Man Truck Series TGL TGM Fitting Bodies Operator’s Manual PDF

Description

Man Truck Series TGL TGM Fitting Bodies Operator’s Manual – PDF DOWNLOAD

FILE DETAILS:

Man Truck Series TGL TGM Fitting Bodies Operator’s Manual – PDF DOWNLOAD 

Language : English
Pages : 360
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Man Truck Series TGL TGM Fitting Bodies Operator’s Manual – PDF DOWNLOAD 

I Applicability and legal agreements1
10 General2
20 Legal agreements 2
21 Requirements 2
22 Responsibility 3
23 Registration of the vehicle4
30 Liability7
31 Liability for material defects7
32 Product liability 7
33 Limitation of liability for accessories/spare parts 8
34 Operational and road safety8
35 Instructions from body-building and conversion companies 9
40 Quality assurance 10
50 Approvals 11
51 Body approval 11
52 Manufacturer Confirmation13
53 Trademarks 14
II Edition 2018 V20 MAN Guide to fitting bodies TGL/TGM
Contents
II Product identification17
10 General18
20 Terms18
21 Model range 18
22 Model number 18
23 Tonnage class 20
24 Power rating 20
25 Type of suspension 20
26 Wheel configuration 21
27 Suffix22
28 Cabs23
30 Door designation 25
40 Variant descriptor 25
50 Base vehicle number 26
60 Vehicle identification number and vehicle production number 26
MAN Guide to fitting bodies TGL/TGM Edition 2018 V20 III
Contents
III Chassis29
10 General30
11 Obtaining technical vehicle data30
12 Standards, guidelines, regulations, tolerances 30
13 Quality of execution 31
131 Corrosion protection 31
132 Welding work on the vehicle31
133 Drill holes, riveted and bolted connections 35
14 Fire-protection measures for vehicle bodies and modifications 38
141 General38
142 Statutory requirements 38
143 Measures in the vicinity of the engine and exhaust system 39
144 Measures on the air intake system39
145 Electric wiring/fittings 40
20 Overall vehicle 41
21 General41
22 Terms, dimensions and weights41
221 Theoretical wheelbase 41
222 Theoretical and permitted overhang lengths 43
223 Permissible axle load 44
224 Permissible gross weight44
225 Permissible gross train weight45
226 Axle overload 46
227 Wheel-load difference 47
228 Minimum front-axle load49
229 Calculating the axle load and weighing procedure 51
2210 Rolling circumference and difference in rolling circumference 51
23 Modifications to the overall vehicle 52
231 Modifications to the wheelbase52
232 Modifying the frame overhang58
233 Modifying the wheel configuration 62
234 Changing the tyre type 63
235 Changing the vehicle type and interchangeable operation as
semitrailer 63
tractor/truck 63
236 Retrofitting additional units, attachments and accessories 64
24 Homologated vehicle components / vehicle components
relevant to safety 65
30 Cab66
IV Edition 2018 V20 MAN Guide to fitting bodies TGL/TGM
Contents
31 General66
32 Cabs67
33 Spoilers, roof extensions, roofwalk 68
34 Roof sleeper cabs 71
35 Fastening of warning plates to the front flap 74
40 Chassis frame 75
41 General75
42 Frame materials 75
43 Frame profiles 76
50 Frame attachments 77
51 General77
52 Front underride protection78
53 Side underride protection79
54 Rear underride protection83
55 Fuel tanks 85
551 Mounting fuel tanks 87
552 Modifications to fuel lines88
56 Coupling devices 91
57 Front-mounted attachments92
60 Engine and driveline 94
61 General94
62 Engine versions 95
621 Type codes for MAN engines96
63 Engine environment 97
631 Modifications to the engine97
632 Modification to the air intake97
633 Modifications to the engine cooling system 103
634 Modifications to engine encapsulation, noise insulation 105
635 Compressed-air supply105
6351 Basic principles 105
6352 Routing lines 105
6353 Connecting auxiliary consumers108
6354 Loss of compressed-air pressure 109
6355 External air supply 110
64 Exhaust system 113
641 Modifications to the exhaust routing 113
642 AdBlue-System 121
6421 Basic principles and structure of the AdBlue system 121
6422 AdBlue line set 125
MAN Guide to fitting bodies TGL/TGM Edition 2018 V20 V
Contents
6423 AdBlue tank 135
6424 AdBlue supply module138
6425 AdBlue cable harness 140
6426 Parts list159
65 Gearbox and propshafts163
651 Basic principles 163
652 Propshaft configurations164
653 Forces in the propshaft system168
654 Modifying the propshaft configuration 168
655 Fitting other manual or automatic gearboxes and transfer cases169
66 PTOs169
67 Brake system 170
671 Basic principles 170
672 Installing and fastening brake lines 170
673 ALB, EBS brake system170
674 Retrofitting continuous brakes170
70 Running gear 171
71 General171
72 Modifications to the running gear 172
73 Equipment-related notes172
80 Electrical/electronic system (on-board network) 173
81 General173
811 Electromagnetic compatibility174
812 Static discharge 174
813 Radio equipment and aerials174
814 Diagnostics concept and parameterisation using MAN-cats 177
82 Cables178
821 Routing cables 178
822 Ground cable 179
823 Wiring harnesses for wheelbase extensions 179
824 Cable harnesses for rear position lamps, additional rear
position lamps, trailer sockets, side marker lamps and
supplementary ABS sockets183
825 Supplementary wiring diagrams and cable-harness drawings 188
826 Battery cable 188
83 Interfaces on the vehicle, preparations for the body 189
831 Tapping into the engine-on (D+) signal 190
832 Electrical interface for liftgate190
833 Engine-Start-stop system193
834 Tapping into the speed signal193
VI Edition 2018 V20 MAN Guide to fitting bodies TGL/TGM
Contents
835 Tapping into the reverse gear signal 194
836 Interfaces for intermediate speed control with VMC/PTM and
CSM (ISC interfaces) 194
837 Interface for reversing-camera preparation 197
84 Additional consumers 203
841 Notes on charging balance208
85 Batteries210
851 Handling and maintaining batteries 210
852 Handling and care of maintenance-free batteries 211
86 Lighting installations 212
87 Display and instrumentation concept 213
88 Safety and assistance systems214
881 Yaw-rate sensor 214
882 Radar sensor 216
883 Multi-functional camera219
89 Electrical Boxes on the chassis frame 222
MAN Guide to fitting bodies TGL/TGM Edition 2018 V20 VII
Contents
IV Body225
10 General requirements 226
11 Requirements 226
12 Accessibility and clearance226
13 Handling characteristics and driving resistances 228
14 Vibration229
15 Special feature of vehicles with lifting axles 229
16 Vehicles with outriggers230
161 Outrigger operation with the wheels in contact with the ground 230
162 Outrigger operation with the wheels not in contact with
the ground 231
17 Tolerances 231
18 Assembly 231
19 Corrosion protection of bodywork 232
110 Standards, directives and regulations 233
1101 Machinery Directive (2006/42/EC) 233
1102 Securing of cargo 235
1103 Contour markings 235
1104 Radio Equipment Directive 2014/53/EU 236
20 Body and auxiliary-frame design239
21 General requirements 239
22 Body with auxiliary frame241
221 Permissible materials 241
222 Auxiliary-frame design 241
223 Connection to chassis frame244
224 Equipment-specific notes and restrictions 245
23 Body without auxiliary frame249
24 Attaching auxiliary frames and bodies 251
25 Bolt connections and riveted joints 252
26 Flexible connection 254
261 General requirements for flexible body fasteners 254
262 Implementations of flexible body fasteners 256
27 Rigid connection 261
30 Bodies264
31 Semitrailer tractors 264
311 Chassis and equipment264
312 Requirements for bodies264
32 Platform and box bodies266
33 Swap body fittings 267
VIII Edition 2018 V20 MAN Guide to fitting bodies TGL/TGM
331 Chassis and equipment267
332 Requirements to be met by the body 267
34 Liftgates268
35 Tank and container bodies279
351 Chassis and equipment279
352 Requirements to be met by the body 279
36 Refuse-collector body 282
361 Chassis and equipment282
362 Requirements to be met by the body 282
37 Tippers283
371 Chassis and equipment283
372 Requirements to be met by the body 284
38 Set-down and roll-off skip loaders 286
39 Loading crane 287
391 Chassis and equipment287
392 Requirements to be met by the body 289
393 Requirements to be met by auxiliary frames for loading cranes 291
310 Transport mixers 298
3101 Chassis and equipment298
3102 Requirements to be met by the body 299
311 Cable winch 300
312 Single-pivot body 300
Contents
MAN Guide to fitting bodies TGL/TGM Edition 2018 V20 IX
V Calculations303
10 General304
11 Speed304
12 Efficiency 306
13 Tractive force 308
14 Gradeability 309
141 Distance travelled on uphill or downhill gradients 309
142 Angle of uphill or downhill gradient 310
143 Calculating the gradeability311
15 Torque315
16 Power output 317
17 Rotational speeds for power take-offs on the transfer case 319
18 Driving resistances 320
19 Turning circle 323
110 Axle-load calculation 326
1101 Performing an axle-load calculation 326
1102 Calculation of weight with trailing axle lifted 333
111 Support length for body without auxiliary frame 335
112 Coupling devices 336
1121 Trailer coupling for steerable drawbar trailer (D value) 336
1122 Trailer coupling for rigid drawbar trailer/ center-axle trailer
(DC value, V value)337
1123 Trailer coupling for semi-trailer (D value) 339
113 Theoretical wheelbase and permissible overhang length 341

DESCRIPTION:

Man Truck Series TGL TGM Fitting Bodies Operator’s Manual – PDF DOWNLOAD 

General:
The statements in these MAN guidelines to fitting 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 fitting 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 confirmed 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.

S.V 23/02/2025