MAN Guidelines to fitting bodies Truck - MANTED · PDF fileMAN Guidelines to fitting bodies Truck ... TGL Table 01: Assignment to ... Final cross member and technical data TGL MAN

MAN Guidelines to fitting bodies TruckCoupling devices TG Edition 2016 V1.0

Engineering the Future – since 1758

MAN Truck & Bus AG

P U B L I S H E R

MAN Truck & Bus AG

(hereinafter referred to as MAN)

Technical Sales SupportApplication Engineering

Dachauer Str. 667D-80995 Munich

E-Mail: [email protected]

Fax: + 49 (0) 89 1580 4264

www.manted.de

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.

© 2016 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 2016 V1.0 MAN Guide to fitting bodies Coupling devices TG

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 1

If not otherwise specified: all dimensions are in mm, all weights and loads are in kg.

Contents

1.0 General .............................................................................................. 2

2.0 Trailer coupling, D-value.................................................................... 5

3.0 Rigid drawbar trailer, center-axle trailer, Dc value, V value ................ 6

4.0 Final cross members and trailer couplings ....................................... 8

5.0 Ball-type couplings ......................................................................... 30

6.0 Fifth-wheel coupling ........................................................................ 30

≥ 60

≥ 100

≥ 60

≥ 240

≤ 420

≤ 420

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2 Edition 2016 V1.0 MAN Guide to fitting bodies Coupling devices TG

1.0 GeneralIf 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 74058 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 R55

T_420_000003_0001_G

140m

in.

A A

250max.

300max.

R20max.

R40max.

100max.

45°max.

30°m

ax.

30°max.

65°min.

300max.

55m

in.

32m

in.

350m

in.

420m

ax.

45°m

in.

75m

in.

75m

in.

100max.

15°max.

30°max.

65min.


Fig. 02: Clearance for ball-type couplings as per DIN74058

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).

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T_420_000005_0001_G


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 Figs. 03 and 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

Fig. 04: Trailer coupling fitted below the frame


2.0 Trailer coupling, D-valueThe required trailer coupling size is determined by the D value. A model plate showing the maximum permissible D value is affixed to the trailer coupling by its manufacturer. The D value is stated in kilonewtons [kN].

The formula for the D value is as follows:

Formula 01: D value

9,81 • T • R D = T + R

Where the D value 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

R • D T = (9,81 • R) – D

Where the D value 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

T • D R = (9,81 • T) – D

Where: D = D value 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.


3.0 Rigid drawbar trailer, center-axle trailer, Dc value, V valueThe 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 “Dc value” and “V value” were introduced with Directive 94/20/EC or ECE R55.

The following formulae apply:

Formula 04: Dc-value formula for center-axle and rigid drawbar trailers

9,81 • T • C Dc = 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

x2 x2 x2

V = a • • c; ≥ 1 If the values for < 1, then 1.0 is to be used. l2 l2 l2

Calculation examples can be found in the section entitled “Calculations“ in the booklets dealing with the respectivemodel ranges

Where:

DC = Reduced D value 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 [kg] x = Length of trailer body [m], see Fig. 05 l = Theoretical drawbar length [m], see Fig. 05

x

v

x

v

l l

T_510_000003_0001_G


Fig. 05: Length of trailer body and theoretical drawbar length

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, 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).

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A


4.0 Final cross members and trailer couplingsNote: If the final cross member bearing the MAN item number 81.41250.0133 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. 06.

Fig. 06: 45° chamfer of the trailer coupling mounting plate if final cross member 81.41250.0133 is fitted

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. MAN item no. Hole pattern [mm] Comment

N01, N02N11, N12

N61

81.41250.0131 Without Not for trailer coupling81.41250.5179 140x80 For trailer coupling Type G14581.41660.5189 (3x)83x56 Underride protection and KKK trailer bracket (replaced by .5219)81.41660.5219 (3x)83x56 Underride protection and KKK trailer bracket (replaces .5189)

N03, N04 N05, N13 N14, N15

81.41250.0131 Without Not for trailer coupling81.41250.5179 140x80 For trailer coupling Type G145

81.41250.5188 120x55 Lowered by 100 mm, for fire service, for Type G 135 trailer coupling, additional hole pattern 83x56

81.41660.5189 (3x)83x56 Underride protection and KKK trailer bracket (replaced by .5219)81.41660.5219 (3x)83x56 Underride protection and KKK trailer bracket (replaces .5189)


Table 02: Final cross member and technical data TGL

MAN item no.,

Final cross member

Hole pattern [mm]

D[kN] S [kg] C [kg] Rc=C+S

[kg]DC

[kN]V

[kN]

Max. trailer

load [kg]

t [mm]

Weight[kg] Comment

81.41250.0131 Without 0 0 0 0 0 0 0 4 8,2

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.

81.41250.2317 140x80 # # # # # # # 8 26,5

Basic part for 81.41250.5179; # only with internal reinforcement 81.41250.2314.

81.41250.5179 140x80 69 1000 13.000 14000 64 35 16.000 8 29

Final cross member for 7- to 12-tonne TGL, for trailer cou-pling Type G145

81.41250.5179 140x80 30 500 4.500 5.000 30 19 4.500 8 29

Final cross member for 7-tonne TGL, Type N01/N11, for trailer coupling Type G145

81.41250.5188 83x56 19 80 2.000 2.080 18 10 2.080 8 31

Lowered by 100 mm, for fire ser-vice, additional hole pattern 120x55

81.41250.5188 120x55 60 700 6.500 7.200 40 18 12.000 8 31

Lowered by 100 mm, for fire service, additional hole pattern 83x56

81.41660.5189 (3x)83x56 26,8 200 3.500 3.700 0 0 3.500 - 30

Underride protec-tion and KKK trailer bracket, only in conjunction with final cross member 81.41250.0131 or .5179 (replaced by 81.41660.5219)

81.41660.5219 (3x)83x56 26,8 200 3.500 3.700 0 0 3.500 - 30

Underride protec-tion and KKK trailer bracket, only in conjunction with final cross member 81.41250.0131 or .5179 (replaces 81.41660.5189)


Table 03: Assignment of trailer-coupling installation drawings to final cross members - TGL

MAN item no.,Final cross

memberHole pattern

[mm]

Trailer coupling

bolts40 mm

Ball-type coupling

Trailer coupling installation drawing

MAN item no.Comment

81.41250.5179 140x80 G 145 - 81.42000.8154 Observe the max. permissible values in the TGL final cross member table.

81.41250.5188 120x55 G 135 - 81.42000.8200 Observe the max. permissible values in the TGL final cross member table.

81.41250.5188 83x56 TK 226 - 81.42000.8186 Observe the max. permissible values in the TGL final cross member table.

81.41660.5189 (3x)83x56 - X 81.42000.8166See also the installation of underride protection trailer bracket 81.41660.8186.Replaced by 81.41660.5219

81.41660.5219 (3x)83x56 - X 81.42000.8166See also the installation of underride protection trailer bracket 81.41660.8186.Replaced 81.41660.5189

81-42000-8153_1.pdf

81-42000-8153_1.pdf

81-42000-8153_2.pdf

81-42000-8166_1.pdf

81-42000-8166_1.pdf


TGM

Table 04: Assignment to vehicle by model range, model number and final cross member - TGM

Model no. MAN item no. Hole pattern [mm] Comment

N08



N16



N18



N2681.41250.0131 Without Not for trailer coupling81.41250.5180 160x100 For trailer coupling Type G150

N2881.41250.0131 Without Not for trailer coupling81.41250.5180 160x100 For trailer coupling Type G150

N3481.41250.5179 140x80 For trailer coupling Type G145


N36

81.41250.5180 160x100 For trailer coupling Type G15081.41250.5179 140x80 For trailer coupling Type G145




N3881.41250.5180 160x10081.41250.5188 120x55 For trailer coupling Type G150

N4481.41250.0131 Without Lowered by 100 mm, for fire service, for Type G 135 trailer coupling,

additional hole pattern 83x5681.41250.5180 160x100 Not for trailer coupling

N4681.41250.0131 Without For trailer coupling Type G15081.41250.5180 160x100 Not for trailer coupling

N4881.41250.0139 160x100 For trailer coupling Type G15081.41250.0133 160x100 Not for trailer load, only for tow coupling

N6281.41250.0131 Without On N48 only for trailer load up to 3,500 kg with overrun braking, as

well as for tow coupling81.41250.5180 160x100 Not for trailer coupling


N64 81.41250.5180 160x100 For trailer coupling Type G150





Table 05: Final cross member and technical data TGM

MAN item no. Final cross

member

Hole pattern [mm]

D [kN]

S [kg]

C [kg] Rc=C+S [kg]

DC [kN]

V [kN]

Max. trailer

load [kg]

t [mm]

Weight [kg]

Comment

81.41250.0131 Without 0 0 0 0 0 0 0 4 8,2 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.

81.41250.0133 160x100 31 250 3.500 3.750 31 18 3.500 9,5 31,5 Installed only on N48, only for trailer load up to 3,500 kg with overrun braking, as well as for tow coupling

81.41250.0139 160x100 0 0 0 0 0 0 0 8,5 23,7 Not approved for trailer load, only for tow cou-pling

81.41250.2313 160x100 # # # # # # # 9,3 31 Basic part for 81.41250.5180; # only with internal reinforce-ment 81.41250.2315.

81.41250.2317 140x80 # # # # # # # 8 26,5 Basic part for 81.41250.5179; # only with internal reinforce-ment 81.41250.2314.

81.41250.5179 140x80 69 1.000 13.000 14.000 64 35 16.000 8 29 Final cross member for 13-tonne TGM Type N34/N36 for trailer coupling Type G145

81.41250.5180 160x100 104 1.000 16.000 17.000 90 50 24.000 9,3 38 Final cross member for 13/15/18-tonne TGM for trailer coup-ling Type G150, only in conjunction with shims 81.41290.0164(1)

81.41250.5188 83x56 19 80 2.000 2.080 18 10 2.080 8 31 Fire service, additional hole pattern 120x55

81.41250.5188 120x55 60 700 6.500 7.200 40 18 12.000 8 31 Additional hole pattern 83x56

(1) When retrofitting a final cross member: bolt the final cross member to the main frame using two shims 81.41290.0164 on the inside of the final cross member.


Table 06: Assignment of trailer-coupling installation drawings to final cross members - TGM

MAN item no. final cross member

Hole pattern [mm]

Trailer-coupling

bolts40 mm

Trailer-coupling

bolts50 mm

Trailer coupling installation drawing

MAN item no.

Comment

81.41250.0133 160x100 n/v* Installed only on N48, only for trailer load up to 3,500 kg with overrun braking, as well as for tow coupling

81.41250.5179 140x80 G145 - 81.42000.8154 Observe the max. permissible values in the TGM final cross member table.



81.41250.5188 83x56 TK226 - 81.42000.8186 Observe the max. permissible values in the TGM final cross member table.

*not available at this time

81-42000-8153_1.pdf

81-42000-8153_1.pdf

81-42000-8153_1.pdf

81-42000-8153_2.pdf


TGA

Table 07: Assignment to vehicle by model range, model number and final cross member - TGA

Model no. MAN item no. Hole pattern [mm] CommentH01 81.41250.0129 Without Semitrailer tractor, not for trailer coupling, replaced by .0135

81.41250.0132 160x100 Semitrailer tractor, operation with trailer not permitted81.41250.0135 Without Semitrailer tractor, not for trailer coupling, replaces .0129

H02 81.41250.0130 160x100 Tipper, chassis, replaced by .013381.41250.0133 160x100 Tipper, chassis, replaces .5145 and .013081.41250.5145 160x100 Tipper, chassis, replaced by .0130

H03 81.41250.0133 160x100 Tipper, chassis, replaces .514581.41250.5145 160x100 Tipper, chassis, replaced by .0133

H04 81.41250.0128 160x100 Semitrailer tractor81.41250.5145 160x100 Tipper, chassis

H05 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0129 Without Semitrailer tractor, not for trailer coupling, replaced by .013581.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0133 160x100 Tipper, chassis, replaces .514581.41250.0135 Without Semitrailer tractor, not for trailer coupling, replaces .012981.41250.5145 160x100 Tipper, chassis, replaced by .0133

H06 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0129 Without Semitrailer tractor, not for trailer coupling, replaced by .013581.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0133 160x100 Tipper, chassis81.41250.0135 Without Semitrailer tractor, not for trailer coupling, replaces .0129

H07 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0129 Without Semitrailer tractor, not for trailer coupling, replaced by .013581.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0133 160x100 Chassis, replaces .514581.41250.0135 Without Semitrailer tractor, not for trailer coupling, replaces .012981.41250.5145 160x100 Chassis, replaced by .0133

H08 81.41250.0129 Without Semitrailer tractor, not for trailer coupling, replaced by .013581.41250.0132 160x100 Semitrailer tractor, operation with trailer not permitted81.41250.0135 Without Semitrailer tractor, not for trailer coupling, replaces .0129


H10 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0129 Without Semitrailer tractor, not for trailer coupling, replaced by .013581.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0133 160x100 Chassis81.41250.0135 Without Semitrailer tractor, not for trailer coupling, replaces .0129

H11 81.41250.0133 160x100 Tipper


Table 07: Assignment to vehicle by model range, model number and final cross member - TGA - continued

Model no. MAN item no. Hole pattern [mm] CommentH12 81.41250.0128 160x100 Semitrailer tractor, replaced by .0132

81.41250.0132 160x100 Semitrailer tractor, replaces .0128H13 81.41250.0128 160x100 Semitrailer tractor, replaced by .0132

81.41250.0132 160x100 Semitrailer tractor, replaces .0128H14 81.41250.0130 160x100 Chassis, replaced by .0133

81.41250.0133 160x100 Chassis, replaces .0130H15 81.41250.0133 160x100 ChassisH16 81.41250.0133 160x100 Chassis, replaces .5145

81.41250.5145 160x100 Chassis, replaced by .0133H17 81.41250.0128 160x100 Semitrailer tractor, replaced by .0132

81.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0133 160x100 Chassis, replaces .514581.41250.5145 160x100 Chassis, replaced by .0133

H18 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Chassis, replaces .514581.41250.5145 160x100 Chassis, replaced by .0133

H19 81.41250.0133 160x100 Chassis, replaces .514581.41250.5145 160x100 Chassis, replaced by .0133

H20 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0133 160x100 Chassis, replaces .514581.41250.5145 160x100 Chassis, replaced by .0133

H21 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Chassis, replaces .514581.41250.5145 160x100 Chassis, replaced by .0133

H22 81.41250.0129 Without Semitrailer tractor, not for trailer coupling, replaced by .013581.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Chassis81.41250.0135 Without Semitrailer tractor, not for trailer coupling, replaces .0129


H24 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0133 160x100 Chassis, replaces .5145

H25 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0130 160x100 Tipper, chassis, truck mixer, replaced by .013381.41250.0133 160x100 Tipper, chassis, truck mixer, replaces .013081.41250.5184 160x100 Tipper, 150 mm lower



Model no. MAN item no. Hole pattern [mm] CommentH26 81.41250.0132 160x100 Semitrailer tractor

81.41250.0130 160x100 Tipper, chassis, truck mixer, replaced by .013381.41250.0133 160x100 Tipper, chassis, truck mixer, replaces .013081.41250.5184 160x100 Tipper, 150 mm lower

H27 81.41250.0133 160x100 Chassis, replaces .514581.41250.5145 160x100 Chassis, replaced by .0133

H28 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0130 160x100 Tipper, chassis, replaced by .013381.41250.0133 160x100 Tipper, chassis, replaces .013081.41250.5184 160x100 Tipper, 150 mm lower

H29 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0130 160x100 Tipper, chassis, replaced by .013381.41250.0133 160x100 Tipper, chassis, replaces .013081.41250.5184 160x100 Tipper, 150 mm lower

H30 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Tipper, chassis81.41250.5184 160x100 Tipper, 150 mm lower

H32 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0129 Without Semitrailer tractor, not for trailer coupling, replaced by .013581.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0135 Without Semitrailer tractor, not for trailer coupling, replaces .0129

H33 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Tipper81.41250.5184 160x100 Tipper, 150 mm lower


H35 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Chassis

H36 81.41250.0130 160x100 Tipper, chassis, truck mixer, replaced by .013381.41250.0133 160x100 Tipper, chassis, truck mixer, replaces .0130



H39 81.41250.0133 160x100 Tipper, chassis, truck mixerH40 81.41250.0130 160x100 Tipper, chassis, replaced by .0133

81.41250.0133 160x100 Tipper, chassis, replaces .0130H41 81.41250.0133 160x100 Tipper, chassisH42 81.41250.0132 160x100 Semitrailer tractor

81.41250.0133 160x100 Chassis



Model no. MAN item no. Hole pattern [mm] CommentH43 81.41250.0128 160x100 Semitrailer tractor, replaced by .0132

81.41250.0132 160x100 Semitrailer tractor, replaces .0128H44 81.41250.0130 160x100 Chassis, replaced by .0133

81.41250.0133 160x100 Chassis, replaces .0130H45 81.41250.0133 160x100 ChassisH46 81.41250.0130 160x100 Replaced by .0133

81.41250.0133 160x100 Replaces .0130H47 81.41250.0132 160x100 Semitrailer tractor

81.41250.0133 160x100 Tipper81.41250.5184 160x100 Tipper, 150 mm lower

H48 81.41250.0133 160x100 Truck mixerH49 81.41250.0133 160x100 Chassis, truck mixer

81.41250.5187 Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthroughH50 81.41250.0133 160x100 Tipper, chassis, truck mixerH51 81.41250.0128 160x100 Semitrailer tractor, replaced by .0132

81.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0130 160x100 Tipper, chassis, replaced by .013381.41250.0133 160x100 Tipper, chassis, replaces .013081.41250.5184 160x100 Tipper, chassis, 150 mm lower

H52 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Tipper, chassis81.41250.5184 160x100 Tipper, chassis, 150 mm lower


H55 81.41250.0128 160x100 Semitrailer tractor, replaced by .013281.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0130 160x100 Tipper, chassis, replaced by .013381.41250.0133 160x100 Tipper, chassis, replaces .013081.41250.5184 160x100 Tipper, chassis, 150 mm lower

H56 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Tipper, chassis81.41250.5184 160x100 Tipper, chassis, 150 mm lower

H57 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Tipper

H58 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Tipper

H59 81.41250.0133 160x100 TipperH60 81.41250.0132 160x100 Semitrailer tractorH61 81.41250.0128 160x100 Semitrailer tractor, replaced by .0132

81.41250.0132 160x100 Semitrailer tractorH62 81.41250.0132 160x100 Semitrailer tractor

81.41250.0133 160x100 Tipper, chassis81.41250.0141 160x100 Semitrailer tractor, replaces .0132




81.41250.0133 160x100 Chassis81.41250.0141 160x100 Semitrailer tractor, replaces .0132

H64 81.41250.0132 160x100 Semitrailer tractor81.41250.0141 160x100 Semitrailer tractor, replaces .0132


H66 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Tipper, chassis81.41250.0141 160x100 Semitrailer tractor, replaces .0132

H67 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Chassis81.41250.0141 160x100 Semitrailer tractor, replaces .0132

H68 81.41250.0133 160x100 TipperH69 81.41250.0133 160x100 ChassisH70 81.41250.0128 160x100 Semitrailer tractor, replaced by .0132

81.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0130 160x100 Tipper, replaced by .013381.41250.0133 160x100 Tipper, replaces .013081.41250.5184 160x100 Tipper, 150 mm lower

H71 81.41250.0133 160x100 ChassisH72 81.41250.0128 160x100 Semitrailer tractor, replaced by .0132

81.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0130 160x100 Tipper, chassis, replaced by .013381.41250.0133 160x100 Tipper, chassis, replaces .013081.41250.5184 160x100 Tipper, chassis, 150 mm lower

H73 81.41250.0130 160x100 Tipper, replaced by .013381.41250.0133 160x100 Tipper, replaces .013081.41250.5184 160x100 Tipper, 150 mm lower

H74 81.41250.0133 160x100 ChassisH75 81.41250.0133 160x100 ChassisH76 81.41250.0130 160x100 Tipper, chassis, replaced by .0133

81.41250.0133 160x100 Tipper, chassis, replaces .013081.41250.5184 160x100 Tipper, 150 mm lower

H78 81.41250.0132 160x100 Semitrailer tractor81.41250.0135 Without Semitrailer tractor, not for trailer coupling81.41250.0141 160x100 Semitrailer tractor, replaces .0132



H81 81.41250.0133 160x100 Tipper, chassis81.41250.5184 160x100 Tipper, chassis, 150 mm lower




81.41250.0133 160x100 Tipper, chassis81.41250.5184 160x100 Tipper, chassis, 150 mm lower

H84 81.41250.0133 160x100 Tipper, chassis81.41250.5184 160x100 Tipper, chassis, 150 mm lower

H85 81.41250.0133 160x100 ChassisH86 81.41250.0128 160x100 Semitrailer tractor, replaced by .0132

81.41250.0132 160x100 Semitrailer tractor, replaces .012881.41250.0133 160x100 Chassis, replaces .514581.41250.5145 160x100 Chassis, replaced by .0133

H87 81.41250.0130 160x100 Chassis, replaced by .013381.41250.0133 160x100 Chassis, replaces .0130

H88 81.41250.0130 160x100 Chassis, replaced by .013381.41250.0133 160x100 Chassis, replaces .0130

H89 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Chassis

H90 81.41250.0133 160x100 ChassisH91 81.41250.0133 160x100 ChassisH92 81.41250.0133 160x100 ChassisH93 81.41250.0133 160x100 Tipper

81.41250.5184 160x100 Tipper, 150 mm lowerH94 BLLL 81.41250.0133 160x100 Semitrailer tractor, no trailer operation permitted with BLLLH94 BLBB 81.41250.0133 160x100 Semitrailer tractor

82.41250.5092 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal and lowered, frame overhang 725 mm/925 mm

81.41250.5094 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal, frame overhang 725 mm/925 mm

H95 BLLL 81.41250.0133 160x100 Semitrailer tractor, no trailer operation permitted with BLLLH95 BLBB 81.41250.0133 160x100 Semitrailer tractor

82.41250.5092 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal and lowered, frame overhang 725 mm/925 mm

81.41250.5094 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal, frame overhang 725 mm/925 mm

H96 81.41250.0133 160x100 Tipper81.41250.5184 160x100 Tipper, 150 mm lower

H99 81.41250.0133 160x100 ChassisHH1 81.41250.0132 160x100 Semitrailer tractor

81.41250.0133 160x100 Chassis81.41250.0141 160x100 Semitrailer tractor, replaces .0132

HH4 81.41250.0133 160x100 ChassisHV1 81.41250.0133 160x100 Chassis

81.41250.0141 160x100 Semitrailer tractorHV2 81.41250.0141 160x100 Semitrailer tractor



Model no. MAN item no. Hole pattern [mm] CommentHV4 81.41250.0133 160x100 Chassis

81.41250.0141 160x100 Semitrailer tractorHV5 81.41250.0133 160x100 Tipper, chassis

81.41250.0141 160x100 Semitrailer tractor81.41250.5184 160x100 Tipper, 150 mm lower

HV6 81.41250.0133 160x100 Tipper81.41250.5184 160x100 Tipper, 150 mm lower

HV7 81.41250.0141 160x100 Semitrailer tractor 81.41250.0133 160x100 Chassis

HV8 81.41250.5187 Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthrough

HW1 81.41250.0132 160x100 Semitrailer tractor81.41250.0141 160x100 Semitrailer tractor, replaces .0132

HW2 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Tipper, chassis, truck mixer81.41250.0141 160x100 Semitrailer tractor, replaces .013281.41250.5184 160x100 Tipper, 150 mm lower

HW3 81.41250.0133 160x100 Tipper, chassis, truck mixerHW4 81.41250.0132 160x100 Semitrailer tractor

81.41250.0133 160x100 Tipper, chassis81.41250.0141 160x100 Semitrailer tractor, replaces .013281.41250.5184 160x100 Tipper, chassis, 150 mm lower

HW5 81.41250.0141 160x100 Semitrailer tractorHW6 81.41250.0133 160x100 Tipper, chassisHW7 81.41250.0135 Without Semitrailer tractor, not for trailer coupling

81.41250.0141 160x100 Semitrailer tractor81.41250.0142 Without Semitrailer tractor, replaces .0135, not for trailer coupling

HW8 81.41250.0132 160x100 Semitrailer tractor81.41250.0141 160x100 Semitrailer tractor, replaces .0132

HW9 81.41250.0132 160x100 Semitrailer tractor81.41250.0141 160x100 Semitrailer tractor, replaces .013281.41250.0133 160x100 Fahrgestell81.41250.0141 160x100 Sattel, Ersatz für .0132


Table 08: Final cross member and technical data TGA

MAN item no.,final cross member

Hole pattern [mm]

D [kN]

S [kg]

C [kg] Rc=C+S [kg]

DC [kN]

V [kN]

Max. turntable drawbar

trailer load [kg]

t [mm]

Weight[kg]

Comment

81.41250.0128 160x100 130 1.000 9.500 10.500 64 35 As per D value

9,5 25,6 Only semitrai-ler tractor with frame tapering, no exchange possi-ble! Replaced by 81.41250.0132

81.41250.0129 Without 0 0 0 0 0 0 0 5 13,4 Not for trailer coup-ling, only semitrailer tractor with frame tapering, replaced by 81.41250.0135

81.41250.0130 160x100 190 1.000 18.000 19.000 125 65 As per D value

9,5 31,9 Trailer-coupling hole pattern centra-lised at height of final cross mem-ber, replaced by 81.41250.0133

81.41250.0132 160x100 130 1.000 9.500 10.500 64 35 As per D value

9,5 25,6 Only semitrailer tractor with frame tapering; derives from and replaces 81.41250.0128, exchange not pos-sible!

81.41250.0133 160x100 200 1.000 18.000 19.000 130 70 As per D value

9,5 31,5 Trailer-coupling hole pattern 27.5 mm lower than 81.41250.0130, replaces 81.41250.0130 and .5145

81.41250.0135 Without 0 0 0 0 0 0 0 5 12,9 Not for trailer coup-ling, only semitrailer tractor with frame tapering, replaces 81.41250.0129

81.41250.5145 160x100 200 1.000 18.000 19.000 130 70 As per D value

11 28,7 Final cross member reinforced, TGA and F2000, replaced by 81.41250.0133

81.41250.5184 160x100 190 1.000 18.000 19.000 130 70 As per D value

9,5 50,1 150 mm lower than series

82.41250.5092 330x110 314 0 0 0 0 0 As per D value

20 156,6 10-bolt connection for 100-t coupling installation, normal and lowered, addi-tional hole pattern 160x100 normal and lowered, only in conjunction with MAN nos. 82.41250.5090 and 82.41250.5091 corner plates, frame overhang 725 mm/925 mm.


Table 08: Final cross member and technical data TGA - continued


Hole pattern [mm]

D [kN]

S [kg]

C [kg] Rc=C+S [kg]

DC [kN]

V [kN]


trailer load [kg]

t [mm]

Weight[kg]

Comment

82.41250.5092 160x100 200 0 0 0 0 0 As per D value

20 156,6 Normal and lowe-red, additional hole pattern for 10-bolt connection for 100-t coupling installation, normal and lowered, only in conjunction with MAN nos. 82.41250.5090 and 82.41250.5091 corner plates, frame overhang 725mm/925mm

82.41250.5094 330x110 314 0 0 0 0 0 As per D value

15 50,6 10-bolt connection for 100-t coupling installation normal, additional hole pattern 160x100, normal, only in con-junction with MAN nos. 82.41250.5090 and 82.41250.5091 corner plates, frame overhang 725 mm/925 mm

82.41250.5094 160x100 200 0 0 0 0 0 As per D value

15 50,6 Additional hole pattern for 10-bolt connection for 100-t coupling installation normal, only in con-junction with MAN nos. 82.41250.5090 and 82.41250.5091 corner plates, frame overhang 725 mm/925mm

81.42030.5116 160x100 190 1.000 24.000 25.000 130 75 As per D value

44,5 Only with MAN low-coupling system

81.42030.5116 160x100 190 1.000 24.000 25.000 141 63 As per D value


81.42030.5116 160x100 190 1.000 24.000 25.000 150 50 As per D value


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 09: Assignment of trailer-coupling installation drawings to final cross members - TGA


member

Holepattern[mm]

Trailer-coupling

bolts40 mm

Trailer-coupling

bolts 50 mm

100 t Trailer-

couplingbolts

50 mm

Trailer-coupling installation drawing

MAN item no.

Comment

81.41250.0128 160x100 X X 81.42000.8152_3 Semitrailer tractor81.41250.0130 160x100 X X 81.42000.8129_381.41250.0132 160x100 X X 81.42000.8152_3 Semitrailer tractor81.41250.0133 160x100 X X 81.42000.8152_2 Chamfers required on top and

bottom of trailer-coupling mounting plate

81.41250.5145 160x100 X X 81.42000.8129_181.41250.5184 160x100 X X 81.42000.8152_4 Lowered by 150 mm81.42030.5116 160x100 X 81.42000.8152_1 MAN low-coupling system82.41250.5092 160x100 X X n/v*82.41250.5092 330x110 82.42000.8021_1 Heavy-duty trailer coupling,

normal or lowered82.41250.5094 160x100 X X n/v*82.41250.5094 330x110 X 82.42000.8021_1 Heavy-duty trailer coupling,

normal

*not available at this time

81-42000-8152_3.pdf

81-42000-8129_3.pdf

81-42000-8152_3.pdf

81-42000-8152_2.pdf

81-42000-8129_1.pdf

81-42000-8152_4.pdf

81-42000-8152_1.pdf

82-42000-8021_1.pdf

82-42000-8021_1.pdf


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 [mm]

Comment

03S 81.41250.0133 160x100 Tipper, chassis81.41250.5184 160x100 Tipper, chassis, 150 mm lower

05X 81.41250.0142 Without Semitrailer tractor, not for trailer coupling06S/06X 81.41250.0133 160x100 Tipper, chassis

81.41250.0135 Without Semitrailer tractor, not for trailer coupling81.41250.0141 160x100 Semitrailer tractor81.41250.0142 Without Semitrailer tractor, replaces .0135, not for trailer coupling

08S 81.41250.0135 Without Semitrailer tractor, not for trailer coupling81.41250.0141 160x100 Semitrailer tractor81.41250.0142 Without Semitrailer tractor, replaces .0135, not for trailer coupling

10S/10X 81.41250.0133 160x100 Chassis81.41250.0135 Without Semitrailer tractor, not for trailer coupling81.41250.0141 160x100 Semitrailer tractor81.41250.0142 Without Semitrailer tractor, replaces .0135, not for trailer coupling

13S/13X 81.41250.0132 160x100 Semitrailer tractor81.41250.0141 160x100 Semitrailer tractor, replaces .0132

15S/15X 81.41250.0133 160x100 Chassis18S/18X 81.41250.0133 160x100 Chassis

81.41250.0141 160x100 Semitrailer tractor21S/21X 81.41250.0133 160x100 Chassis

81.41250.0141 160x100 Semitrailer tractor22S 81.41250.0133 160x100 Chassis

81.41250.0141 160x100 Semitrailer tractor81.41250.0142 Without Semitrailer tractor, not for trailer coupling

22X 81.41250.0135 Without Semitrailer tractor, not for trailer coupling81.41250.0141 160x100 Semitrailer tractor81.41250.0142 Without Semitrailer tractor, replaces .0135, not for trailer coupling

24S 81.41250.0132 160x100 Semitrailer tractor81.41250.0133 160x100 Chassis81.41250.0141 160x100 Semitrailer tractor, replaces .013281.41250.0142 Without Semitrailer tractor, not for trailer coupling

24X 81.41250.0135 Without Semitrailer tractor, not for trailer coupling81.41250.0141 160x100 Semitrailer tractor81.41250.0142 Without Semitrailer tractor, replaces .0135, not for trailer coupling

26S 81.41250.0133 160x100 Tipper, chassis, truck mixer81.41250.0141 160x100 Semitrailer tractor81.41250.5184 160x100 Tipper, 150 mm lower

26X 81.41250.0133 160x100 Tipper, chassis81.41250.0141 160x100 Semitrailer tractor


Table 10: Assignment to vehicle by model range, model number and final cross member - TGS/TGX - continued

Model no.

MAN item no. Hole pattern [mm]

Comment

28X 81.41250.0141 160x100 Semitrailer tractor 81.41250.0144 160x100 Semitrailer tractor, not approved for trailer coupling61.41250.0000 160x100 Semitrailer tractor, replaces .0144, not approved for trailer coupling

30S 81.41250.0133 160x100 Tipper, chassis81.41250.0141 160x100 Semitrailer tractor81.41250.5184 160x100 Tipper, 150 mm lower

30X 81.41250.0133 160x100 Tipper, chassis81.41250.0141 160x100 Semitrailer tractor

35S 81.41250.0133 160x100 Chassis81.41250.0141 160x100 Semitrailer tractor

37S 81.41250.0133 160x100 Tipper, chassis, truck mixer81.41250.5187 Without Tipper, not for trailer coupling

39S 81.41250.0133 160x100 Tipper, chassis, truck mixer41S 81.41250.0133 160x100 Tipper, chassis

42S/42X 81.41250.0141 160x100 Semitrailer tractor45S/45X 81.41250.0133 160x100 Chassis

49S 81.41250.0133 160x100 Tipper, truck mixer81.41250.5187 Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadt-

hrough52S 81.41250.0133 160x100 Tipper, chassis

81.41250.0141 160x100 Semitrailer tractor81.41250.5184 160x100 Tipper, chassis, 150 mm lower

56S 81.41250.0133 160x100 Tipper, chassis81.41250.0141 160x100 Semitrailer tractor81.41250.5184 160x100 Tipper, chassis, 150 mm lower

59S 81.41250.0133 160x100 Tipper70S 81.41250.0133 160x100 Tipper, chassis

81.41250.0141 160x100 Semitrailer tractor81.41250.5184 160x100 Tipper, 150 mm lower

71S 81.41250.0133 160x100 Chassis73S 81.41250.0133 160x100 Chassis74S 81.41250.0133 160x100 Chassis78X 81.41250.0135 Without Semitrailer tractor, not for trailer coupling

81.41250.0141 160x100 Semitrailer tractor81.41250.0142 Without Semitrailer tractor, replaces .0135, not for trailer coupling

79X 81.41250.0133 160x100 Chassis81.41250.0141 160x100 Semitrailer tractor

80S 81.41250.0133 160x100 Tipper81.41250.0141 160x100 Semitrailer tractor81.41250.5184 160x100 Tipper, 150 mm lower

82S 81.41250.0133 160x100 Tipper, chassis81.41250.0141 160x100 Semitrailer tractor81.41250.5184 160x100 Tipper, chassis, 150 mm lower



Model no. MAN item no. Hole pattern [mm]

Comment

84S 81.41250.0133 160x100 Tipper, chassis81.41250.5184 160x100 Tipper, chassis, 150 mm lower

86X 81.41250.0133 160x100 Semitrailer tractor82.41250.5092 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal and

lowered, frame overhang 725 mm82.41250.5094 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal,

frame overhang 725 mm87X 81.41250.0133 160x100 Semitrailer tractor88X 81.41250.0144 160x100 Semitrailer tractor, not approved for trailer coupling

61.41250.0000 160x100 Semitrailer tractor, replaces .0144, not approved for trailer coupling89S/89X 81.41250.0133 160x100 Chassis

81.41250.0141 160x100 Semitrailer tractor90S 81.41250.0133 160x100 Chassis

92S/92X 81.41250.0133 160x100 Chassis93S 81.41250.0133 160x100 Tipper

81.41250.5184 160x100 Tipper, 150 mm lower94X 81.41250.0133 160x100 Semitrailer tractor

82.41250.5092 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal and lowered, frame overhang 725 mm

82.41250.5094 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal, frame overhang 725 mm

95X 81.41250.0133 160x100 Semitrailer tractor96S 81.41250.0133 160x100 Tipper, chassis

81.41250.5184 160x100 Tipper, chassis, 150 mm lower03W 81.41250.0141 160x100 Semitrailer tractor06W 81.41250.0141 160x100 Semitrailer tractor18W 81.41250.0133 160x100 Chassis

81.41250.0141 160x100 Semitrailer tractor19W 81.41250.0133 160x100 Chassis

81.41250.0141 160x100 Semitrailer tractor26W 81.41250.0133 160x100 Tipper, chassis, truck mixer

81.41250.0141 160x100 Semitrailer tractor30W 81.41250.0141 160x100 Semitrailer tractor34W 81.41250.0133 160x100 Tipper

81.41250.0141 160x100 Semitrailer tractor39W 81.41250.0133 160x100 Tipper, chassis, truck mixer49W 81.41250.5187 Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadt-

hrough52W 81.41250.0133 160x100 Tipper, chassis

81.41250.0141 160x100 Semitrailer tractor56W 81.41250.0133 160x100 Tipper, chassis

81.41250.0141 160x100 Semitrailer tractor58W 81.41250.0133 160x100 Tipper

81.41250.0141 160x100 Semitrailer tractor85.41250.5000 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling



Model no.

MAN item no. Hole pattern [mm]

Comment

60W 81.41250.0133 160x100 Tipper71W 81.41250.0141 160x100 Semitrailer tractor72W 81.41250.0141 160x100 Semitrailer tractor73W 81.41250.0133 160x100 Chassis

81.41250.0141 160x100 Semitrailer tractor76W 81.41250.0133 160x100 Tipper, chassis

81.41250.0141 160x100 Semitrailer tractor77W 81.41250.0133 160x100 Tipper78W 81.41250.0133 160x100 Chassis

81.41250.0141 160x100 Semitrailer tractor79W 81.41250.0133 160x100 Tipper, chassis, truck mixer


Table 11: Final cross member and technical data TGS/TGX


Hole pattern [mm]

D [kN]

S [kg]

C [kg] Rc=C+S [kg]

DC [kN]

V [kN]


trailer load [kg]

t [mm]

Weight[kg]

Comment

61.41250.0000 160x100 0 0 0 0 0 0 0 9,5 n/v* Not approved for trai-ler coupling, only for TGX Brazil, replaces 81.41250.0144

81.41250.0133 160x100 200 1.000 18.000 19.000 130 70 As per D value

9,5 31,5 Trailer-coupling hole pattern 27.5 mm lower than 81.41250.0130, repla-ces 81.41250.0130 and .5145

81.41250.0141 160x100 130 1.000 9.500 10.500 64 35 As per D value

9,5 25,6 Only semitrailer tractor with frame tapering, no exchange possible! Replaces 81.41250.0132

81.41250.0142 Without 0 0 0 0 0 0 0 5 12,9 Not for trailer coup-ling, only semitrailer tractor with frame tapering, replaces 81.41250.0135

81.41250.0144 160x100 0 0 0 0 0 0 0 9,5 n/v* Not approved for trailer coupling, only for TGX Brazil

81.41250.5184 160x100 200 1.000 18.000 19.000 130 70 As per D value

9,5 50,1 150 mm lower than series

81.41250.5187 Without 0 0 0 0 0 0 0 8 33,6 Not for trailer coupling, only for rear tipper

82.41250.5092 330x110 314 0 0 0 0 0 As per D value

20 156,6 10-bolt connection for 100-t coupling in-stallation, normal and lowered, additional hole pattern 160x100 normal, only in con-junction with MAN nos. 82.41250.5090 and 82.41250.5091 corner plates, frame overhang 725 mm.

82.41250.5092 160x100 200 0 0 0 0 0 As per D value

20 156,6 Normal hole pattern, additional hole pattern for 10-bolt connection for 100-t coupling installation, normal and lowered, only in conjunction with MAN nos. 82.41250.5090 and 82.41250.5091 corner plates, frame overhang 725 mm


Table 11: Final cross member and technical data TGS/TGX - continued


Hole pattern [mm]

D [kN]

S [kg]

C [kg] Rc=C+S [kg]

DC [kN]

V [kN]


trailer load [kg]

t [mm]

Weight[kg]

Comment

82.41250.5094 330x110 314 0 0 0 0 0 As per D value

15 50,0 10-bolt connection for 100-t coupling installation normal, additional hole pattern 160x100, normal, only in conjunction with MAN nos. 82.41250.5090 and 82.41250.5091 corner plates, frame overhang 725 mm

82.41250.5094 160x100 200 0 0 0 0 0 As per D value

15 50,0 Additional hole pattern for 10-bolt connection for 100-t coupling installation normal, only in conjunction with MAN nos. 82.41250.5090 and 82.41250.5091 corner plates, frame overhang 725 mm

85.41250.5000 330x110 314 0 0 0 0 0 As per D value

15 60,4 10-bolt connection for 100-t coupling installation, normal

81.42030.5116 160x100 190 1.000 24.000 25.000 130 75 As per D value

22 44,5 Only with MAN low-coupling system

81.42030.5116 160x100 190 1.000 24.000 25.000 141 63 As per D value


81.42030.5116 160x100 190 1.000 24.000 25.000 150 50 As per D value


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/TGX


member

Hole pattern [mm]

Trailer-coupling

bolts40 mm

Trailer-coupling

bolts50 mm

100 t trailer

couplingBolts

50 mm

Trailer-coupling installation

drawingMAN item no.

Comment

81.41250.0133 160x100 X X 81.42000.8152_2 Chamfers required on top and bottom of trailer-coupling moun-ting plate

81.41250.0141 160x100 X X 81.42000.8152_3 Semitrailer tractor81.41250.5184 160x100 X X 81.42000.8152_4 Lowered by 150 mm81.42030.5116 160x100 X 81.42000.8152_1 MAN low-coupling system82.41250.5092 330x110 X 82.42000.8021_1 Heavy-duty trailer coupling, nor-

mal or lowered82.41250.5092 160x100 X X n/v*82.41250.5094 330x110 X 82.42000.8021_1 Heavy-duty trailer coupling,

normal82.41250.5094 160x100 X X n/v*85.41250.5000 330x110 X n/v* Heavy-duty trailer coupling,

normal*not available at this time


5.0 Ball-type couplingsLike 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 74058 must be observed (see Fig. 02).

6.0 Fifth-wheel couplingThe 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).

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Fig. 07: Dimensions on semitrailer tractors

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 fifth-wheel 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.

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Fig. 08: Example of installation with auxiliary frame

1) Fifth-wheel coupling base plate2) Fifth-wheel coupling3) Mounting angle4) Auxiliary frame

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Fig. 09: Example of installation without auxiliary frame

1) Fifth-wheel coupling base plate2) Fifth-wheel coupling3) Mounting angle

The size of the auxiliary frame and the quality of the material (σ0.2 > 350 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.


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:

• 50-mm kingpins with a diameter of 2 inches• 90-mm kingpins with a diameter of 3.5 inches

The one used depends on different factors. As is the case for trailer couplings, the D value and the fifth wheel load is the decisive factor. The D value and the fifth wheel load value are marked on the model plates.

The following formulae are used to determine the D value for the tractor-semitrailer vehicle:

Formula 06: D value of semitrailer connection device

0,6 • 9,81 • T • R D = T + R – U

For a given D value and sought permissible gross weight of the semitrailer:

Formula 07: Permissible gross weight of trailer

D • (T - U) R = (0,6 • 9,81 • T) – D

If the permissible gross weight of the semitrailer and the D value of the coupling device have been established, the permissible gross weight of the semitrailer tractor can be calculated using the following formula:

Formula 08: Permissible gross weight of tractor

D • (R - U) T = (0,6 • 9,81 • R) - D

If the fifth-wheel coupling load is sought but all other loads are known, the formula is:

Formula 09: Fifth-wheel coupling load

0,6 • 9,81 • T • R U = T + R - D Where: D = D value [ 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.


NOTICE

MAN Truck & Bus AGTechnical Sales SupportApplication EngineeringDachauer Str. 667D - 80995 MunichE-Mail: [email protected]

MAN Truck & Bus AG –a member of the MAN GroupWe reserve the right to make changes in the course of technical development.

Documents

MAN Guidelines to fitting bodies Truck - MANTED · PDF fileMAN Guidelines to fitting bodies Truck ... TGL Table 01: Assignment to ... Final cross member and technical data TGL MAN