Мануал по ремонту ман тга

TRUCKNOLOGY® GENERATION A (TGA)

The ESC numbers stated in the illustrations are purely for internal reference.

They are of no consequence to the reader.

If not otherwise stated: all dimensions in mm, all weights and loads in kg

1.Applicability and legal agreements

1.1Applicability

The statements in this guide are binding. If technically feasible, exceptions will be approved only if a written request has been submitted to the ESC department at MAN, (see „Publisher“ above).

1.2Legal agreements and approval procedure

1.2.1Preconditions

In addition to this Guide, the company carrying out the work must observe all

•laws and decrees

•accident prevention regulations

•operating instructions

relating to the operation and construction of the vehicle. Standards are technical standards; they are therefore minimum requirements. Anyone who does not endeavour to observe these minimum requirements is regarded as operating negligently.

Standards are binding when they form part of regulations.

Information given by MAN in reply to telephone enquiries is not binding unless confi rmed in writing. Enquiries are to be directed to

the relevant MAN department. Information refers to conditions of use that are usual within Europe. Dimensions, weights and other basic data that differ from these must be taken into consideration when designing the body, mounting the body and designing the subframe. The company carrying out the work must ensure that the entire vehicle can withstand the conditions of use that it is expected

to experience.

For certain types of equipment, such as loading cranes, tail-lifts, cable winches etc, the respective manufacturers have developed their own body regulations. If, when compared with this MAN Guide, they impose further conditions, then these too must be observed.

References to

•legal stipulations

•accident prevention regulations

•decrees from professional associations

•work regulations

•other guidelines and sources of information

are not in any way complete and are only intended as ideas for further information. They do not replace the company’s obligation to carry out its own checks.

Fuel consumption is considerably affected by modifi cations to the vehicle, by the body and its design and by the operation of equipment driven by the vehicle’s engine. It is therefore expected that the company carrying out the work implements a design that facilitates

the lowest possible fuel consumption.

1.2.2Responsibility

The responsibility for proper

•design

•production

•installation of bodies

•modifi cation to the chassis

always lies fully with the company that is manufacturing the body, installing it or carrying out modifi cations (manufacturer’s liability). This also applies if MAN has expressly approved the body or the modifi cation. Bodies/conversions that have been approved in writing by MAN do not release the body manufacturer from his responsibility for the product. Should the company carrying out the work detect a mistake either in the planning stage or in the intentions of

•the customer

•the user

•its own personnel

•the vehicle manufacturer

then that mistake must be brought to the attention of the respective party.

The company is responsible for seeing that the vehicle’s

•operational safety

•traffi c safety

•maintenance possibilities and

•handling characteristics

do not exhibit any disadvantageous properties.

With regard to traffi c safety, the company must operate in accordance with the state of the art and in line with the recognised rules in the fi eld in matters relating to

•the design

•the production of bodies

•the installation of bodies

•the modifi cation of chassis

•instructions and

•operating instructions.

Diffi cult conditions of use must also be taken into account.

1.2.3Quality assurance

In order to meet our customers’ high quality expectations and in view of international product/manufacturer liability legislation an on-going quality monitoring programme is also required for conversions and body manufacture/installation. This requires a functioning quality assurance system. It is recommended that the body manufacturer sets up and provides evidence of a quality system that complies with the general requirements and recognised rules (e.g. DIN EN ISO 9000 et seq. or VDA 8).

Evidence of a qualifi ed system can be provided for example by:

If MAN is the party awarding the contract for the body or conversion evidence of qualifi cation will be requested.

MAN Truck & Bus AG reserves the right to carry out its own system audit in accordance with VDA 8 or a corresponding process check at the supplier’s premises. VDA volume 8 has been agreed with the following body manufacturers’ associations:

ZKF (Zentralverband Karosserieund Fahrzeugtechnik – Central Association of Body and Vehicle Engineering) and

BVM (Bundesverband Metall Vereinigung Deutscher Metallhandwerke – Federation of German Metal Trades Associations).

It has also been agreed with the ZDH (Zentralverband des Deutschen Handwerks – Central Association of German Craft Trades).

Documents:

VDA Volume 8

„Minimum quality assurance requirements for trailer, body manufacturers“, obtainable from the Verband der Automobilindustrie e.V (VDA) (German Engine Industry Association), http://www.vda-qmc.de.

1.2.4Approval

Approval from MAN for a body or a chassis modifi cation is not required if the bodies or modifi cations are carried out in accordance with this Guide. If MAN approves a body or a chassis modifi cation, then this approval refers

•In the case of bodies only to the body’s fundamental compatibility with the respective chassis and the interfaces to the body (e.g. dimensions and mounting of the subframe)

•In the case of chassis modifi cations only to the fact that, from a design point of view, the modifi cations to the chassis in question are fundamentally permissible.

The approval note that MAN enters on the submitted technical documents does not indicate a check on the

•Function

•Design

•Equipment of the body or the modifi cation.

Observance of this Guide does not free the user from responsibility to perform modifi cations and manufacture bodies properly from

a technical point of view. The approval note only refers to such measures or components as are to be found in the submitted technical documents.

MAN reserves the right to refuse to issue approvals for bodies or modifi cations, even if a comparable approval has already been issued. Later submissions for approval are not automatically treated the same as earlier ones, because technical advances achieved in

the interim period have to be taken into account.

MAN also reserves the right to change this Guide at any time or to issue instructions that differ from this Guide for individual chassis.

If several identical chassis have the same bodies or modifi cations MAN can, to simplify matters, issue a collective approval.

1.2.5Submission of documents

Documents should only be sent to MAN if bodies/conversions diverge from this Guide. Before work begins on the vehicle, technical documents that require approval or inspection must be sent to the ESC Department at MAN (see „Publisher“ above).

For an approval process to proceed swiftly, the following are required:

•Documents should be submitted in duplicate

•The number of individual documents should be kept to a minimum

•All the technical data and documents must be submitted.

The following information should be included:

•Vehicle model (see Chapter 2.2 for model code) with

—cab design

—wheelbase

—frame overhang

•· Vehicle identifi cation number or vehicle number (if already available, see Chapter 2.2)

Identifi cation of deviations from this Guide to Fitting Bodies in all documentation!

•Loads and their load application points:

—Forces from the body

—Axle load calculation

•Special conditions of use:

•Subframe:

—Material and cross-sectional data

—Dimensions

—Type of section

—Arrangement of cross members in the subframe

—Special features of the subframe design

—Cross-section modifi cations

—Additional reinforcements

—Upsweeps, etc.

•Means of connection:

—Positioning (in relation to the chassis)

—Type

—Size

—Number.

The following are not suffi cient for inspection or approval:

•Parts lists

•Brochures

•Photographs

•Other not binding information.

Drawings are only valid if they bear the number that has been assigned to them. It is therefore not permitted to draw in the bodies or modifi cations on chassis drawings that have been provided by MAN and to submit these for approval.

1.2.6Liability for defects

Liability claims in respect of defects only exist within the framework of the purchasing contract between buyer and seller. In accordance with this, liability for defects lies with the respective seller of the goods.

Claims against MAN are not valid if the fault that is the subject of the complaint was due to the fact that

•This Guide was not observed

•In view of the purpose for which the vehicle is used, an unsuitable chassis has been selected

•The damage to the chassis has been caused by

—the body

—the type of body mounting or how the body has been mounted

—the modifi cation to the chassis

—improper use.

1.2.7Product liability

Any faults in the work that are identifi ed by MAN are to be corrected. Insofar as is legally permissible, MAN disclaims all liability, in particular for consequential damage.

Product liability regulates:

•The liability of the manufacturer for its product or component

•The compensation claim made by the manufacturer against whom a claim has been made against the manufacturer of an integral component, if the damage that has occurred is due to a fault in that component.

The company that has made the body or carried out the modifi cation is to relieve MAN of any liability to its customer or other third party if the damage that has occurred is due to the fact that

•The company did not observe this Guide

•The body or chassis modifi cation has caused damage on account of its faulty

—design

—manufacture

—installation

—instructions

•The fundamental rules that are laid down have not been complied with in any other way.

1.2.8Safety

Companies carrying out work on the chassis/vehicle are liable for any damage that may be caused by poor functional and operational safety or inadequate operating instructions. Therefore, MAN requires the body manufacturer or vehicle conversion company to:

•Ensure the highest possible safety, in line with the state of the art

•Provide comprehensible, suffi cient operating instructions

•Provide permanent, easily visible instruction plates on hazardous points for operators and/or third parties

•Observe the necessary protection measures (e.g. fi re and explosion prevention)

•Provide full toxicological information

•Provide full environmental information.

Safety is top priority! All available technical means of avoiding incidents that will undermine operational safety are to be implemented. This applies equally to

•Active safety = prevention of accidents. This includes:

—Driving safety achieved by the overall vehicle design, including the body

—Safety as a consequence of the driver’s well-being achieved by keeping occupant stress caused by vibrations, noise, climatic conditions etc. to a minimum

—Safety as a consequence of observation and perception, in particular through the correct design of lighting systems, warning equipment, providing suffi cient direct and indirect visibility

—Safety as a consequence of operating equipment and controls this includes optimising the ease of operation of all equipment, including that of the body.

•Passive safety = avoidance and reduction of the consequences of accidents. This includes:

—Exterior safety such as the design of the outside of the vehicle and body with respect to deformation behaviour and the installation of protective devices

—Interior safety including the protection of occupants of vehicles and cabs that are installed by the body builders.

Climatic and environmental conditions have effects on:

•Operational safety

•Readiness for use

•Operational performance

•Service life

•Cost-effectiveness.

Climatic and environmental conditions are, for example:

•The effects of temperature

•Humidity

•Aggressive substances

•Sand and dust

•Radiation.

Suffi cient space for all parts required to carry out a movement, including all pipes and cables, must be guaranteed. The operating instructions for MAN trucks provide information about the maintenance points on the vehicle. Regardless of what type of body is fi tted, good access to the maintenance points must be ensured in all cases. It must be possible to carry out maintenance unhindered and without having to remove any components. Suffi cient ventilation and/or cooling of the components is to be guaranteed.

1.2.9Manuals from body and conversion companies

In the event of a body being added or modifi cations to the vehicle being carried out, the operator of the vehicle is also entitled to receive operating instructions from the conversion company. All specifi c advantages offered by the product are of no use if the customer is

not able to:

•Handle the product safely and properly

•Use it rationally and effortlessly

•Maintain it properly

•Master all of its functions.

As a result, every vehicle body builder and converter must check his technical instructions for:

•Clarity

•Completeness

•Accuracy

•Comprehensibility

•Product-specifi c safety instructions.

Inadequate or incomplete operating instructions carry considerable risks for the user. Possible effects are:

•Reduced benefi t, because the advantages of the product remain unknown

•Complaints and annoyance

•Faults and damage, which are normally blamed on the chassis

•Unexpected and unnecessary additional cost through repairs and time lost

•A negative image and thereby less inclination to buy the same product or brand again.

Depending on the vehicle body or modifi cation, the operating personnel must be instructed about operation and maintenance. Such instruction must also include the possible effects on the static and dynamic performance of the vehicle.

1.2.10Limitation of liability for accessories/spare parts

Accessories and spare parts that MAN has not manufactured or approved for use in its products may affect the traffi c safety and operational safety of the vehicle and create hazardous situations. MAN Truck & Bus AG (or the seller) accepts

no liability for claims of any kind resulting from a combination of the vehicle together with an accessory that was made by another manufacturer, regardless of whether MAN Truck & Bus AG (or the seller) has sold the accessory itself or fi tted it to the vehicle (or the subject of the contract).

2.Product designations

2.1Vehicle designation and wheel formula

To enable unique and easily comprehensible identification of the different variants new vehicle designations have been systematically introduced. The vehicle designation system is based on three levels:

—Door designation

—Variant descriptor (in the sales and technical documentation e.g. data sheets, chassis drawings)

—Model code.

2.1.1Door designation

The door designation comprises:

Model range + permissible weight + engine power

TGA 18.400

Abbreviated notation of model range TGA = Trucknology® Generation A, technically permissible weight in [t],

engine power [DIN-hp] rounded to the nearest 10hp

2.1.2Variant descriptor

The variant descriptor = vehicle designation which comprises the door designation + wheel formula + suffi x. The terms ‘wheel formula’ and ‘suffi x’ are defi ned in the following sections.

Model range + permissible weight + engine power + wheel formula + suffi x

TGA 25.480 6×2-2 LL-U

2.1.3Wheel formula

The wheel formula stipulates the number of axles and provides additional identifi cation of drive, steered and leading/trailing axles. Wheel formula is a commonly used, but not standardised term. It is “wheel locations” that are counted and not the individual wheels. Twin tyres are therefore regarded as one wheel.

The following two examples illustrate the wheel formula:

Table 1: Wheel formula examples

6 x 2 — 4

6 x 2 / 4

6= Total number of wheel locations, i.e. 3 axles x = No function

2= Number of driven wheels

—= Trailing axle behind the rear drive-axle assembly

/= Leading axle ahead of the rear drive-axle assembly

4= Number of steered wheels

The number of steered wheels is only stated if, aside from steered front wheels, leading axles or trailing axles are also involved. A leading axle is located “ahead of” a rear drive-axle assembly and a trailing axle is “behind” the rear drive-axle assembly.

A slash “/” represents a leading axle and a hyphen “-” represents a trailing axle.

If a chassis is fi tted with both leading and trailing axles the number of steered wheels follows the hyphen “-”.

If the vehicle is fi tted with MAN HydroDrive® hydrostatic front axle drive then the wheel formula receives an additional H, e.g. 6x4H = a front axle with MAN HydroDrive®, 2 rear axles, one of which is driven.

Currently the following wheel formulae are available ex-works:

Table 2: TGA wheel formulae

4×2 Two-axle vehicle with one drive axle

4×4 Two-axle vehicle with two drive axles “All-wheel drive”

4x4H Two-axle vehicle with two drive axles, front axle with MAN HydroDrive®

6×2/2 Three-axle vehicle with non-steered “Pusher” leading axle

6×2/4 Three-axle vehicle with steered leading axle

6×2-2 Three-axle vehicle with non-steered trailing axle

6×2-4 Three-axle vehicle with steered trailing axle

6×4 Three-axle vehicle with two driven non-steered rear axles

6×4/4 Three-axle vehicle with 2 driven axles (fi rst and last axles), steered leading axle

6×4-4 Three-axle vehicle with 2 driven axles, (fi rst and second axles), steered trailing axle

6x4H/2 Three-axle vehicle with MAN HydroDrive® front axle drive, one driven rear axle, non-steered leading axle

6x4H/4 Three-axle vehicle with MAN HydroDrive® front axle drive, one driven rear axle, steered leading axle

6x4H-2 Three-axle vehicle with MAN HydroDrive® front axle drive, one driven rear axle, non-steered trailing axle

6x4H-4 Three-axle vehicle with MAN HydroDrive® front axle drive, one driven rear axle, steered trailing axle

Table 2: TGA wheel formulae (continuation)

6×6 Three-axle vehicle with all-wheel drive

6×6-4 Three-axle vehicle with all-wheel drive, steered and driven trailing axle

6x6H Three-axle vehicle with all-wheel drive, front axle with MAN HydroDrive®

8×2-4 Four-axle vehicle with one drive axle, two steered front axles, non steered trailing axle or four-axle vehicle with three rear axles with front and trailing axles steered

8×2-6 Four-axle vehicle with one drive axle, two steered front axles, steered trailing axle

8×4 Four-axle vehicle with two steered front axles and two driven rear axles

8×4/4 Four-axle vehicle with one front axle, one steered leading axle and two driven rear axles

8×4-4 Four-axle vehicle with one front axle, two driven rear axles and one steered trailing axle

8x4H-4 Four-axle vehicle with two steered front axles (2nd front axle with MAN HydroDrive®), one driven rear axle and a non-steered trailing axle

8x4H-6 Four-axle vehicle with two steered front axles (2nd front axle with MAN HydroDrive®), one driven rear axle and a steered trailing axle

8×6 Four-axle vehicle “All wheel drive” with two front axles (2nd driven) and two driven rear axles

8x6H Four-axle vehicle “All wheel drive” with two front axles (2nd front axle with MAN HydroDrive®) and two driven rear axles

8×8 Four-axle vehicle “All wheel drive” with two front axles and two rear axles, all driven

2.1.4Suffix

The suffi x to the vehicle designation defi nes the type of suspension, differentiates trucks from tractor units and describes special product features.

Semitrailer tractor units are designated with an ‘S’ suffi x. Trucks have no special designation.

Example for semitrailer tractor:

Special product (design) features are added separately following a hyphen ‘-’ after the fi rst section of the suffi x:

Example for special product features:

2.2Model number, vehicle identification number, vehicle number, basic vehicle number

The three-digit model number, also called model code, provides a technical identifi cation of the MAN chassis and also identifi es

to which vehicle range it belongs. This number is part of the 17-digit vehicle identifi cation number (VIN) and is located at digits 4 to 6 in the VIN. The basic vehicle number, formulated for sales purposes, also contains the model number at digits 2 to 4.

The seven-fi gure vehicle number describes the technical equipment on a vehicle; it contains the model number at digits 1 to 3, followed by a four-digit sequential number. The vehicle number is to be found in the vehicle papers and on the vehicle’s manufacturing plate. The vehicle number can be quoted instead of the 17-digit vehicle identifi cation number in the event of any technical queries regarding conversions and bodies. Table 5 gives some examples of the model number, vehicle identifi cation number, basic vehicle number and vehicle number.

Table 5: Example vehicle designation, model number, vehicle identifi cation number, basic vehicle number and vehicle number

Up to the date of going to press (03/2007) the Trucknology® Generation A or TGA for short, comprises the following model numbers:

Table 6: Model numbers, tonnage class, vehicle designation and suspension on the TGA

2.3Use of logos

MAN logos on the chassis may not be removed or modifi ed in any way without prior approval from MAN.

Modifi cations to the chassis or body that do not conform with this Guide to Fitting Bodies and that have not received MAN approval by the ESC department (for address see „Publisher“ above) must receive a new vehicle identifi cation number (VIN) from the manufacturer responsible for the modifi cation (normally the vehicle conversion company).

In such cases where the chassis/vehicle has received a new VIN, the logos on the radiator grille (MAN lettering, lion emblem) and the doors (door designation – see Section 2.1.1) must be removed.

2.4Cabs

There are 6 different Trucknology® Generation A cabs:

*) Dimensions refer to the cab without attachments such as mudguards, front spoiler, mirrors, roof spoiler etc.

*) Dimensions refer to the cab without attachments such as mudguards, front spoiler, mirrors, roof spoiler etc.

2.5Engine variants

In-line six-cylinder Diesel engines (R6) and a V10 with 4-valve technology from the D28 family of engines are installed in the TGA (D28 = 1st – 3rd digits of the engine designation). Engines with common rail injection are new additions to the range.

The engine programme has been extended since 2004 with two further engine ranges – the well known engines from the D08 range and the new D20 Common Rail range that are also available as Euro 4 engines with the PM-Kat®. Cummins engines of the ISMe range are only installed in ERF brand trucks (see table 6, model numbers).

Table 8: TGA engines/engine designations D08D08 / D20 / D26 / D28