MAN TGL TGM Body Fitting Guidelines 2018 V1.0 – Bodybuilder Manual PDF

Description

MAN TGL TGM Body Fitting Guidelines 2018 V1.0 – The Complete Bodybuilder Reference

The MAN TGL TGM Body Fitting Guidelines 2018 V1.0 is the working reference MAN Truck & Bus AG issues to body manufacturers, conversion specialists and workshops for fitting bodies and modifications to TGL and TGM truck chassis. This 2018 edition is written in English (translated from the German original) and covers every engineering, legal and technical requirement needed to design, build and install a body correctly on a TGL or TGM chassis.

File Details

• Manual type: Body Fitting Guidelines / Bodybuilder Manual
• Brand: MAN Truck & Bus AG
• Series covered: TGL and TGM (with cross-references to TGS and TGX)
• Language: English (translation; German original governs)
• Edition: 2018, Version 1.0
• Page count: 358 pages
• File format: PDF
• Publisher: MAN Truck & Bus AG, Engineering Vehicle Truck Application Engineering, Munich

Chapters Covered

• I. Applicability and Legal Agreements
• II. Product Identification
• III. Chassis
• IV. Body
• V. Calculations

I. Applicability and Legal Agreements

Opens with the binding legal framework that governs any bodybuilding or chassis modification on an MAN vehicle: MAN’s requirements, the responsibility of the executing company, EU multi-stage type-approval procedures under 2007/46/EC, liability for material defects and product liability, operational and road-safety obligations, quality-assurance expectations (EN ISO 9000 ff, VDA Vol. 8), the approvals process, manufacturer confirmations, and the rules on MAN trademarks and documentation non-disclosure.

II. Product Identification

Explains how MAN truck designations are put together so you can confirm exactly which chassis is on the workshop floor: model ranges (TGL Light, TGM Medium), model numbers, tonnage classes, power ratings, suspension types (BB leaf/leaf, BL leaf/air, LL air/air), wheel configurations (4×2, 4×4, 6×2-4, 6×4), suffix codes (S, CKD, TIB, FW, FOC, TS, WW, EL, U), cab variants (C, M, L, LX, XL, XLX, XXL, DK), door designations, variant descriptors, base vehicle numbers and the 17-character vehicle identification number.

III. Chassis

The largest and most technical section of the manual. Covers obtaining vehicle data through MANTED, applicable standards and tolerances, corrosion-protection coating systems (MAN works standards M3297, M3018, M3162-C, M3078-2 and M3094), welding on the frame (filler material selection, MAG and MMA techniques, protection of heat-sensitive parts, earthing for electronic sub-assemblies), drill-hole and riveted/bolted connection rules, and fire-protection measures in the vicinity of the engine, exhaust and electrical systems. Progresses into theoretical wheelbase and permitted overhang, permissible axle loads, gross weight and gross train weight, axle overload, wheel-load difference, minimum front-axle load, weighing procedure, rolling-circumference limits, and every approved route for modifying the wheelbase (relocating the rear-axle unit or cutting the frame side member with inserts) or the frame overhang. Also covers cab details, chassis frame materials and profiles, frame attachments (fuel tanks, coupling devices, front-mounted attachments), engine and driveline, exhaust system and AdBlue, gearboxes and propshafts, PTOs, brake system, running gear, and the entire electrical/electronic system with wiring-harness extension tables and part numbers.

IV. Body

Deals with the body itself: general requirements around weight distribution, accessibility and clearance, handling characteristics, vibration, tolerances, corrosion protection of bodywork and applicable standards (Machinery Directive 2006/42/EC, EN 12640/12641/12642 for cargo securing, contour markings, Radio Equipment Directive 2014/53/EU). Devotes major space to auxiliary-frame design and to body-without-auxiliary-frame design, permissible auxiliary-frame materials and profiles, and the full range of connection methods (flexible, rigid, thrust-plate and bolted/riveted joints). Then covers body-type-specific requirements: semitrailer tractors, platform and box bodies, swap body fittings, liftgates (with detailed two- and three-axle liftgate tables listing minimum auxiliary-frame profiles for each wheelbase), tank and container bodies, refuse-collector bodies, tippers, set-down and roll-off skip loaders, loading cranes (with crane-total-moment-to-planar-moment-of-inertia graphs for the TGL and TGM), transport mixers, cable winches and single-pivot bodies.

V. Calculations

Practical engineering formulae and worked examples for the calculations bodybuilders need every day: speed, efficiency, tractive force, gradeability (with and without accounting for tyre/road adhesion), torque, power output, PTO rotational speeds on the transfer case, driving resistances, turning circle, axle-load calculation (with full worked example tables), weight calculation with the trailing axle lifted, support length for a body without an auxiliary frame, coupling-device D, DC and V value calculations, and the theoretical-wheelbase and permissible-overhang formulae for two-, three- and four-axle vehicles.

Why this manual matters for TGL and TGM bodybuilders

Body fitting on a commercial truck is not a free-form job. Every TGL and TGM chassis has its own drill-hole pattern, frame-material grade, axle-load limits, minimum front-axle loads and permitted overhang lengths. Get any of these wrong and the consequences range from failed registration and rejected insurance cover to compromised road safety and voided warranty. The 2018 V1.0 edition of the MAN TGL TGM Body Fitting Guidelines is the reference that documents all of it in one place, in the numbers and procedures MAN expects bodybuilders to follow.

What you can do with this manual

Whether you are converting a TGL 7.xxx 4×2 BB into a tipper, adding a loading crane behind the cab of a TGM 18.xxx 4×2 BL, relocating the AdBlue tank or supply module, extending or shortening the wheelbase, changing tyre types, mounting a fifth-wheel coupling, planning a liftgate for a TGL 12.xxx with L cab, or calculating whether a proposed auxiliary frame will support a 150 kNm crane, this manual provides the specifications and procedures. The chassis chapter walks through every approved method for wheelbase and overhang changes, the electrical chapter gives the cable-harness extension item numbers to order from MAN, and the calculations chapter supplies every formula you need to verify axle loads and stability before cutting metal.

Who this manual is written for

This is a professional document for trained bodybuilders, conversion companies, workshops and engineering staff. Where the manual states that a task must be carried out by MAN or its qualified conversion suppliers, that instruction is part of the guidelines and not a suggestion. The bodybuilder retains full responsibility for the safety and roadworthiness of any body or modification, even where MAN has granted approval.

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Order the MAN TGL TGM Body Fitting Guidelines 2018 V1.0 as an instant-download PDF. No shipping, no waiting – after payment the file is available straight away and can be saved to any device, printed for the workshop or opened on a laptop next to the chassis. The complete 358-page reference, with every figure, table and formula from the 2018 V1.0 edition, in a single PDF.