MAN TGS/TGX Series Guidelines to fitting bodies Manual

MAN Series TGS/TGX Edition 2018 V2.0 Guidelines bodies Manual

These Guidelines to fitting bodies aimed at professional bodybuilder.
Therefore, in this guideline, background knowledge is assumed. It should be noted that some work may only be carried out by suitably qualified personnel in order to avoid the risk of injury and to achieve the necessary quality for construction work.

Notational conventions
In this guideline the following notational conventions are used:

• Information: This notice points out further information to you.
• Important notice: This notice draws your attention to possible damage to the vehicle.
• Environmental notice: An environmental notice provides you with tips for environmental protection.
• Warning notice: A hazard warning notice points out possible risks of accident or injury to you and others.

Applicability and legal agreements
1.0 General
The statements in these MAN guidelines to fitting bodies are binding. Exceptions may only be approved by MAN following a written request and provided such exceptions are technically feasible (for address see “Publisher”).

2.0 Legal agreements
2.1 Requirements
In addition to these guidelines to fitting bodies the executing company must observe all of the following that apply to the operation and bodywork of the vehicle:

• Legislation, rules and regulations
• Accident-prevention regulations
• Operating instructions observed.

Standards are technical standards and thus contain minimum requirements. Failure to observe such minimum requirements is a negligent act. Standards are binding if they are part of rules and regulations. Information received from MAN in answer to telephone enquiries is non-binding unless confirmed in writing.Enquiries must be directed to the MAN department responsible.

Information is based on conditions of use such as are typical in Europe. Dimensions, weights and other basic values deviating therefrom must consequently be taken into account for the engineering design and attachment of bod-ywork and the design of the auxiliary frame. The executing company must ensure that the entire vehicle is able to sustain the conditions of use to be expected.

Various manufacturers have worked out specifications for certain units, e.g. loading cranes, liftgates, cable winches and so on. These are also to be observed if they contain requirements extra to the MAN guidelines to fitting bodies.

Mentions of:

1. Legal regulations
2. Accident-prevention regulations
3. Regulations issued by professional associations
4. Standard operating procedures
5. Other guidelines and sources are by no means complete and are only for purposes of information. They are no replacement for due diligence on the part of the particular company.

2.2 Responsibility

• Responsibility for professional
• Engineering Design
• Production
• fitting of bodywork,
• modifications to chassis

Is always, and in full, that of the company producing or assembling the bodywork or carrying out the modification (manufacturer’s liability). This also applies when MAN has expressly granted approval of the bodywork or modification. Written approval of bodywork or modifications by MAN does not release the bodywork manufacturer from their responsibility for the product.

Should the executing company detect an error in the planning stage or in the intentions of the
customers

1. user
2. its own personnel
3. vehicle manufacturer they will draw the attention of the particular party to it.

The company is responsible for ensuring that the

• Operational safety
• Road safety
• serviceability,
• Driving characteristics of the vehicle are not negatively affected in any way.

In terms of road safety the company must construe and base:

1. Engineering Design
2. production of bodywork,
3. fitting of bodywork,
4. modifications to chassis
5. instructions,
6. Operating instructions

by the latest state of the art and recognized rules of the discipline. More difficult operating conditions are in addition to be taken into consideration.

2.3 Registration of the vehicle
National laws and technical regulations with respect to the registration of modified vehicles are to be complied with. Modification work carried out in on the chassis must be submitted to a Technical Service for assessment. The executing company remains responsible even subsequent to the registration of the vehicle in the event of the competent authorities having issued the vehicle registration in ignorance of the operational safety of the product.

EU multi-stage type-approval procedure as per Annex XVII 2007/46/EC

Process
Within the framework of the multi-stage process pursuant to Annex XVII of Directive 2007/46/EC, each manufacturer shall bear independent responsibility for approval and conformity of production of all systems, components or independent technical units that it manufactures or adds in an earlier stage of manufacturing.

The body manufacturer is the manufacturer of the second or additional production stage pursuant to 2007/46/EC.

Responsibilities

As a basic principle, the body builder is responsible for:

• modifications it carried out on the base vehicle.
• objects granted approval at an earlier stage if, due to modifications to the base vehicle, the approvals granted are no longer applicable to this vehicle.
• ensuring that the modification carried out complies with the respective national/international statutory regulations, in particular those of the destination country.
• submitting the modifications it carried out to a technical service for assessment.
• documenting compliance with statutory regulations in appropriate form (test report and/or permit or documents meeting the legal requirements of the destination country).

As a basic principle, MAN as manufacturer of the base vehicle is responsible for:

• providing the body builder with the homologation documentation (EU/EEC approvals) available forthe scope of delivery of the base vehicles in electronic form on request.

Identification of the vehicles
The respective vehicle shall receive a vehicle identification number (“VIN”), which identifies MAN as manufacturer of the incomplete base vehicle.

As a basic principle, the requirements laid down in Annex XVII to 2007/46/EU and the published associated procedural instructions apply.

Conformity of production (COP)
As a basic principle, the requirements laid down in individual EU Directives and Annex X to 2007/46/EU as well as the requirements laid down in Annex 2 to the EEC Agreement of 1958 apply.

Provision of documentation for registration/following stage
In accordance with Annex XVII to 2007/46/EU, MAN as manufacturer of the base vehicle provides the body builder or builders the available EU/EEC system approvals and the Certificate of Conformity (CoC)1)for the base vehicle in electronic form.

• Only in cases where the vehicle is EU-compliant and a Certificate of Conformity (CoC) has been printed by the plant.

Case I: Registration in Germany
In the case of MAN acting as general contractor (“single-invoice transaction”) the body builder/s as later-stage man-ufacturer/s undertake/s to provide the following documentation in electronic form:

1. The individual supplier conditions provide for an acceptance/approval and registration processby the vehicle manufacturer (MAN).
   • In the case of an existing and valid whole vehicle type-approval in accordance with 2007/46/EC for the manufacturing stages, a CoC. On request, existing EC/EEC system approvals or technical reports must be submitted.
   • Alternatively to 1, the test reports and approval documentation required for national individual approval procedures in accordance with Section 13 of the EC vehicle approval Directive.
   • The latest time for submitting the above stated documentation in printable form is the day the completed vehicle is returned to the contractually agreed place of delivery. The documentation shall be sent to the following e-mail address documents@de.man-mn.com. In cases where MAN receives a CoC from the bodybuilder, then original certificates may onlybe generated by MAN on behalf of the bodybuilder.
2. The acceptance/approval and registration process is to be carried out by the contract partner or by the manufacturer of the final completion stage of the vehicle.
   • None.The registration process is the responsibility of the contract partner or the manufacturer of the final completion stage of the vehicle.

In all other cases the acceptance/approval and registration process is to be carried out by the manufacturer of the final completion stage of the vehicle or by the corresponding contract partner.

Case II: Registration outside Germany but inside the area of application of Directive 2007/46/EC
If MAN serves as general contractor then the bodybuilder is under an obligation, as the final stage manufacturer, to provide in electronic form, all the necessary approval/registration documentation for all modifications made during the subsequent manufacturing stages of the respective responsible sales organisation or importer which exceed the scope of the basic vehicle.

Irrespective of any general contractor status of the importers, the acceptance/approval and registration process is to be carried out by the manufacturer of the final completion stage of the vehicle or by the corresponding contract partner.

The importer in the respective country or the corresponding contract partner has the authority and responsibility for the registration process.

MAN does not supply any national data for registration purposes exceeding that for incomplete vehicles set forth in Annex IX to Directive 2007/46/EG in its current form and as amended from time to time. This also applies in particular to national model codes and encrypted basic technical data.

MAN as a manufacturer reserves the right - following corresponding feasibility studies and economic implementation - and after reaching corresponding specifically applicable agreements with national sales organisations and importers, to provide data for national registration which exceeds the scope of that set forth above (e.g. vehicle’s manufacturing plates etc.).

Non-disclosure agreement
The bodybuilder may not forward the approval documentation provided by MAN to any third parties without obtaining prior, express permission from MAN.

The forwarding of documentation that is directly associated with the registration of the vehicle in questionto persons of the institutions listed below is excepted:

• MAN Sales partners
• Technical vehicle inspection centers or testing organisations
• Approval authorities
• Registration authorities or licensing centers acting for the government

Note on type approval / homologation for TiB, CiB, BiB, CKD, SKD and PKD vehicles

Where:

• TiBstands for “truckin thebox”
• CiB stands for “chassisin thebox”
• BiB stands for “busin thebox”
• CKD stands for “completely knocked down”
• SKD stands for “semi knocked down”
• PKD stands for “partly knocked down”

For these versions MAN is not considered to be the manufacturer within the meaning of Directive 2007/46/EC - therefore, the responsibility for the homologation and registration process lies with the manufacturer ofthese vehicles. In principle, the substance of the contracts respectively concluded with MAN shall apply.

In principle, MAN does not provide registration-related data for completed vehicles. Exceptions include homologation documentation for components subject to approval such as the engine, which MAN providesin electronic form.

However, this does not exclude MAN as a manufacturer reserving the right - following corresponding feasibility studies and economic implementation - and after reaching corresponding specifically applicable agreements with national sales organisations and importers, to provide data for national registration which exceeds the scope of that set forth above (e.g. vehicle’s manufacturing plates etc.). Enquiries in this regard shall be sent toMAN’s Homologation Department.

3.0 Liability
3.1 Liability for material defects
Claims on liability for defects only exist within the contract of sale between the purchaser and the seller.The liability for defects consequently rests with the seller of the article of sale. Claims may not be made of MAN if the reported defect results from the following:

• Non-adherence to these body guidelines
• Selection of a chassis unsuitable for the intended purpose of the vehicle
• Damage to the chassis caused by:
  • the body,
  • the nature/execution of body installation,
  • modification to the chassis,
  • incorrect operation.

3.2 Product liability
Defects in workmanship detected by MAN are to be corrected. In as much as this is legally admissible,MAN will bear no liability, in particular for consequential damages.

Product liability regulates:

1. The liability of the manufacturer for their product or component of a product.
2. The claim to compensation from the manufacturer of an integrated component of a product made by the manufacturer claimed upon if the occurring damage results from a defect of this component of a product.

The company that executes the bodywork or modification to the chassis shall indemnify MAN from any claims for liability made by its customers or other third parties, in as much as any damage results from the following:

• The company having failed to comply with the guidelines to fitting bodies valid at the time.
• The bodywork or chassis modification has caused damage through faulty
  • Engineering Design
  • Manufacture
  • Assembly
  • instructions.
• The set principles were not complied with in any other way.

3.3 Limitation of liability for accessories/spare parts
Warning notice
Accessories and spare parts not manufactured by MAN or approved for use in its products can impair the operational and road safety of the vehicle and lead to dangerous 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. Excepted from the aforementioned are cases in which MAN Truck & Bus AG (or the seller) itself offers the accessory for sale or fits it to the vehicle (or the subject of the contract).

3.4 Operational and road safety
In order to ensure operational and road safety or to maintain the validity of any claims under the guarantee, the bodybuilder must observe the instructions given in these guidelines to fitting bodies exactly. MAN shall not be liable for non-compliance.

Before commencing work on the body, making modifications or starting installation work, the bodybuilder must also have knowledge of the sections of the operator‘s manual that relate to the work he is completing. It will otherwise be impossible to recognise risks and other persons may be endangered.

MAN cannot be liable for reliability, safety and suitability under the following circumstances.

1. Bodies are not constructed and fitted in accordance with these guidelines to fitting bodies
2. MAN Genuine Parts or approved parts and modifications are replaced with other parts
3. Unauthorised modifications are made to the vehicle

Approvals by third parties, for example Technical Inspection Agencies or approvals from public authorities, shall not be considered sufficient for precluding safety risks.

Companies handling and working on the vehicle are liable for any damages that result from deficient functional and operational safety or inadequate operating manuals. MAN consequently requires of the bodybuilder or modifier:

• maximum state-of-the-art safety standards,
• comprehensible and adequately detailed operating instructions,
• easily visible, permanently affixed plates at points posing a risk to operators and/or third persons,
• adherence to necessary protective measures (e.g. against fire and explosion risks),
• full details relating to toxicology,
• full details relating to ecology.

Safety has priority! Make use of all technical possibilities to avoid and eliminate insecure operation.

This applies equally to:

• Active safety = prevention of accidents. This includes:
  • driving safety as a result of the overall concept of the vehicle with its bodywork
  • conditional safety produced by minimal physical stress on occupants through vibration, noise,climate, etc.
  • assured perception, especially correct design of lighting fittings, warning devices, sufficient direct and indirect visibility
  • operational safety, including optimum operability of all devices and fittings, and those ofthe bodywork
• Passive safety = avoidance and containment of accident consequences. This includes:
  • outer safety, e.g. design of the exterior of the vehicle/bodywork in terms of deformation, fittingof protective devices
  • inner safety, including protection of the occupants of vehicles, but also cabs installed bybodywork producers

Climatic and environmental conditions affect:

• Operational safety
• readiness for use,
• in-service performance,
• Service life
• cost-effectiveness,

Climatic and environmental influences are, for example:

• effects of temperature
• Humidity
• aggressive substances,
• sand and dust,
• radiation.

Ensure sufficient clearance of all parts involved in movement, including all cables and leads. The operating manuals for MAN vehicles provide information on the maintenance points on the vehicle. Regardless of the kind of bodywork,ensure good access to these maintenance points in all cases. Maintenance must be possible unhindered by having to remove any parts. Ensure adequate ventilation and/or cooling of sub-assemblies.

3.5 Instructions from body-building and conversion companies
In the event of a body atng added or modifications to the vehicle atng carried out by a conversion company, the operator of the vehicle is also entitled to receive the operating instructions. All the benefits of a product are of no use if the customer is unable to:

• handle it safely and true to its purpose,
• use it rationally and effortlessly,
• correctly service and maintain it,
• work with it expertly in all its functions.

Every bodybuilder and modifier shall consequently ensure that their technical manuals exhibit:

• Comprehensibility
• Complete
• Accuracy
• Traceability
• Product-specific notes on safety

A poor or incomplete operating manual means considerable risk factors for the user. Possible consequences are:

• reduced value because product advantages go unrecognized;
• complaints, irritation and annoyance;
• failures and damage that are usually attributed to the chassis,
• unexpected and unnecessary extra costs through repairs and loss of time;
• a negative image and thus less inclination to purchase from the same source again.

Operating personnel is to be instructed in operation and maintenance for the particular vehicle body or modification.Instruction must also include possible effects on the static and dynamic performance of the vehicle.

4.0 Quality assurance
To satisfy the high quality demands of our customers and comply with international product/producer liability,continuous quality inspection is also needed to conduct retrofits and in the production/fitting of bodywork. This calls for a properly functioning quality-assurance system. The bodybuilder is advised to set up and provide evidence of a quality management system complying with general requirements and accepted rules (e.g. EN ISO 9000 ff or VDA Vol. 8).

If MAN is the contracting body for the bodywork or modification, it will demand evidence of qualification. MAN Truck& Bus AG reserves the right to conduct its own VDA Vol. 8 system audit of a supplier or appropriate examinations of processes. VDA Vol. 8 is harmonised with the bodywork manufacturer associationsZKF(federal association of bodywork and vehicle engineering),BVM(federal association of the metalworking trade) as well as with theZDH(federal association of skilled crafts).

5.0 Approvals
The “Approvals” section contains information on the approval of bodies and manufacturer’s confirmation.The prerequisites, basic principles to be complied with when submitting applications and the options for obtaining applications are described.

5.1 Body approval
General information
Body approval from MAN is not required if the bodies or modifications are carried out in accordance with these guidelines to fitting bodies.
If MAN approves a body, this approval applies, in the case of bodies,

1. to their basic compatibility with the respective chassis,
2. to interfaces with the body (e.g. dimensioning and fastening the auxiliary frame).

The endorsement of approval entered by MAN in the submitted technical documents does not cover inspection of the:

1. Function
2. Engineering Design
3. equipment of the body or the modification.

The endorsement of approval only concerns measures or parts to be seen or taken from the submitted technical documents. MAN reserves the right to refuse issue of an approval of bodywork, even if comparable approval was issued at an earlier date. Technical advances rule out the possibility of cases atng fully identical. MAN furthermore reserves the right to alter these guidelines at any time, or to issue instructions differing from those contained herein in the case of single chassis.

Should a number of identical chassis have identical bodywork, MAN may issue a collective approval for the sake of simplicity.

Template for inspection documentation
Documents should only be sent to MAN if bodies deviate from these guidelines to fitting bodies. If this is the case,technical documents enabling inspection must be sent to MAN (for address see “Publisher” above) before work on the vehicle begins.

Manufacturer Confirmation
In the case of modifications to vehicles, a manufacturer confirmation may become necessary. Upon special request,MAN can issue an exception to existing technical stipulations. Manufacturer confirmations may only be issued if this can be arranged with the functional, traffic and operational safety guidelines.