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

Transcription

1 MAN GUIDELINES TO FITTING BODIES Coupling devices TG Edition 218 V1.

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-8995 Munich info.manted@man.eu Fax: + 49 () 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. 218 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 218 V1.

3 Contents 1. General Trailer coupling, D-value Rigid drawbar trailer, center-axle trailer, Dc value, V value Final cross members and trailer couplings Ball-type couplings Fifth-wheel coupling... 3 If not otherwise specified: all dimensions are in mm, all weights and loads are in kg. Edition 218 V1. 1

4 1. 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 94/2/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 7458 and EC directives 94/2/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. Clearance for trailer couplings as per 94/2/EC or ECE R Fig. 1: 42 T_42_2_1_G 2 Edition 218 V1.

5 Fig. 2: Clearance for ball-type couplings as per DIN max. 1max. 45 m 35min. 42max.. 45 min 55min. 3max. ax. R4m R2m ax. 75min. 32min. 14min. A ax. 3 m A 65min.. min 65 25max. x. 3max. 75min. ax. 3 ma 1max. 3 max. T_42_3_1_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). Edition 218 V1. 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. 3 and Fig. 4. 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. 3: Lowered trailer coupling T_42_4_1_G Fig. 4: Trailer coupling fitted below the frame T_42_5_1_G 4 Edition 218 V1.

7 2. 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 1: 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 2: D-value formula for permissible gross weight T RD (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 3: D-value formula for permissible gross trailer weight R Where: TD (9,81 T) D 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. Edition 218 V1. 5

8 3. Rigid drawbar trailer, center-axle trailer, Dc 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 1% of the mass of the trailer or 1 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 Dc value and V value were introduced with Directive 94/2/EC or ECE R55. The following formulae apply: Formula 4: Dc-value formula for center-axle and rigid drawbar trailers Dc Formula 5: 9,81 T C T+C V-value formula for center-axle and rigid drawbar trailers with a permissible nose weight of < 1 % of the trailer mass and not more than 1 kg V a x2 c; l2 x2 1 If the values for l2 x2 l2 < 1, then 1. is to be used. Calculation examples can be found in the section entitled Calculations in the booklets dealing with the respectivemodel ranges Where: DC 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. 5 l Theoretical drawbar length [m], see Fig. 5 6 Edition 218 V1.

9 Fig. 5: Length of trailer body and theoretical drawbar length x x v v l l T_51_3_1_G MAN specifies the following for operation with center-axle/rigid drawbar trailers: For equipment delivered ex-works, a trailer nose weight that exceeds 1% of the permissible trailer mass and trailers exceeding 1 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 94/2/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, Dc 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). Edition 218 V1. 7

10 4. 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. 6. Fig. 6: ted 45 chamfer of the trailer coupling mounting plate if final cross member is fit- A T_42_6_1_G A) Height of plan surface - coupling mounting plate TGL Table 1: Model no. N1, N2 N11, N12 N61 N3, N4 N5, N13 N14, N15 Assignment to vehicle by model range, model number and final cross member - TGL Hole pattern Not for trailer coupling 14x8 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) Not for trailer coupling x8 For trailer coupling Type G x55 Lowered by 1 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 218 V1.

11 Table 2: MAN item no., Final cross member Final cross member and technical data TGL Hole pattern 14x8 14x8 D [kn] 69 S 1 C 13. RcC+S 14 DC [kn] 64 V [kn] 35 Max. t Weight trailer load ,2 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. 26,5 Basic part for ; only with internal reinforcement Final cross member for 7- to 12-tonne TGL, for trailer coupling Type G x Final cross member for 7-tonne TGL, Type N1/N11, for trailer coupling Type G x Lowered by 1 mm, for fire service, additional hole pattern 12x x Lowered by 1 mm, for fire service, additional hole pattern 83x56 3 Underride protection and KKK trailer bracket, only in conjunction with final cross member or.5179 (replaced by ) 3 Underride protection and KKK trailer bracket, only in conjunction with final cross member or.5179 (replaces ) (3x)83x56 (3x)83x56 26,8 26, Edition 218 V

12 Table 3: Assignment of trailer-coupling installation drawings to final cross members - TGL, Final cross member Hole pattern Trailer coupling bolts 4 mm Ball-type coupling Trailer coupling installation drawing x8 G Observe the max. permissible values in the TGL final cross member table x55 G Observe the max. permissible values in the TGL final cross member table x56 TK Observe the max. permissible values in the TGL final cross member table (3x)83x See also the installation of underride protection trailer bracket Replaced by (3x)83x See also the installation of underride protection trailer bracket Replaced TGM Table 4: Model no. Assignment to vehicle by model range, model number and final cross member - TGM N8 N16 N18 N26 N28 N34 N36 N37 N38 Hole pattern Not for trailer coupling For trailer coupling Type G x55 Lowered by 1 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x Not for trailer coupling For trailer coupling Type G x55 Lowered by 1 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x Not for trailer coupling For trailer coupling Type G x55 Lowered by 1 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x Not for trailer coupling For trailer coupling Type G Not for trailer coupling For trailer coupling Type G x8 For trailer coupling Type G x55 Lowered by 1 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x For trailer coupling Type G x8 For trailer coupling Type G x55 Lowered by 1 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x For trailer coupling Type G x55 Lowered by 1 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x x55 For trailer coupling Type G15 1 Edition 218 V1.

13 Table 4: Assignment to vehicle by model range, model number and final cross member - TGM continued Model no. N44 N46 N48 N62 N63 N64 N65 N66 N67 Hole pattern Lowered by 1 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x Not for trailer coupling For trailer coupling Type G Not for trailer coupling For trailer coupling Type G15 Not for trailer load, only for tow coupling On N48 only for trailer load up to 3,5 kg with overrun braking, as well as for tow coupling Not for trailer coupling For trailer coupling Type G Not for trailer coupling For trailer coupling Type G For trailer coupling Type G Not for trailer coupling For trailer coupling Type G x55 Lowered by 1 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x x8 For trailer coupling Typ G145 Edition 218 V1. 11

14 Table 5: Final cross member and technical data TGM Final cross member Hole pattern D [kn] S C RcC+S DC [kn] V [kn] ,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 ,5 31,5 Installed only on N48, only for trailer load up to 3,5 kg with overrun braking, as well as for tow coupling ,5 23,7 Not approved for trailer load, only for tow coupling ,3 31 Basic part for ; only with internal reinforcement x8 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 ,3 38 Final cross member for 13/15/18-tonne TGM for trailer coupling Type G15, only in conjunction with shims (1) x Fire service, additional hole pattern 12x x Additional hole pattern 83x56 (1) Max. t trailer load Weight 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 218 V1.

15 Table 6: Assignment of trailer-coupling installation drawings to final cross members - TGM final cross member Hole pattern Trailercoupling bolts 4 mm Trailercoupling bolts 5 mm x8 G G x55 G x56 TK226 - Trailer coupling installation drawing n/v* Installed only on N48, only for trailer load up to 3,5 kg with overrun braking, as well as for tow coupling 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. *not available at this time Edition 218 V1. 13

16 TGA Table 7: Model no. H1 H2 H3 H4 H5 H6 H7 H8 H9 H1 H11 Assignment to vehicle by model range, model number and final cross member - TGA Hole pattern, not for trailer coupling, replaced by , operation with trailer not permitted , not for trailer coupling, replaces , replaced by , replaces.5145 and , replaced by.13, replaces , replaced by , replaced by , not for trailer coupling, replaced by , replaces.128, replaces , not for trailer coupling, replaces , replaced by , replaced by , not for trailer coupling, replaced by , replaces , not for trailer coupling, replaces , replaced by , not for trailer coupling, replaced by , replaces.128, replaces , not for trailer coupling, replaces , replaced by , not for trailer coupling, replaced by , operation with trailer not permitted , not for trailer coupling, replaces , replaced by , not for trailer coupling, replaced by , replaces.128, replaces , not for trailer coupling, replaces , replaced by , replaced by , not for trailer coupling, replaced by , replaces , not for trailer coupling, replaces Edition 218 V1.

17 Table 7: Model no. H12 H13 H14 Assignment to vehicle by model range, model number and final cross member - TGA - continued Hole pattern , replaces , replaced by , replaces , replaced by , replaced by.133, replaces.13 H15 H16, replaces , replaced by , replaced by , replaces.128, replaces , replaced by.133 H17 H18 H19 H2 H21 H22 H23 H24 H , replaces , replaced by.133, replaces , replaced by , replaced by , replaces.128, replaces , replaced by , replaces , replaced by , not for trailer coupling, replaced by , not for trailer coupling, replaces , replaced by , not for trailer coupling, replaced by , replaces.128, replaces , not for trailer coupling, replaces , replaced by , replaced by , replaces.128, replaces , replaced by , replaces , truck mixer, replaced by.133, truck mixer, replaces , 15 mm lower Edition 218 V1. 15

18 Table 7: Model no. H26 H27 H28 H29 H3 H32 H33 H34 H35 H36 H37 H38 Assignment to vehicle by model range, model number and final cross member - TGA - continued Hole pattern , truck mixer, replaced by.133, truck mixer, replaces , 15 mm lower , replaces , replaced by , replaced by , replaces , replaced by.133, replaces , 15 mm lower , replaced by , replaces , replaced by.133, replaces , 15 mm lower , 15 mm lower , replaced by , not for trailer coupling, replaced by , replaces , not for trailer coupling, replaces , 15 mm lower , 15 mm lower , truck mixer, replaced by.133, truck mixer, replaces , truck mixer, replaced by.133, truck mixer, replaces , truck mixer, replaced by.133, truck mixer, replaces.13 H39, truck mixer H , replaced by.133, replaces.13 H41 H Edition 218 V1.

19 Table 7: Model no. Assignment to vehicle by model range, model number and final cross member - TGA - continued Hole pattern H , replaces.128 H , replaced by.133, replaces.13 H45 H46 H47, replaced by Replaced by.133 Replaces , 15 mm lower H48 Truck mixer H49, truck mixer Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthrough, truck mixer H5 H51 H52 H54 H55 H , replaced by , replaces , replaced by.133, replaces , 15 mm lower , 15 mm lower , 15 mm lower , replaced by , replaces , replaced by.133, replaces , 15 mm lower , 15 mm lower H H H59 H H , replaced by , replaces.132 H62 Edition 218 V1. 17

20 Table 7: Model no. Assignment to vehicle by model range, model number and final cross member - TGA - continued Hole pattern , replaces.132 H , replaces.132 H , replaces H63 H66 H , replaces , replaces.132 H68 H69 H , replaced by , replaces.128 H71 H72 H , replaced by.133, replaces , 15 mm lower , replaced by , replaces , replaced by.133, replaces , 15 mm lower , replaced by.133, replaces , 15 mm lower H74 H75 H , replaced by.133, replaces.13 H78 H79 H8 H , 15 mm lower , not for trailer coupling , replaces , replaces , 15 mm lower , 15 mm lower 18 Edition 218 V1.

21 Table 7: Model no. Assignment to vehicle by model range, model number and final cross member - TGA - continued Hole pattern , 15 mm lower H , 15 mm lower H85 H , replaced by , replaces.128, replaces , replaced by , replaced by.133, replaces.13 H , replaced by.133, replaces.13 H H82 H87 H H91 H92 H , 15 mm lower H94 BLLL, no trailer operation permitted with BLLL H94 BLBB x11, 1-bolt connection for 1-t coupling, normal and lowered, frame overhang 725 mm/925 mm x11, 1-bolt connection for 1-t coupling, normal, frame overhang 725 mm/925 mm H95 BLLL, no trailer operation permitted with BLLL H95 BLBB x11, 1-bolt connection for 1-t coupling, normal and lowered, frame overhang 725 mm/925 mm x11, 1-bolt connection for 1-t coupling, normal, frame overhang 725 mm/925 mm , 15 mm lower H96 H99 HH , replaces.132 HH4 HV HV2 Edition 218 V1. 19

22 Table 7: Model no. HV4 HV5 Assignment to vehicle by model range, model number and final cross member - TGA - continued Hole pattern , 15 mm lower , 15 mm lower HV HV Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthrough HW , replaces , truck mixer , replaces.132 HV6 HW , 15 mm lower HW3, truck mixer HW , replaces , 15 mm lower HW HW6 HW , not for trailer coupling HW8 HW , replaces.135, not for trailer coupling , replaces , replaces.132 Fahrgestell Sattel, Ersatz für Edition 218 V1.

23 Table 8: Final cross member and technical data TGA, final cross member Hole pattern D [kn] S C RcC+S DC [kn] V [kn] ,5 25,6 Only semitrailer tractor with frame tapering, no exchange possible! Replaced by ,4 Not for trailer coupling, only semitrailer tractor with frame tapering, replaced by ,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! ,5 31,5 Trailer-coupling hole pattern 27.5 mm lower than , replaces and ,9 Not for trailer coupling, only semitrailer tractor with frame tapering, replaces ,7 Final cross member reinforced, TGA and F2, replaced by ,5 5,1 15 mm lower than series x ,6 1-bolt connection for 1-t coupling installation, normal and lowered, additional hole pattern normal and lowered, only in conjunction with MAN nos and corner plates, frame overhang 725 mm/925 mm. Max. t turntable drawbar trailer load Edition 218 V1. Weight 21

24 Table 8: Final cross member and technical data TGA - continued, final cross member Hole pattern D [kn] S C RcC+S DC [kn] V [kn] Max. turntable drawbar trailer load t Weight ,6 Normal and lowered, additional hole pattern for 1-bolt connection for 1-t coupling installation, normal and lowered, only in conjunction with MAN nos and corner plates, frame overhang 725mm/925mm x ,6 1-bolt connection for 1-t coupling installation normal, additional hole pattern, normal, only in conjunction with MAN nos and corner plates, frame overhang 725 mm/925 mm ,6 Additional hole pattern for 1-bolt connection for 1-t coupling installation normal, only in conjunction with MAN nos and corner plates, frame overhang 725 mm/925mm ,5 Only with MAN lowcoupling system ,5 Only with MAN lowcoupling system ,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 RC: permissible gross weight of CAT 22 Edition 218 V1.

25 Table 9: Assignment of trailer-coupling installation drawings to final cross members - TGA, Final cross member Hole pattern Trailercoupling bolts 4 mm Trailercoupling bolts 5 mm _ _ _2 Chamfers required on top and bottom of trailer-coupling mounting plate _ x x11 1 t Trailercoupling bolts 5 mm Trailer-coupling installation drawing _ _4 Lowered by 15 mm _1 MAN low-coupling system n/v* _1 Heavy-duty trailer coupling, normal or lowered n/v* _1 Heavy-duty trailer coupling, normal *not available at this time Edition 218 V1. 23

26 TGS/TG Table 1: Assignment to vehicle by model range, model number and final cross member - TGS/TG Model no. 3S 4 Hole pattern , 15 mm lower , , not for trailer coupling 6S/ , not for trailer coupling , replaces.135, not for trailer coupling , not for trailer coupling , replaces.135, not for trailer coupling 8S 1S/1 13S/ , not for trailer coupling , replaces.135, not for trailer coupling , replaces S/15 18S/ S/21 22S 22 24S 24 26S , not for trailer coupling , not for trailer coupling , replaces.135, not for trailer coupling , replaces , not for trailer coupling , not for trailer coupling , replaces.135, not for trailer coupling, truck mixer , 15 mm lower Edition 218 V1.

27 Table 1: Assignment to vehicle by model range, model number and final cross member - TGS/TG - continued Model no S Hole pattern , not approved for trailer coupling , replaces.144, not approved for trailer coupling , 15 mm lower S , truck mixer 37S , not for trailer coupling 39S, truck mixer 41S 42S/ S/45 46S S, truck mixer Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthrough , 15 mm lower 52S 56S , 15 mm lower 59S 66S S , 15 mm lower 71S 73S 74S , not for trailer coupling , replaces.135, not for trailer coupling Edition 218 V1. 25

28 Table 1: Assignment to vehicle by model range, model number and final cross member - TGS/TG - continued Model no. 79 8S 82S Hole pattern , 15 mm lower , 15 mm lower , 15 mm lower x11, 1-bolt connection for 1-t coupling, normal and lowered, frame overhang 725 mm x11, 1-bolt connection for 1-t coupling, normal, frame overhang 725 mm , not approved for trailer coupling , replaces.144, not approved for trailer coupling 89S/ S 92S/92 84S 86 93S S , 15 mm lower x11, 1-bolt connection for 1-t coupling, normal and lowered, frame overhang 725 mm x11, 1-bolt connection for 1-t coupling, normal, frame overhang 725 mm , 15 mm lower 3W W W 19W 26W , truck mixer W W W, truck mixer 26 Edition 218 V1.

29 Table 1: Model no. Assignment to vehicle by model range, model number and final cross member - TGS/TG - continued 49W W Hole pattern Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthrough x11, 1-bolt connection for 1-t coupling 6W 71W W W W 76W 56W 58W 74W W 78W , truck mixer 79W Edition 218 V1. 27

30 Table 11: Final cross member and technical data TGS/TG, final cross member Hole pattern D [kn] S C RcC+S DC [kn] V [kn] ,5 n/v* Not approved for trailer coupling, only for TG Brazil, replaces ,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 ,9 Not for trailer coupling, only semitrailer tractor with frame tapering, replaces ,5 n/v* Not approved for trailer coupling, only for TG Brazil ,5 5,1 15 mm lower than series ,6 Not for trailer coupling, only for rear tipper x ,6 1-bolt connection for 1-t coupling installation, normal and lowered, additional hole pattern normal, only in conjunction with MAN nos and corner plates, frame overhang 725 mm ,6 Normal hole pattern, additional hole pattern for 1-bolt connection for 1-t coupling installation, normal and lowered, only in conjunction with MAN nos and corner plates, frame overhang 725 mm 28 Edition 218 V1. Max. t turntable drawbar trailer load Weight

31 Table 11: Final cross member and technical data TGS/TG - continued, final cross member Hole pattern D [kn] S C RcC+S DC [kn] V [kn] Max. turntable drawbar trailer load t Weight x , 1-bolt connection for 1-t coupling installation normal, additional hole pattern, normal, only in conjunction with MAN nos and corner plates, frame overhang 725 mm , Additional hole pattern for 1-bolt connection for 1-t coupling installation normal, only in conjunction with MAN nos and corner plates, frame overhang 725 mm x ,4 1-bolt connection for 1-t coupling installation, normal ,5 Only with MAN low-coupling system ,5 Only with MAN low-coupling system ,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 RC: permissible gross weight of CAT Table 12: Assignment of trailer-coupling installation drawings to final cross members - TGS/TG, Final cross member Hole pattern Trailercoupling bolts 4 mm Trailercoupling bolts 5 mm x x x11 1 t trailer coupling Bolts 5 mm Trailer-coupling installation drawing _2 Chamfers required on top and bottom of trailer-coupling mounting plate _ _4 Lowered by 15 mm _1 MAN low-coupling system _1 Heavy-duty trailer coupling, normal or lowered _1 n/v* n/v* n/v* *not available at this time Heavy-duty trailer coupling, normal Edition 218 V1. Heavy-duty trailer coupling, normal 29

32 5. 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: 6. 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 7458 must be observed (see Fig. 2). 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). 3 Edition 218 V1.

33 Fig. 7: Dimensions on semitrailer tractors T_995_2_1_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 94/2/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. Edition 218 V1. 31

34 Fig. 8: Example of installation with auxiliary frame T_427_1_1_G 1) 2) 3) 4) Fifth-wheel coupling base plate Fifth-wheel coupling Mounting angle Auxiliary frame 32 Edition 218 V1.

35 Fig. 9: Example of installation without auxiliary frame T_427_2_1_G 1) 2) 3) Fifth-wheel coupling base plate Fifth-wheel coupling Mounting angle The size of the auxiliary frame and the quality of the material (σ.2 > 35 N/mm2) must be the same as for a comparable series-production vehicle. The fifth-wheel coupling base plate must lie only on the fifth-wheel auxiliary frame and not on the frame side members. The mounting plate must only be attached using bolts approved by MAN or by the fifth-wheel coupling base plate manufacturer. Instructions/guidelines issued by the manufacturer of the fifth-wheel coupling must be observed. Edition 218 V1. 33

36 Connection cables for air supply, brakes, electrics and ABS must not rub against the body or get snagged when cornering. For this reason, the bodybuilder must check the ease of movement of all cables when cornering with the semitrailer. When operating without a semitrailer, all lines must be securely attached in dummy couplings or connectors. Kingpins come in various sizes: 5-mm kingpins with a diameter of 2 inches 9-mm kingpins with a diameter of 3.5 inches The one used depends on different factors. As is the case for trailer couplings, the and the fifth wheel load is the decisive factor. The and the fifth wheel load value are marked on the model plates. The following formulae are used to determine the for the tractor-semitrailer vehicle: Formula 6: of semitrailer connection device D,6 9,81 T R T+R U For a given and sought permissible gross weight of the semitrailer: Formula 7: Permissible gross weight of trailer R D (T - U) (,6 9,81 T) D If the permissible gross weight of the semitrailer and the of the coupling device have been established, the permissible gross weight of the semitrailer tractor can be calculated using the following formula: Formula 8: Permissible gross weight of tractor T D (R - U) (,6 9,81 R) - D If the fifth-wheel coupling load is sought but all other loads are known, the formula is: Formula 9: Fifth-wheel coupling load,6 9,81 T R U T+R D Where: D [ kn ] R permissible gross weight of semitrailer [t] including fifth-wheel coupling load T permissible gross weight of semitrailer tractor [t] including fifth-wheel coupling load U fifth-wheel coupling load [ t ] Calculation examples can be found in the section entitled Calculations in the booklets dealing with the respective model ranges. 34 Edition 218 V1.

37 NOTICE Edition 218 V1. 35

38 MAN Truck & Bus AG Engineering Vehicle Truck Application Engineering Dachauer Straße 667 D Munich info.manted@man.eu We reserve the right to make changes in the course of technical development MAN Truck & Bus a member of the MAN Group