MAN GUIDELINES TO FITTING BODIES. Coupling devices TG Edition 2018 V1.0

Transcription

1 MAN GUIDELINES TO FITTING BODIES Coupling devices TG Edition 2018 V1.0

2 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 Munich info.manted@man.eu Fax: + 49 (0) This English version is a translation. In case of doubt or conflict the valid German language original will govern. We reserve the right to make technical modifications in the course of further development 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 and MANTED are registered trademarks of MAN Truck & Bus AG. If names constitute trademarks, they are also recognised as protected by the relevant owner without use of the appropriate symbols ( ). Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

3 Contents 1.0 General Trailer coupling, D-value Rigid drawbar trailer, center-axle trailer, D c value, V value Final cross members and trailer couplings Ball-type couplings Fifth-wheel coupling If not otherwise specified: all dimensions are in mm, all weights and loads are in kg. MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 1

4 1.0 General If a truck is intended to pull loads, the equipment required for this purpose must of course be fitted and also approved. Compliance with the legislative minimum engine capacity and/or the installation of the appropriate trailer couplings does not guarantee that the truck is suitable for pulling loads. The following are prerequisites for retrofitting the equipment for towing a trailer. The necessary final cross member and trailer coupling Two-line brake connection The electrical system for trailer operation, including an ABS socket Installation of trailer control module ( ASM ) and/or activation of same by means of reparameterisation Only trailer couplings in accordance with EC Directive 94/20/EC or ECE R55 may be used. When manoeuvring, there must be no collision with the trailer. To this end, a drawbar of an adequate length must be selected. The required clearance dimensions must be taken into consideration (in Germany: DIN and EC directives 94/20/EC or ECE R55). In principle, the bodybuilder is responsible for designing and constructing the body so that coupling can be done smoothly and without risk, including monitoring. Freedom of movement of the trailer drawbar must be ensured. If coupling heads and sockets are fitted to the side (e.g. on the rear light holder on the driver s side), the trailer producer and operator must ensure sufficient cable length for cornering. Fig. 01: Clearance for trailer couplings as per 94/20/EC or ECE R T_420_000002_0001_G 2 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

5 Fig. 02: Clearance for ball-type couplings as per DIN max. 100max. 45 max. 100max. 250max. 65 min. 300max. 30 max. 75min. 300max. R40max. 140min. 55min. A 65min. 32min. 45 min. A 350min. 420max. 30 max. 75min. 30 max. R20max. T_420_000003_0001_G Use original MAN final cross members and the matching reinforcing plates to fit trailer couplings. Final cross members feature an appropriate hole pattern for the relevant trailer coupling. Never alter this hole pattern to attach a different trailer coupling. Follow the instructions of the coupling producer in their installation guidelines (e.g. tightening torque and checks). MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 3

6 It is impermissible to lower a trailer coupling without at the same time lowering the final cross member. Examples of lowering a coupling are shown in Fig. 03 and Fig. 04. The examples are purposely schematic, they are not intended as design instructions. Responsibility for the design is that of the particular bodybuilder or converter. Fig. 03: Lowered trailer coupling T_420_000004_0001_G Fig. 04: Trailer coupling fitted below the frame T_420_000005_0001_G 4 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

7 2.0 Trailer coupling, D-value The required trailer coupling size is determined by the. A model plate showing the maximum permissible is affixed to the trailer coupling by its manufacturer. The is stated in kilonewtons [kn]. The formula for the is as follows: Formula 01: D = 9,81 T R T + R Where the of the trailer coupling and the permissible gross weight of the trailer are known, the maximal permissible gross weight of the towing vehicle can be calculated using the following formula: Formula 02: D-value formula for permissible gross weight T = R D (9,81 R) D Where the and the permissible gross weight of the towing vehicle are known, the maximum permissible gross weight of the trailer can be calculated using the following formula: Formula 03: D-value formula for permissible gross trailer weight R = T D (9,81 T) D Where: D = in [kn] T = permissible gross weight of towing vehicle [t] R = permissible gross weight of trailer [t] Calculation examples can be found in the section entitled Calculations in the booklets dealing with the respective model ranges. MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 5

8 3.0 Rigid drawbar trailer, center-axle trailer, D c value, V value The terms are defined as follows. Rigid drawbar trailer (RDT): A trailer vehicle with one axle or axle group, where - the hinged connection to the towing vehicle is achieved by means of a towing device (drawbar), - the drawbar connection to the chassis is fixed such that it can transfer vertical moments and - depending on its design, part of its gross weight is borne by the towing vehicle. Center-axle trailer (CAT): Towed vehicle equipped with a towing device that does not move vertically in relation to the trailer and in which the axles are positioned close to the center of gravity of the vehicle such that only a small static vertical load not exceeding 10% of the mass of the trailer or 1000 kg (whichever is less) is transmitted to the towing vehicle. Center-axle trailers are therefore a subgroup of rigid drawbar trailers. Nose weight S: Vertical load exerted by the drawbar at the coupling point. This is added to the weight of the towing vehicle when a trailer is coupled and must therefore be taken into consideration when designing the vehicle (axle-load calculation). In addition to the D-value formula, other conditions apply to center-axle and rigid drawbar trailers: trailer couplings and final cross members have lower trailer loads because in this case the nose weight acting on the trailer coupling and the final cross member has to be taken into account. To harmonise regulations within the European Union, the terms D c value and V value were introduced with Directive 94/20/EC or ECE R55. The following formulae apply: Formula 04: D c -value formula for center-axle and rigid drawbar trailers D c = 9,81 T C T + C Formula 05: V-value formula for center-axle and rigid drawbar trailers with a permissible nose weight of < 10 % of the trailer mass and not more than 1000 kg x 2 x 2 x 2 V = a c; 1 If the values for < 1, then 1.0 is to be used. l 2 l 2 l 2 Calculation examples can be found in the section entitled Calculations in the booklets dealing with the respectivemodel ranges Where: D C = Reduced when operating with center-axle trailer [kn] V = V value [kn] T = Permissible gross weight of the towing vehicle [t] C = Sum of the axle loads of a center-axle trailer loaded with permissible mass [t], not including nose weight. a = Reference acceleration in coupling point [m/s²] Use the following: 1.8 m/s² for air or comparable suspension on towing vehicle, or 2.4 m/s² for all other types of suspension. S = Permissible nose weight on coupling point x = Length of trailer body [m], see Fig. 05 l = Theoretical drawbar length [m], see Fig Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

9 Fig. 05: Length of trailer body and theoretical drawbar length x x v v l l T_510_000003_0001_G MAN specifies the following for operation with center-axle/rigid drawbar trailers: For equipment delivered ex-works, a trailer nose weight that exceeds 10% of the permissible trailer mass and trailers exceeding 1000 kg is not permitted (with the exception of the MAN low-coupling system). Other loads are the responsibility of the manufacturer of the respective towing device. MAN cannot make any statements in relation to the permissible loads and calculations (e.g. as per 94/20/EC or ECE R55) with respect to these towing devices. Like all rear loads, trailer nose weights affect axle-load distribution. For this reason, particularly in conjunction with additional rear loads (e.g. liftgates, rear loading cranes), perform an axle-load calculation to check whether trailer nose weights are possible. The trailing axle of vehicles having a lifting trailing axle must not be lifted when a center-axle trailer/rigid drawbar trailer is coupled. An unladen vehicle may only tow an unladen center-axle/rigid drawbar trailer. To ensure sufficient steerability, minimum front-axle loads for the vehicle must be observed (see booklets on model ranges). The tables below list possible combinations of trailer loads and nose weights and D, D c and V values and assign them to the different vehicles (listed by model number and type of vehicle). Under certain circumstances, it is possible to change the loads listed. Further information can be obtained from MAN (for address see Publisher above). MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 7

10 4.0 Final cross members and trailer couplings Note: If the final cross member bearing the MAN item number is fitted (the last four digits are stamped into the final cross member at rear right), then the top and bottom of the mounting plate for the respective trailer coupling must be chamfered as shown in Fig chamfer of the trailer coupling mounting plate if final cross member is fit- Fig. 06: ted A T_420_000006_0001_G A) Height of plan surface - coupling mounting plate TGL Table 01: Assignment to vehicle by model range, model number and final cross member - TGL Model no. N01, N02 N11, N12 N61 N03, N04 N05, N13 N14, N15 MAN item no. Hole pattern Comment Without Not for trailer coupling x80 For trailer coupling Type G (3x)83x56 Underride protection and KKK trailer bracket (replaced by.5219) (3x)83x56 Underride protection and KKK trailer bracket (replaces.5189) Without Not for trailer coupling x80 For trailer coupling Type G x55 Lowered by 100 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x (3x)83x56 Underride protection and KKK trailer bracket (replaced by.5219) (3x)83x56 Underride protection and KKK trailer bracket (replaces.5189) 8 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

11 Table 02: Final cross member and technical data TGL MAN item no., Final cross member Hole pattern D [kn] S C R c =C+S D C [kn] V [kn] Max. trailer load t Without ,2 Weight x80 # # # # # # # 8 26, x x x x (3x)83x56 26, (3x)83x56 26, Comment Not for trailer coupling; minimum final cross member, if no final cross member is installed; for fitting a liftgate or a KKK trailer bracket and/or if the underride protection is omitted. Basic part for ; # only with internal reinforcement Final cross member for 7- to 12-tonne TGL, for trailer coupling Type G145 Final cross member for 7-tonne TGL, Type N01/N11, for trailer coupling Type G145 Lowered by 100 mm, for fire service, additional hole pattern 120x55 Lowered by 100 mm, for fire service, additional hole pattern 83x56 Underride protection and KKK trailer bracket, only in conjunction with final cross member or.5179 (replaced by ) Underride protection and KKK trailer bracket, only in conjunction with final cross member or.5179 (replaces ) MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 9

12 Table 03: Assignment of trailer-coupling installation drawings to final cross members - TGL MAN item no., Final cross member Hole pattern Trailer coupling bolts 40 mm Ball-type coupling Trailer coupling installation drawing MAN item no x80 G x55 G x56 TK (3x)83x56 - X (3x)83x56 - X Comment Observe the max. permissible values in the TGL final cross member table. Observe the max. permissible values in the TGL final cross member table. Observe the max. permissible values in the TGL final cross member table. See also the installation of underride protection trailer bracket Replaced by See also the installation of underride protection trailer bracket Replaced TGM Table 04: Assignment to vehicle by model range, model number and final cross member - TGM Model no. N08 N16 N18 N26 N28 N34 N36 N37 N38 MAN item no. Hole pattern Comment Without Not for trailer coupling x100 For trailer coupling Type G x Without Not for trailer coupling x100 For trailer coupling Type G x Without Not for trailer coupling x100 For trailer coupling Type G x Without Not for trailer coupling x100 For trailer coupling Type G Without Not for trailer coupling x100 For trailer coupling Type G x80 For trailer coupling Type G x x100 For trailer coupling Type G x80 For trailer coupling Type G x x100 For trailer coupling Type G x x x55 For trailer coupling Type G150 Lowered by 100 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x56 Lowered by 100 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x56 Lowered by 100 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x56 Lowered by 100 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x56 Lowered by 100 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x56 Lowered by 100 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x56 10 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

13 Table 04: Assignment to vehicle by model range, model number and final cross member - TGM continued Model no. N44 N46 N48 N62 N63 MAN item no. Hole pattern Without Comment x100 Not for trailer coupling Without For trailer coupling Type G x100 Not for trailer coupling x100 For trailer coupling Type G150 Lowered by 100 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x x100 Not for trailer load, only for tow coupling Without x100 Not for trailer coupling Without For trailer coupling Type G x100 Not for trailer coupling N x100 For trailer coupling Type G150 N65 N Without For trailer coupling Type G x100 Not for trailer coupling x100 For trailer coupling Type G x55 N x80 For trailer coupling Typ G145 On N48 only for trailer load up to 3,500 kg with overrun braking, as well as for tow coupling Lowered by 100 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x56 MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 11

14 Table 05: Final cross member and technical data TGM MAN item no. Final cross member Hole pattern D [kn] S C R c =C+S D C [kn] V [kn] Max. trailer load t Weight Comment Without ,2 Not for trailer coupling; minimum final cross member, if no final cross member is installed; for fitting a liftgate and/or if the underride protection is omitted x ,5 31,5 Installed only on N48, only for trailer load up to 3,500 kg with overrun braking, as well as for tow coupling x ,5 23,7 Not approved for trailer load, only for tow coupling x100 # # # # # # # 9,3 31 Basic part for ; # only with internal reinforcement x80 # # # # # # # 8 26,5 Basic part for ; # only with internal reinforcement x Final cross member for 13-tonne TGM Type N34/ N36 for trailer coupling Type G x ,3 38 Final cross member for 13/15/18-tonne TGM for trailer coupling Type G150, only in conjunction with shims (1) x Fire service, additional hole pattern 120x x Additional hole pattern 83x56 (1) When retrofitting a final cross member: bolt the final cross member to the main frame using two shims on the inside of the final cross member. 12 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

15 Table 06: Assignment of trailer-coupling installation drawings to final cross members - TGM MAN item no. final cross member Hole pattern Trailercoupling bolts 40 mm Trailercoupling bolts 50 mm Trailer coupling installation drawing MAN item no. Comment x100 n/v* Installed only on N48, only for trailer load up to 3,500 kg with overrun braking, as well as for tow coupling x80 G x100 G x55 G x56 TK226 - *not available at this time Observe the max. permissible values in the TGM final cross member table. Observe the max. permissible values in the TGM final cross member table. Observe the max. permissible values in the TGM final cross member table. Observe the max. permissible values in the TGM final cross member table. MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 13

16 TGA Table 07: Assignment to vehicle by model range, model number and final cross member - TGA Model no. MAN item no. Hole pattern Comment H Without Semitrailer tractor, not for trailer coupling, replaced by x100 Semitrailer tractor, operation with trailer not permitted Without Semitrailer tractor, not for trailer coupling, replaces.0129 H x100 Tipper, chassis, replaced by x100 Tipper, chassis, replaces.5145 and x100 Tipper, chassis, replaced by.0130 H x100 Tipper, chassis, replaces x100 Tipper, chassis, replaced by.0133 H x100 Semitrailer tractor x100 Tipper, chassis H x100 Semitrailer tractor, replaced by Without Semitrailer tractor, not for trailer coupling, replaced by x100 Tipper, chassis, replaces Without Semitrailer tractor, not for trailer coupling, replaces x100 Tipper, chassis, replaced by.0133 H x100 Semitrailer tractor, replaced by Without Semitrailer tractor, not for trailer coupling, replaced by x100 Tipper, chassis Without Semitrailer tractor, not for trailer coupling, replaces.0129 H x100 Semitrailer tractor, replaced by Without Semitrailer tractor, not for trailer coupling, replaced by x100 Chassis, replaces Without Semitrailer tractor, not for trailer coupling, replaces x100 Chassis, replaced by.0133 H Without Semitrailer tractor, not for trailer coupling, replaced by x100 Semitrailer tractor, operation with trailer not permitted Without Semitrailer tractor, not for trailer coupling, replaces.0129 H x100 Semitrailer tractor, replaced by Without Semitrailer tractor, not for trailer coupling, replaced by x100 Chassis, replaces Without Semitrailer tractor, not for trailer coupling, replaces x100 Chassis, replaced by.0133 H x100 Semitrailer tractor, replaced by Without Semitrailer tractor, not for trailer coupling, replaced by x100 Chassis Without Semitrailer tractor, not for trailer coupling, replaces.0129 H x100 Tipper 14 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

17 Table 07: Assignment to vehicle by model range, model number and final cross member - TGA - continued Model no. MAN item no. Hole pattern Comment H x100 Semitrailer tractor, replaced by.0132 H x100 Semitrailer tractor, replaced by.0132 H x100 Chassis, replaced by x100 Chassis, replaces.0130 H x100 Chassis H x100 Chassis, replaces x100 Chassis, replaced by.0133 H x100 Semitrailer tractor, replaced by x100 Chassis, replaces x100 Chassis, replaced by.0133 H x100 Semitrailer tractor x100 Chassis, replaces x100 Chassis, replaced by.0133 H x100 Chassis, replaces x100 Chassis, replaced by.0133 H x100 Semitrailer tractor, replaced by x100 Chassis, replaces x100 Chassis, replaced by.0133 H x100 Semitrailer tractor x100 Chassis, replaces x100 Chassis, replaced by.0133 H Without Semitrailer tractor, not for trailer coupling, replaced by x100 Semitrailer tractor x100 Chassis Without Semitrailer tractor, not for trailer coupling, replaces.0129 H x100 Semitrailer tractor, replaced by Without Semitrailer tractor, not for trailer coupling, replaced by x100 Chassis, replaces Without Semitrailer tractor, not for trailer coupling, replaces x100 Chassis, replaced by.0133 H x100 Semitrailer tractor, replaced by x100 Chassis, replaces.5145 H x100 Semitrailer tractor, replaced by x100 Tipper, chassis, truck mixer, replaced by x100 Tipper, chassis, truck mixer, replaces.0130 MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 15

18 Table 07: Assignment to vehicle by model range, model number and final cross member - TGA - continued Model no. MAN item no. Hole pattern Comment H x100 Semitrailer tractor x100 Tipper, chassis, truck mixer, replaced by x100 Tipper, chassis, truck mixer, replaces.0130 H x100 Chassis, replaces x100 Chassis, replaced by.0133 H x100 Semitrailer tractor, replaced by x100 Tipper, chassis, replaced by x100 Tipper, chassis, replaces.0130 H x100 Semitrailer tractor, replaced by x100 Tipper, chassis, replaced by x100 Tipper, chassis, replaces.0130 H x100 Semitrailer tractor x100 Tipper, chassis H x100 Semitrailer tractor, replaced by Without Semitrailer tractor, not for trailer coupling, replaced by Without Semitrailer tractor, not for trailer coupling, replaces.0129 H x100 Semitrailer tractor x100 Tipper H x100 Semitrailer tractor x100 Tipper H x100 Semitrailer tractor x100 Chassis H x100 Tipper, chassis, truck mixer, replaced by x100 Tipper, chassis, truck mixer, replaces.0130 H x100 Tipper, chassis, truck mixer, replaced by x100 Tipper, chassis, truck mixer, replaces.0130 H x100 Tipper, chassis, truck mixer, replaced by x100 Tipper, chassis, truck mixer, replaces.0130 H x100 Tipper, chassis, truck mixer H x100 Tipper, chassis, replaced by x100 Tipper, chassis, replaces.0130 H x100 Tipper, chassis H x100 Semitrailer tractor x100 Chassis 16 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

19 Table 07: Assignment to vehicle by model range, model number and final cross member - TGA - continued Model no. MAN item no. Hole pattern Comment H x100 Semitrailer tractor, replaced by.0132 H x100 Chassis, replaced by x100 Chassis, replaces.0130 H x100 Chassis H x100 Replaced by x100 Replaces.0130 H x100 Semitrailer tractor x100 Tipper H x100 Truck mixer H x100 Chassis, truck mixer Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthrough H x100 Tipper, chassis, truck mixer H x100 Semitrailer tractor, replaced by x100 Tipper, chassis, replaced by x100 Tipper, chassis, replaces x100 Tipper, chassis, 150 mm lower H x100 Semitrailer tractor x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower H x100 Semitrailer tractor x100 Tipper H x100 Semitrailer tractor, replaced by x100 Tipper, chassis, replaced by x100 Tipper, chassis, replaces x100 Tipper, chassis, 150 mm lower H x100 Semitrailer tractor x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower H x100 Semitrailer tractor x100 Tipper H x100 Semitrailer tractor x100 Tipper H x100 Tipper H x100 Semitrailer tractor H x100 Semitrailer tractor, replaced by x100 Semitrailer tractor H x100 Semitrailer tractor x100 Tipper, chassis, replaces.0132 MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 17

20 Table 07: Assignment to vehicle by model range, model number and final cross member - TGA - continued Model no. MAN item no. Hole pattern Comment H x100 Semitrailer tractor x100 Chassis, replaces.0132 H x100 Semitrailer tractor, replaces.0132 H x100 Semitrailer tractor, replaces.0132 H x100 Semitrailer tractor x100 Tipper, chassis, replaces.0132 H x100 Semitrailer tractor x100 Chassis, replaces.0132 H x100 Tipper H x100 Chassis H x100 Semitrailer tractor, replaced by x100 Tipper, replaced by x100 Tipper, replaces.0130 H x100 Chassis H x100 Semitrailer tractor, replaced by x100 Tipper, chassis, replaced by x100 Tipper, chassis, replaces x100 Tipper, chassis, 150 mm lower H x100 Tipper, replaced by x100 Tipper, replaces.0130 H x100 Chassis H x100 Chassis H x100 Tipper, chassis, replaced by x100 Tipper, chassis, replaces.0130 H x100 Semitrailer tractor Without Semitrailer tractor, not for trailer coupling, replaces.0132 H x100 Semitrailer tractor, replaces.0132 H x100 Semitrailer tractor x100 Tipper H x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower 18 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

21 Table 07: Assignment to vehicle by model range, model number and final cross member - TGA - continued Model no. MAN item no. Hole pattern Comment H x100 Semitrailer tractor x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower H x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower H x100 Chassis H x100 Semitrailer tractor, replaced by x100 Chassis, replaces x100 Chassis, replaced by.0133 H x100 Chassis, replaced by x100 Chassis, replaces.0130 H x100 Chassis, replaced by x100 Chassis, replaces.0130 H x100 Semitrailer tractor x100 Chassis H x100 Chassis H x100 Chassis H x100 Chassis H x100 Tipper H94 BLLL x100 Semitrailer tractor, no trailer operation permitted with BLLL H94 BLBB x100 Semitrailer tractor x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal and lowered, frame overhang 725 mm/925 mm x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal, frame overhang 725 mm/925 mm H95 BLLL x100 Semitrailer tractor, no trailer operation permitted with BLLL H95 BLBB x100 Semitrailer tractor x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal and lowered, frame overhang 725 mm/925 mm x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal, frame overhang 725 mm/925 mm H x100 Tipper H x100 Chassis HH x100 Semitrailer tractor x100 Chassis, replaces.0132 HH x100 Chassis HV x100 Chassis HV2 MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 19

22 Table 07: Assignment to vehicle by model range, model number and final cross member - TGA - continued Model no. MAN item no. Hole pattern Comment HV x100 Chassis HV x100 Tipper, chassis HV x100 Tipper HV x100 Chassis HV Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthrough HW x100 Semitrailer tractor, replaces.0132 HW x100 Semitrailer tractor x100 Tipper, chassis, truck mixer, replaces.0132 HW x100 Tipper, chassis, truck mixer HW x100 Semitrailer tractor x100 Tipper, chassis, replaces x100 Tipper, chassis, 150 mm lower HW5 HW x100 Tipper, chassis HW Without Semitrailer tractor, not for trailer coupling Without Semitrailer tractor, replaces.0135, not for trailer coupling HW x100 Semitrailer tractor, replaces.0132 HW x100 Semitrailer tractor, replaces x100 Fahrgestell x100 Sattel, Ersatz für Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

23 Table 08: Final cross member and technical data TGA MAN item no., final cross member Hole pattern D [kn] S C R c =C+S D C [kn] V [kn] Max. turntable drawbar trailer load x As per t Weight Comment 9,5 25,6 Only semitrailer tractor with frame tapering, no exchange possible! Replaced by Without ,4 Not for trailer coupling, only semitrailer tractor with frame tapering, replaced by x As per x As per x As per 9,5 31,9 Trailer-coupling hole pattern centralised at height of final cross member, replaced by ,5 25,6 Only semitrailer tractor with frame tapering; derives from and replaces , exchange not possible! 9,5 31,5 Trailer-coupling hole pattern 27.5 mm lower than , replaces and Without ,9 Not for trailer coupling, only semitrailer tractor with frame tapering, replaces x As per x As per x As per 11 28,7 Final cross member reinforced, TGA and F2000, replaced by ,5 50,1 150 mm lower than series ,6 10-bolt connection for 100-t coupling installation, normal and lowered, additional hole pattern 160x100 normal and lowered, only in conjunction with MAN nos and corner plates, frame overhang 725 mm/925 mm. MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 21

24 Table 08: Final cross member and technical data TGA - continued MAN item no., final cross member Hole pattern D [kn] S C R c =C+S D C [kn] V [kn] Max. turntable drawbar trailer load x As per x As per x As per x As per x As per x As per t Weight Comment ,6 Normal and lowered, additional hole pattern for 10-bolt connection for 100-t coupling installation, normal and lowered, only in conjunction with MAN nos and corner plates, frame overhang 725mm/925mm 15 50,6 10-bolt connection for 100-t coupling installation normal, additional hole pattern 160x100, normal, only in conjunction with MAN nos and corner plates, frame overhang 725 mm/925 mm 15 50,6 Additional hole pattern for 10-bolt connection for 100-t coupling installation normal, only in conjunction with MAN nos and corner plates, frame overhang 725 mm/925mm 44,5 Only with MAN lowcoupling system 44,5 Only with MAN lowcoupling system 44,5 Only with MAN lowcoupling system Abbreviations: CAT: rigid drawbar/center-axle trailer: TC: trailer coupling; GW: gross weight t: sheet thickness of final cross member R C : permissible gross weight of CAT 22 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

25 Table 09: Assignment of trailer-coupling installation drawings to final cross members - TGA MAN item no., Final cross member Hole pattern Trailercoupling bolts 40 mm Trailercoupling bolts 50 mm 100 t Trailercoupling bolts 50 mm Trailer-coupling installation drawing MAN item no. Comment x100 X X _3 Semitrailer tractor x100 X X _ x100 X X _3 Semitrailer tractor x100 X X _2 Chamfers required on top and bottom of trailer-coupling mounting plate x100 X X _ x100 X X _4 Lowered by 150 mm x100 X _1 MAN low-coupling system x100 X X n/v* x _1 Heavy-duty trailer coupling, normal or lowered x100 X X n/v* x110 X _1 Heavy-duty trailer coupling, normal *not available at this time MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 23

26 TGS/TGX Table 10: Assignment to vehicle by model range, model number and final cross member - TGS/TGX Model no. MAN item no. Hole pattern Comment 03S x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower 04X, 05X Without Semitrailer tractor, not for trailer coupling 06S/06X x100 Tipper, chassis Without Semitrailer tractor, not for trailer coupling Without Semitrailer tractor, replaces.0135, not for trailer coupling 08S Without Semitrailer tractor, not for trailer coupling Without Semitrailer tractor, replaces.0135, not for trailer coupling 10S/10X x100 Chassis Without Semitrailer tractor, not for trailer coupling Without Semitrailer tractor, replaces.0135, not for trailer coupling 13S/13X x100 Semitrailer tractor, replaces S/15X x100 Chassis 18S/18X x100 Chassis 21S/21X x100 Chassis 22S x100 Chassis Without Semitrailer tractor, not for trailer coupling 22X Without Semitrailer tractor, not for trailer coupling Without Semitrailer tractor, replaces.0135, not for trailer coupling 24S x100 Semitrailer tractor x100 Chassis, replaces Without Semitrailer tractor, not for trailer coupling 24X Without Semitrailer tractor, not for trailer coupling Without Semitrailer tractor, replaces.0135, not for trailer coupling 26S x100 Tipper, chassis, truck mixer 26X x100 Tipper, chassis 24 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

27 Table 10: Assignment to vehicle by model range, model number and final cross member - TGS/TGX - continued Model no. MAN item no. Hole pattern Comment 28X x100 Semitrailer tractor, not approved for trailer coupling x100 Semitrailer tractor, replaces.0144, not approved for trailer coupling 30S x100 Tipper, chassis 30X x100 Tipper, chassis 35S x100 Chassis 37S x100 Tipper, chassis, truck mixer Without Tipper, not for trailer coupling 39S x100 Tipper, chassis, truck mixer 41S x100 Tipper, chassis 42S/42X 45S/45X x100 Chassis 46S x100 Chassis 49S x100 Tipper, truck mixer Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthrough 52S x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower 56S x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower 59S x100 Tipper 66S x100 Tipper x100 Tipper 70S x100 Tipper, chassis 71S x100 Chassis 73S x100 Chassis 74S x100 Chassis 78X Without Semitrailer tractor, not for trailer coupling Without Semitrailer tractor, replaces.0135, not for trailer coupling MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 25

28 Table 10: Assignment to vehicle by model range, model number and final cross member - TGS/TGX - continued Model no. MAN item no. Hole pattern Comment 79X x100 Chassis 80S x100 Tipper 82S x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower 84S x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower 86X x100 Semitrailer tractor x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal and lowered, frame overhang 725 mm x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal, frame overhang 725 mm 87X x100 Semitrailer tractor 88X x100 Semitrailer tractor, not approved for trailer coupling x100 Semitrailer tractor, replaces.0144, not approved for trailer coupling 89S/89X x100 Chassis 90S x100 Chassis 92S/92X x100 Chassis 93S x100 Tipper 94X x100 Semitrailer tractor x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal and lowered, frame overhang 725 mm x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal, frame overhang 725 mm 95X x100 Semitrailer tractor 96S x100 Tipper, chassis x100 Tipper, chassis, 150 mm lower 03W 06W 18W x100 Chassis 19W x100 Chassis 26W x100 Tipper, chassis, truck mixer 30W 34W x100 Tipper 39W x100 Tipper, chassis, truck mixer 26 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

29 Table 10: Assignment to vehicle by model range, model number and final cross member - TGS/TGX - continued Model no. MAN item no. Hole pattern Comment 49W Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthrough 52W x100 Tipper, chassis 56W x100 Tipper, chassis 58W x100 Tipper x110 Semitrailer tractor, 10-bolt connection for 100-t coupling 60W x100 Tipper 71W 72W 73W x100 Chassis 74W x100 Tipper, chassis x100 Tipper, chassis 75W x100 Tipper 76W x100 Tipper, chassis 77W x100 Tipper 78W x100 Chassis 79W x100 Tipper, chassis, truck mixer MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 27

30 Table 11: Final cross member and technical data TGS/TGX MAN item no., final cross member Hole pattern D [kn] S C R c =C+S D C [kn] V [kn] Max. turntable drawbar trailer load t Weight Comment x ,5 n/v* Not approved for trailer coupling, only for TGX Brazil, replaces x As per x As per 9,5 31,5 Trailer-coupling hole pattern 27.5 mm lower than , replaces and ,5 25,6 Only semitrailer tractor with frame tapering, no exchange possible! Replaces Without ,9 Not for trailer coupling, only semitrailer tractor with frame tapering, replaces x ,5 n/v* Not approved for trailer coupling, only for TGX Brazil x As per 9,5 50,1 150 mm lower than series Without ,6 Not for trailer coupling, only for rear tipper x As per x As per ,6 10-bolt connection for 100-t coupling installation, normal and lowered, additional hole pattern 160x100 normal, only in conjunction with MAN nos and corner plates, frame overhang 725 mm ,6 Normal hole pattern, additional hole pattern for 10-bolt connection for 100-t coupling installation, normal and lowered, only in conjunction with MAN nos and corner plates, frame overhang 725 mm 28 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

31 Table 11: Final cross member and technical data TGS/TGX - continued MAN item no., final cross member Hole pattern D [kn] S C R c =C+S D C [kn] V [kn] Max. turntable drawbar trailer load x As per x As per x As per x As per x As per x As per t Weight Comment 15 50,0 10-bolt connection for 100-t coupling installation normal, additional hole pattern 160x100, normal, only in conjunction with MAN nos and corner plates, frame overhang 725 mm 15 50,0 Additional hole pattern for 10-bolt connection for 100-t coupling installation normal, only in conjunction with MAN nos and corner plates, frame overhang 725 mm 15 60,4 10-bolt connection for 100-t coupling installation, normal 22 44,5 Only with MAN low-coupling system 22 44,5 Only with MAN low-coupling system 22 44,5 Only with MAN low-coupling system Abbreviations: CAT: rigid drawbar/center-axle trailer: TC: trailer coupling; GW: gross weight t: sheet thickness of final cross member R C : permissible gross weight of CAT Table 12: Assignment of trailer-coupling installation drawings to final cross members - TGS/TGX MAN item no., Final cross member Hole pattern Trailercoupling bolts 40 mm Trailercoupling bolts 50 mm 100 t trailer coupling Bolts 50 mm Trailer-coupling installation drawing MAN item no. Comment x100 X X _2 Chamfers required on top and bottom of trailer-coupling mounting plate x100 X X _3 Semitrailer tractor x100 X X _4 Lowered by 150 mm x100 X _1 MAN low-coupling system x110 X _1 Heavy-duty trailer coupling, normal or lowered x100 X X n/v* x110 X _1 Heavy-duty trailer coupling, normal x100 X X n/v* x110 X n/v* Heavy-duty trailer coupling, normal *not available at this time MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 29

32 5.0 Ball-type couplings Like all rear loads, even low trailer nose weights affect axle-load distribution. For this reason, particularly in conjunction with additional rear loads (e.g. liftgates, rear loading cranes), perform an axle-load calculation to check whether trailer nose weights are possible. Other requirements for fitting ball-type couplings are as follows: The ball-type coupling must be adequately dimensioned and type-approved (trailer nose weight, trailer load). The trailer bracket must be adequately dimensioned and type-approved. The trailer bracket must be attached to the vertical webs of the main frame (attachment to the lower flange of the main frame alone is not permitted by MAN) The test center (e.g. DEKRA, TÜV) must check for adequate dimensioning and suitable connection to the vehicle frame when the trailer coupling is registered. Instructions for assembly/guidelines issued by the manufacturers of the trailer bracket and ball-type coupling must be observed. The necessary clearance dimensions, e.g. as per DIN must be observed (see Fig. 02). 6.0 Fifth-wheel coupling The weight and size of semitrailers and semitrailer tractors must be checked to see if they are suitable for forming a tractor-semitrailer vehicle. The following must therefore be checked: Slew radii Fifth-wheel coupling load Ease of movement of all components Statutory requirements In order to achieve maximum fifth-wheel coupling load, the following measures are required before the vehicle goes into operation: Weigh vehicle Calculate axle load Determine optimum fifth-wheel lead Check front slew radius Check rear slew radius Check front angle of inclination Check rear angle of inclination Check total length of tractor-semitrailer vehicle Mount fifth-wheel coupling accordingly. The necessary angle of inclination specified by DIN ISO 1726 is 6 at the front, 7 at the rear and 3 at the side. Different tyre sizes, spring rates or fifth-wheel heights between tractor and semitrailer reduce these angles so that they no longer comply with the standard. In addition to rear inclination of a semitrailer, it is also necessary to consider sideways inclination when cornering, suspension compression (axle guidance, brake cylinders), anti-skid chains, pendulum movement of the axle unit on vehicles with a tandem axle and slew radius. The plane of the fifth-wheel plate on the semitrailer should be parallel to the roadway under a permissible fifth-wheel coupling load. The height of the fifth-wheel coupling must therefore be designed accordingly, in order to comply with the statutory height of maximum 4 m (with semitrailer). 30 Edition 2018 V1.0 MAN Guide to fitting bodies Coupling devices TG

33 Fig. 07: Dimensions on semitrailer tractors T_995_000002_0001_G The distance between rear axle and fifth-wheel kingpin stated in the sales documentation or chassis drawings only applies to a standard vehicle. Under some circumstances, equipment that affects the vehicle s unladen weight or dimensions requires the fifthwheel lead to be modified. This can also change the payload capacity and the vehicle s length. Only type-tested fifth-wheel couplings and assembly plates, in compliance with EC directive 94/20/EC or ECE R55 must be used. A fifth-wheel coupling may not be fitted without an auxiliary frame. Under certain circumstances, it is possible to fit a fifth-wheel coupling directly. Here, the fifth-wheel coupling is installed on the auxiliary frame together with a reinforcing plate (not subject to type approval) and the mounting plate is omitted. MAN Guide to fitting bodies Coupling devices TG Edition 2018 V1.0 31