MAN TGS TGX Body Fitting Guidelines 2014 V2.0 – Truck Bodybuilder Manual PDF

Description

This is the MAN Guidelines to fitting bodies for the TGS and TGX truck series, Edition 2014 V2.0 — the bodybuilder’s reference document issued by MAN Truck & Bus AG for anyone planning, designing or mounting a body, auxiliary frame or conversion onto a TGS or TGX chassis.

File Details

• Manual type: Body fitting guidelines / bodybuilder manual
• Brand: MAN (MAN Truck & Bus AG)
• Model series: TGS, TGX, TGS-WW
• Language: English
• Page count: 324
• File format: PDF
• Edition: 2014 V2.0
• Publisher: MAN Truck & Bus AG, Technical Sales Support, Application Engineering, Dachauer Str. 667, D-80995 Munich

Chapters Covered

• I. Applicability and legal agreements
• II. Product identification
• III. Chassis
• IV. Body
• V. Calculations

I. Applicability and Legal Agreements

Sets the binding legal and quality framework for anyone modifying a TGS or TGX chassis. Covers the multi-stage type-approval procedure under Annex XVII of 2007/46/EC, bodybuilder responsibility, product liability, operational and road safety obligations, quality assurance expectations (including VDA Vol. 8 and EN ISO 9000 ff), the body approval process, and the categories of manufacturer’s confirmation available through the MAN confirmation service.

II. Product Identification

Explains how MAN designates its vehicles: model ranges (TGL, TGM, TGS, TGX), model numbers and tonnage classes, power ratings, suspension types (BB, BL, LL), wheel configurations (4×2 through 8×8, including MAN HydroDrive H variants), suffixes (S, CKD, TiB, FW, FOC, TS, WW, EL, U), cab variants from M and L up to XLX and XXL, door designations, variant descriptors, base vehicle numbers (GFZ), and the 17-character vehicle identification number (VIN) format.

III. Chassis

The largest chapter. Covers general standards and tolerances, corrosion protection and coating systems, welding work on the frame and electronic subassembly precautions, drill hole and bolted/riveted connection rules for frame side members, fire-protection measures around the engine, exhaust, air intake and electrics. Also covers overall vehicle terms, dimensions and weights — theoretical wheelbase, permitted overhang, permissible axle load, gross weight, gross train weight, axle overload, wheel-load difference, minimum front-axle load, rolling circumference and the weighing procedure — plus modifications to wheelbase, frame overhang, wheel configuration, tyre type and vehicle type.

Following sections detail the cab, chassis frame materials and profiles, frame attachments (front, side and rear underride protection, fuel tanks, coupling devices, winter service mounting plates and crane front plates), engine and driveline (engine variants D20, D26, D28, air intake, cooling, compressed-air supply, exhaust routing, AdBlue system, gearbox and propshafts, PTOs, brakes, MAN HydroDrive), the running gear, and the complete electrical/electronic on-board network including cables, ground cables, wheelbase extension harnesses, rear lamp and trailer socket harnesses, interfaces for liftgates, engine start-stop, speed and reverse signals, ISC/KSM interfaces, additional consumers, batteries, lighting and the safety and assistance systems.

IV. Body

General requirements for the body: accessibility and clearance, handling characteristics and driving resistances, vibration, lifting axles, outriggers, tolerances, assembly sequence, corrosion protection of bodywork and applicable standards including the Machinery Directive 2006/42/EC, cargo securing and contour markings. Covers body and auxiliary-frame design — bodies with and without auxiliary frame, attachment to the chassis frame, threaded and riveted joints, flexible and rigid connections — then the specific body types: semitrailer tractors, platform and box bodies, swap body fittings, liftgates, tank and container bodies, refuse collectors, tippers, set-down and roll-off skip loaders, loading cranes (including auxiliary frame requirements and crane total moment design charts), transport mixers, cable winches, single-pivot bodies and vehicle transporters.

V. Calculations

Full working formulae and worked examples: road speed and theoretical top speed, efficiency of series-connected subassemblies, tractive force, gradeability with and without adhesion taken into account, torque, power output, rotational speeds of transfer-case PTOs, driving resistances (rolling, climbing, air), turning circle with steering angle relationships, axle-load calculation using the moment theorem (including the two complete axle-load worked examples with loading crane arm folded vs extended), weight with trailing axle lifted, support length for a body without auxiliary frame using Hertzian contact stress, coupling device D, DC and V values, and theoretical wheelbase / permissible overhang length for two-, three- and four-axle configurations.

What This Manual Enables

This is a bodybuilder’s working document rather than a generic workshop manual. Every rule that decides whether a conversion is legal, safe and accepted for registration is set out here: where you may weld and where you may not, how many and what size drill holes are permitted in a frame web, which bolts and tightening torques must be used, how far the body must sit from the cab, how to compute the theoretical wheelbase and the permitted overhang, how to prove axle loads and minimum front-axle load are respected, when a flexible versus rigid auxiliary frame connection is required, and how the AdBlue, exhaust, compressed-air and electrical systems may and may not be re-routed on a Euro 5 or Euro 6 chassis.

Because MAN states clearly in Chapter I that responsibility for correct execution rests with the company carrying out the conversion, having the actual published guidelines at hand is essential. The manual defines the legal framework under the EU multi-stage type-approval procedure, the body approval process, and the manufacturer’s confirmation categories, so the bodybuilder knows exactly what documentation has to be produced and submitted before a completed vehicle can be registered.

IMAGES PREVIEW

Delivery is by instant PDF download — no shipping, no waiting, printable, and readable on any desktop, tablet or phone. Whether you are a bodybuilder, fleet engineer, converter, or owner commissioning a crane, tipper, tank, liftgate or transporter body on a TGS or TGX, this is the reference document that tells you what MAN permits and what it does not.