be seen or taken from the submitted technical
documents.
MAN reserves the right to refuse issue of an approval of bodywork, even if comparable approval was issued at an
earlier date. Technical advances rule out the possibility of cases atng fully identical. MAN furthermore reserves the
right to alter these guidelines at any time, or to issue instructions differing from those contained herein in the case
of single chassis.
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Should a number of identical chassis have identical bodywork, MAN may issue a collective approval for the sake
of simplicity.
For an approval process to proceed swiftly, the following are required:
Template for inspection documentation
Documents should only be sent to MAN if bodies deviate from these guidelines to tting bodies. If this is the case,
technical documents enabling inspection must be sent to MAN (for address see “Publisher” above) before work on
the vehicle begins.
A rapid processing procedure requires:
• documents preferably submitted in the usual digital formats (e.g. PDF, DWG, DXF, STEP),
• complete technical data and documents,
• as few documents as possible.
The following details will be contained:
• Vehicle model (for model numbers see Chapter II, Section 2.2 “Model numbers”) with
- Cab version
- Wheelbase
- Frame overhang
• Vehicle identication number or vehicle production number (if already existing, see Chapter II, Section 6.0,
“Vehicle identication numbers and vehicle production numbers)
• Appropriate marking of departures from these guidelines in all documents!
• Loads and their points of application
- Forces from bodywork
• Axle load calculation
• Special conditions of use:
• Subframe
- Material and cross-section gures
- Dimensions
- Type of prole
- Cross member arrangement in auxiliary frame
- Particularities of auxiliary frame design
- Changes to cross-sections
- Supplementary reinforcements
- Kick-up, etc.
• Joining means:
- Positioning (with reference to chassis)
- Type
- Size
- Quantity
The following are not sufcient for inspection and approval:
• Parts lists
• Literature
• Photos
• Other non-binding information
Drawings are only of value under the number assigned them.
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5.2 Manufacturer Confirmation
General information
In the case of modications to vehicles, a manufacturer conrmation may become necessary. Upon special request,
MAN can issue an exception to existing technical stipulations. Manufacturer conrmations may only be issued if this
can be arranged with the functional, trafc and operational safety guidelines.
If MAN approves a chassis modication, this approval shall only relate to the basic constructive permissibility for
the relevant chassis.
Manufacturer conrmations can generally be issued in the following categories:
• Vehicle conrmations, e.g.
- Wheelbase modications
- Changing tyre types
- Optional deployment or conversion of truck/semi-trailer tractor
- Axle loads and gross weight
- Trailer load and gross trailer weight
• Factory automatic load-dependent brake force distribution and engine plates
• Documents supplied with the vehicle, e.g.
- COP document
- “Low noise vehicle” certication
• Approval documents, e.g.
- Data conrmation
A detailed overview of the available manufacturer conrmations is available at www.manted.de.
Application for manufacturer conrmations
Manufacturer conrmations may only be applied for outside Germany via the respective central import company.
The applicant is both the invoice recipient and the conrmation recipient, and must be one and the same person.
Manufacturer approvals can be applied for using the following options:
• Application via fax or email
- Obtaining the forms (templates) via www.manted.de → Guidelines and Forms
- Sending the completed application via fax or email to the contact address specied in the
application.
• Application via MANTED-online application
- can be found at www.manted.de →Services → MANTED-online application (additional registration required).
→ Create MANTED-online application → Select the corresponding application.
- Please complete all the required elds in the online application.
- Please see the help document in the online applications area for further information.
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Note
It is a requirement that the conversion measure(s) are only carried out after the receipt of the corresponding
manufacturer conrmation(s) - as far as is necessary.
Such special approval issued by MAN is not binding on the competent authority.
MAN has no inuence on the issuance of exemptions by the competent authority.
Generally, every exemption must be checked and inspected by the ofcially recognised expert, as well as entered
in the ofcial vehicle documents by the responsible accreditation body. If the measure concerned is outside the
national legal provisions and regulations, an exemption must be obtained beforehand from the competent authority.
Compliance with these guidelines to tting bodies does not release the user from his responsibility for technically
exemplary implementation of the modication works.
MAN reserves the right to decline to grant approvals for modications, even if a comparable approval has been
granted before. Technical progress does not automatically allow for equal treatment. Furthermore, MAN reserves
the right to modify these guidelines to tting bodies at any time or, for individual chassis, to issue instructions which
deviate from these guidelines to tting bodies.
5.3 Trademarks
The MAN logo and MAN emblem are trademarks of MAN Truck & Bus AG and may not be removed or repositioned
without permission (for the contact address see “publisher” above).
MAN Truck & Bus AG reserves the right to prohibit the body manufacturer or vehicle modier from using the
MANtrademarks if they breach the Guideline To Fitting Bodies as amended. The body manufacturer or vehiclemodier
will then be required to remove all visible trademarks.
If changes are made that render approvals for the basic vehicle (e.g. type or system approval) invalid; these approvals
or evidence thereof must be reobtained by the body manufacturer or vehicle modier. The body manufacturer or
vehicle modier must afx the legally required markings to the vehicle, e.g. the additional plate in accordance with
Article 59 of the German Road Trafc Licensing Regulation (StVZO).
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