Coupling Devices

MAN Guidelines to fitting bodies Truck
Coupling 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 Support

Application Engineering
Dachauer Str. 667
D-80995 Munich
E-Mail: info.manted@man.eu
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

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
If not otherwise specified: all dimensions are in mm, all weights and loads are in kg.
MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 1

1.0 General
If a truck is intended to pull loads, the equipment required for this purpose must of course be fitted and also
approved. Compliance with the legislative minimum engine capacity and/or the installation of the appropriate trailer
couplings does not guarantee that the truck is suitable for pulling loads.
The following are prerequisites for retrofitting the equipment for towing a trailer.
• The necessary final cross member and trailer coupling

• Two-line brake connection
• The electrical system for trailer operation, including an ABS socket
• Installation of trailer control module („ASM“) and/or activation of same by means of reparameterisation
Only trailer couplings in accordance with EC Directive 94/20/EC or ECE R55 may be used.
When manoeuvring, there must be no collision with the trailer. To this end, a drawbar of an adequate length must
be selected. The required clearance dimensions must be taken into consideration (in Germany: DIN 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
≥ 60
≤ 420 ≥ 60
≥ 240
≥ 100
≤ 420
T_420_000002_0001_G
2 Edition 2016 V1.0 MAN Guide to fitting bodies Coupling devices TG

Fig. 02: Clearance for ball-type couplings as per DIN74058
15°max.
100max.
45°m
ax.
100max.
75min.
300max.
x.
300max.
30°ma
65°
ax.
R40m
min
250max.
.
R20m
ax.
30°m
140min.
32min.
65min.
75min.
A A
ax.
.
min
55min.
420max.
30°max.
350min.
45°
T_420_000003_0001_G
Use original MAN final cross members and the matching reinforcing plates to fit trailer couplings.
Final cross members feature an appropriate hole pattern for the relevant trailer coupling. Never alter this hole
pattern to attach a different trailer coupling.
Follow the instructions of the coupling producer in their installation guidelines (e.g. tightening torque and checks).

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
T_420_000004_0001_G
Fig. 04: Trailer coupling fitted below the frame
T_420_000005_0001_G

2.0 Trailer coupling, D-value
The 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 value
The terms are defined as follows.
• Rigid drawbar trailer (RDT): A trailer vehicle with one axle or axle group, where
- the hinged connection to the towing vehicle is achieved by means of a towing device (drawbar),
- the drawbar connection to the chassis is fixed such that it can transfer vertical moments and
- depending on its design, part of its gross weight is borne by the towing vehicle.
• Center-axle trailer (CAT): Towed vehicle equipped with a towing device that does not move vertically in
relation to the trailer and in which the axles are positioned close to the center of gravity of the vehicle such
that only a small static vertical load not exceeding 10% of the mass of the trailer or 1000 kg (whichever is
less) is transmitted to the towing vehicle. Center-axle trailers are therefore a subgroup of rigid drawbar trailers.
• Nose weight S: Vertical load exerted by the drawbar at the coupling point. This is added to the weight of
the towing vehicle when a trailer is coupled and must therefore be taken into consideration when designing
the vehicle (axle-load calculation).
In addition to the D-value formula, other conditions apply to center-axle and rigid drawbar trailers:
• trailer couplings and final cross members have lower trailer loads because in this case the nose weight
acting on the trailer coupling and the final cross member has to be taken into account.
To harmonise regulations within the European Union, the terms “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

Fig. 05: Length of trailer body and theoretical drawbar length
l l
T_510_000003_0001_G
MAN specifies the following for operation with center-axle/rigid drawbar trailers:
For equipment delivered ex-works, a trailer nose weight that exceeds 10% of the permissible trailer mass and
trailers exceeding 1000 kg is not permitted (with the exception of the MAN low-coupling system).
Other loads are the responsibility of the manufacturer of the respective towing device.
MAN cannot make any statements in relation to the permissible loads and calculations (e.g. as per 94/20/EC or
ECE R55) with respect to these towing devices. Like all rear loads, trailer nose weights affect axle-load distribution.
For this reason, particularly in conjunction with additional rear loads (e.g. liftgates, rear loading cranes), perform an
axle-load calculation to check whether trailer nose weights are possible.
The trailing axle of vehicles having a lifting trailing axle must not be lifted when a center-axle trailer/rigid drawbar
trailer is coupled.
An unladen vehicle may only tow an unladen center-axle/rigid drawbar trailer. To ensure sufficient steerability,
minimum front-axle loads for the vehicle must be observed (see booklets on model ranges).
The tables below list possible combinations of trailer loads and nose weights and D, 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).

4.0 Final cross members and trailer couplings
Note: 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
T_420_000006_0001_G
A) Height of plan surface - coupling mounting plate
TGL
Table 01: Assignment to vehicle by model range, model number and final cross member - TGL
Hole pattern
Model no. MAN item no. Comment
[mm]
81.41250.0131 Without Not for trailer coupling
N01, N02 81.41250.5179 140x80 For trailer coupling Type G145
N11, N12
N61 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)
81.41250.5179 140x80 For trailer coupling Type G145
N03, N04
Lowered by 100 mm, for fire service, for Type G 135 trailer coupling,
N05, N13 81.41250.5188 120x55
additional hole pattern 83x56
N14, N15
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
Hole Max.
no., D Rc=C+S DC V t Weight
pattern S [kg] C [kg] trailer Comment
Final cross [kN] [kg] [kN] [kN] [mm] [kg]
[mm] load [kg]
member
Not for trailer
coupling; minimum
final cross member,
if no final cross
member is installed;
81.41250.0131 Without 0 0 0 0 0 0 0 4 8,2
for fitting a liftgate
or a KKK trailer
bracket and/or if the
underride protection
is omitted.
Basic part for
81.41250.5179; #
81.41250.2317 140x80 # # # # # # # 8 26,5 only with internal
reinforcement
81.41250.2314.
Final cross member
for 7- to 12-tonne
81.41250.5179 140x80 69 1000 13.000 14000 64 35 16.000 8 29
TGL, for trailer cou-
pling Type G145
Final cross member
for 7-tonne TGL,
81.41250.5179 140x80 30 500 4.500 5.000 30 19 4.500 8 29 Type N01/N11, for
trailer coupling Type
G145
Lowered by
100 mm, for fire ser-
81.41250.5188 83x56 19 80 2.000 2.080 18 10 2.080 8 31
vice, additional hole
pattern 120x55
Lowered by 100
mm, for fire service,
81.41250.5188 120x55 60 700 6.500 7.200 40 18 12.000 8 31
additional hole
pattern 83x56
Underride protec-
tion and KKK trailer
bracket, only in
conjunction with
81.41660.5189 (3x)83x56 26,8 200 3.500 3.700 0 0 3.500 - 30
final cross member
81.41250.0131 or
.5179 (replaced by
81.41660.5219)
Underride protec-
tion and KKK trailer
bracket, only in
conjunction with
81.41660.5219 (3x)83x56 26,8 200 3.500 3.700 0 0 3.500 - 30
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
Trailer
MAN item no., Trailer coupling
Hole pattern coupling Ball-type
Final cross installation drawing Comment
[mm] bolts coupling
member MAN item no.
40 mm
Observe the max. permissible values in the
81.41250.5179 140x80 G 145 - 81.42000.8154
TGL final cross member table.
81.41250.5188 120x55 G 135 - 81.42000.8200
81.41250.5188 83x56 TK 226 - 81.42000.8186
See also the installation of underride
81.41660.5189 (3x)83x56 - X 81.42000.8166 protection trailer bracket 81.41660.8186.
Replaced by 81.41660.5219
See also the installation of underride
81.41660.5219 (3x)83x56 - X 81.42000.8166 protection trailer bracket 81.41660.8186.
Replaced 81.41660.5189

TGM
Table 04: Assignment to vehicle by model range, model number and final cross member - TGM
Hole pattern
Model no. MAN item no. Comment
[mm]
N08
81.41250.5188 120x55 additional hole pattern 83x56
N16
N18
N26
N28
N34 Lowered by 100 mm, for fire service, for Type G 135 trailer coupling,
N36
81.41250.5180 160x100
N38
81.41250.0131 Without
N44 additional hole pattern 83x56
81.41250.5180 160x100 Not for trailer coupling
81.41250.0131 Without For trailer coupling Type G150
N46
N48
81.41250.0133 160x100 Not for trailer load, only for tow coupling
On N48 only for trailer load up to 3,500 kg with overrun braking, as
81.41250.0131 Without
N62 well as for tow coupling
N63
N64 81.41250.5180 160x100 For trailer coupling Type G150
N65

Table 05: Final cross member and technical data TGM
MAN item no. Hole D S C [kg] Rc=C+S DC V Max. t Weight Comment

Final cross pattern [kN] [kg] [kg] [kN] [kN] trailer [mm] [kg]
member [mm] load [kg]
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. Hole Trailer- Trailer- Trailer coupling Comment

final cross pattern coupling coupling installation drawing
member [mm] bolts bolts MAN item no.
40 mm 50 mm
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 - Observe the max. permissible values in the
81.42000.8154
TGM final cross member table.
81.42000.8164
81.42000.8200
81.41250.5188 83x56 TK226 - Observe the max. permissible values in the
81.42000.8186
*not available at this time

TGA
Table 07: Assignment to vehicle by model range, model number and final cross member - TGA
Model no. MAN item no. Hole pattern [mm] Comment

H01 81.41250.0129 Without Semitrailer tractor, not for trailer coupling, replaced by .0135
81.41250.0132 160x100 Semitrailer tractor, operation with trailer not permitted
81.41250.0135 Without Semitrailer tractor, not for trailer coupling, replaces .0129
H02 81.41250.0130 160x100 Tipper, chassis, replaced by .0133
81.41250.0133 160x100 Tipper, chassis, replaces .5145 and .0130
81.41250.5145 160x100 Tipper, chassis, replaced by .0130
H03 81.41250.0133 160x100 Tipper, chassis, replaces .5145
H04 81.41250.0128 160x100 Semitrailer tractor
81.41250.5145 160x100 Tipper, chassis
H05 81.41250.0128 160x100 Semitrailer tractor, replaced by .0132
81.41250.0129 Without Semitrailer tractor, not for trailer coupling, replaced by .0135
81.41250.0132 160x100 Semitrailer tractor, replaces .0128
81.41250.0133 160x100 Tipper, chassis, replaces .5145
81.41250.0133 160x100 Tipper, chassis
81.41250.0133 160x100 Chassis, replaces .5145
81.41250.5145 160x100 Chassis, replaced by .0133
81.41250.0132 160x100 Semitrailer tractor, operation with trailer not permitted
81.41250.0133 160x100 Chassis
H11 81.41250.0133 160x100 Tipper

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

H14 81.41250.0130 160x100 Chassis, replaced by .0133
H15 81.41250.0133 160x100 Chassis
H16 81.41250.0133 160x100 Chassis, replaces .5145
81.41250.0132 160x100 Semitrailer tractor
81.41250.0133 160x100 Chassis
81.41250.0130 160x100 Tipper, chassis, truck mixer, replaced by .0133
81.41250.0133 160x100 Tipper, chassis, truck mixer, replaces .0130
81.41250.5184 160x100 Tipper, 150 mm lower


81.41250.0130 160x100 Tipper, chassis, truck mixer, replaced by .0133
81.41250.5184 160x100 Tipper, 150 mm lower
81.41250.5184 160x100 Tipper, 150 mm lower
81.41250.5184 160x100 Tipper, 150 mm lower
81.41250.0133 160x100 Tipper, chassis
81.41250.5184 160x100 Tipper, 150 mm lower
81.41250.0133 160x100 Tipper
81.41250.5184 160x100 Tipper, 150 mm lower
81.41250.0133 160x100 Tipper
81.41250.5184 160x100 Tipper, 150 mm lower
81.41250.0133 160x100 Chassis
H36 81.41250.0130 160x100 Tipper, chassis, truck mixer, replaced by .0133
H39 81.41250.0133 160x100 Tipper, chassis, truck mixer
H41 81.41250.0133 160x100 Tipper, chassis
81.41250.0133 160x100 Chassis


H45 81.41250.0133 160x100 Chassis
H46 81.41250.0130 160x100 Replaced by .0133
81.41250.0133 160x100 Replaces .0130
81.41250.0133 160x100 Tipper
81.41250.5184 160x100 Tipper, 150 mm lower
H48 81.41250.0133 160x100 Truck mixer
H49 81.41250.0133 160x100 Chassis, truck mixer
81.41250.5187 Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadthrough
H50 81.41250.0133 160x100 Tipper, chassis, truck mixer
81.41250.5184 160x100 Tipper, chassis, 150 mm lower
81.41250.0133 160x100 Tipper, chassis
81.41250.0133 160x100 Tipper
81.41250.5184 160x100 Tipper, 150 mm lower
81.41250.0133 160x100 Tipper, chassis
81.41250.0133 160x100 Tipper
81.41250.0133 160x100 Tipper
H59 81.41250.0133 160x100 Tipper
81.41250.0133 160x100 Tipper, chassis


81.41250.0133 160x100 Chassis
81.41250.0133 160x100 Tipper, chassis
81.41250.0133 160x100 Chassis
H68 81.41250.0133 160x100 Tipper
H69 81.41250.0133 160x100 Chassis
81.41250.0130 160x100 Tipper, replaced by .0133
81.41250.0133 160x100 Tipper, replaces .0130
81.41250.5184 160x100 Tipper, 150 mm lower
H71 81.41250.0133 160x100 Chassis
H73 81.41250.0130 160x100 Tipper, replaced by .0133
81.41250.0133 160x100 Tipper, replaces .0130
81.41250.5184 160x100 Tipper, 150 mm lower
H74 81.41250.0133 160x100 Chassis
H75 81.41250.0133 160x100 Chassis
81.41250.5184 160x100 Tipper, 150 mm lower
81.41250.0135 Without Semitrailer tractor, not for trailer coupling
81.41250.0133 160x100 Tipper
81.41250.5184 160x100 Tipper, 150 mm lower


81.41250.0133 160x100 Tipper, chassis
H85 81.41250.0133 160x100 Chassis
81.41250.0133 160x100 Chassis
H90 81.41250.0133 160x100 Chassis
H91 81.41250.0133 160x100 Chassis
H92 81.41250.0133 160x100 Chassis
H93 81.41250.0133 160x100 Tipper
81.41250.5184 160x100 Tipper, 150 mm lower
H94 BLLL 81.41250.0133 160x100 Semitrailer tractor, no trailer operation permitted with BLLL
H94 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 BLLL
H95 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
frame overhang 725 mm/925 mm
H96 81.41250.0133 160x100 Tipper
81.41250.5184 160x100 Tipper, 150 mm lower
H99 81.41250.0133 160x100 Chassis
HH1 81.41250.0132 160x100 Semitrailer tractor
81.41250.0133 160x100 Chassis
HH4 81.41250.0133 160x100 Chassis
HV1 81.41250.0133 160x100 Chassis
HV2 81.41250.0141 160x100 Semitrailer tractor


HV4 81.41250.0133 160x100 Chassis
HV5 81.41250.0133 160x100 Tipper, chassis
81.41250.5184 160x100 Tipper, 150 mm lower
HV6 81.41250.0133 160x100 Tipper
81.41250.5184 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 tractor
81.41250.0133 160x100 Tipper, chassis, truck mixer
81.41250.5184 160x100 Tipper, 150 mm lower
HW3 81.41250.0133 160x100 Tipper, chassis, truck mixer
81.41250.0133 160x100 Tipper, chassis
HW6 81.41250.0133 160x100 Tipper, chassis
HW7 81.41250.0135 Without Semitrailer tractor, not for trailer coupling
81.41250.0142 Without Semitrailer tractor, replaces .0135, not for trailer coupling
81.41250.0133 160x100 Fahrgestell
81.41250.0141 160x100 Sattel, Ersatz für .0132

Table 08: Final cross member and technical data TGA
MAN item no., Hole D S C [kg] Rc=C+S DC V Max. t Weight Comment

final cross pattern [kN] [kg] [kg] [kN] [kN] turntable [mm] [kg]
member [mm] drawbar
trailer load
[kg]
81.41250.0128 160x100 130 1.000 9.500 10.500 64 35 As per 9,5 25,6 Only semitrai-
D value 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 9,5 31,9 Trailer-coupling hole
D value 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 9,5 25,6 Only semitrailer
D value 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 9,5 31,5 Trailer-coupling
D value hole pattern 27.5
mm lower than
81.41250.0130,
replaces
81.41250.0130 and
.5145
tractor with frame
tapering, replaces
81.41250.0129
81.41250.5145 160x100 200 1.000 18.000 19.000 130 70 As per 11 28,7 Final cross member
D value reinforced, TGA and
F2000, replaced by
81.41250.0133
81.41250.5184 160x100 190 1.000 18.000 19.000 130 70 As per 9,5 50,1 150 mm lower than
D value series
82.41250.5092 330x110 314 0 0 0 0 0 As per 20 156,6 10-bolt connection
D value 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

member [mm] drawbar
trailer
load
[kg]
82.41250.5092 160x100 200 0 0 0 0 0 As per 20 156,6 Normal and lowe-
D value 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
D value 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 15 50,6 Additional hole
D value pattern for 10-bolt
connection for 100-t
coupling installation
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 44,5 Only with MAN low-
D value coupling system
Abbreviations: CAT: rigid drawbar/center-axle trailer: TC: trailer coupling; GW: gross weight
t: sheet thickness of final cross member RC: permissible gross weight of CAT

Table 09: Assignment of trailer-coupling installation drawings to final cross members - TGA
MAN item no., Hole Trailer- Trailer- 100 t Trailer-coupling Comment

Final cross pattern coupling coupling Trailer- installation drawing
member [mm] bolts bolts coupling MAN item no.
40 mm 50 mm bolts
50 mm
81.41250.0128 160x100 X X 81.42000.8152_3 Semitrailer tractor
81.41250.0130 160x100 X X 81.42000.8129_3
81.41250.0133 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_1
81.41250.5184 160x100 X X 81.42000.8152_4 Lowered by 150 mm
81.42030.5116 160x100 X 81.42000.8152_1 MAN low-coupling system
82.41250.5092 160x100 X X n/v*
82.41250.5092 330x110 82.42000.8021_1 Heavy-duty trailer coupling,
normal or lowered
82.41250.5094 160x100 X X n/v*
82.41250.5094 330x110 X 82.42000.8021_1 Heavy-duty trailer coupling,
normal

TGS/TGX
Table 10: Assignment to vehicle by model range, model number and final cross member - TGS/TGX
Model no. MAN item no. Hole pattern Comment

[mm]
03S 81.41250.0133 160x100 Tipper, chassis
05X 81.41250.0142 Without Semitrailer tractor, not for trailer coupling
06S/06X 81.41250.0133 160x100 Tipper, chassis
08S 81.41250.0135 Without Semitrailer tractor, not for trailer coupling
10S/10X 81.41250.0133 160x100 Chassis
13S/13X 81.41250.0132 160x100 Semitrailer tractor
15S/15X 81.41250.0133 160x100 Chassis
18S/18X 81.41250.0133 160x100 Chassis
21S/21X 81.41250.0133 160x100 Chassis
22S 81.41250.0133 160x100 Chassis
24S 81.41250.0132 160x100 Semitrailer tractor
81.41250.0133 160x100 Chassis
26S 81.41250.0133 160x100 Tipper, chassis, truck mixer
81.41250.5184 160x100 Tipper, 150 mm lower
26X 81.41250.0133 160x100 Tipper, chassis

Table 10: Assignment to vehicle by model range, model number and final cross member - TGS/TGX - continued
Model MAN item no. Hole pattern Comment

no. [mm]
28X 81.41250.0141 160x100 Semitrailer tractor
81.41250.0144 160x100 Semitrailer tractor, not approved for trailer coupling
61.41250.0000 160x100 Semitrailer tractor, replaces .0144, not approved for trailer coupling
81.41250.5184 160x100 Tipper, 150 mm lower
30X 81.41250.0133 160x100 Tipper, chassis
35S 81.41250.0133 160x100 Chassis
81.41250.5187 Without Tipper, not for trailer coupling
42S/42X 81.41250.0141 160x100 Semitrailer tractor
45S/45X 81.41250.0133 160x100 Chassis
49S 81.41250.0133 160x100 Tipper, truck mixer
81.41250.5187 Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadt-
hrough
59S 81.41250.0133 160x100 Tipper
81.41250.5184 160x100 Tipper, 150 mm lower
71S 81.41250.0133 160x100 Chassis
73S 81.41250.0133 160x100 Chassis
74S 81.41250.0133 160x100 Chassis
79X 81.41250.0133 160x100 Chassis
80S 81.41250.0133 160x100 Tipper
81.41250.5184 160x100 Tipper, 150 mm lower

Model no. MAN item no. Hole pattern Comment

[mm]
82.41250.5092 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal and
lowered, frame overhang 725 mm
frame overhang 725 mm
88X 81.41250.0144 160x100 Semitrailer tractor, not approved for trailer coupling
61.41250.0000 160x100 Semitrailer tractor, replaces .0144, not approved for trailer coupling
89S/89X 81.41250.0133 160x100 Chassis
90S 81.41250.0133 160x100 Chassis
92S/92X 81.41250.0133 160x100 Chassis
93S 81.41250.0133 160x100 Tipper
81.41250.5184 160x100 Tipper, 150 mm lower
82.41250.5092 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling, normal and
lowered, frame overhang 725 mm
frame overhang 725 mm
03W 81.41250.0141 160x100 Semitrailer tractor
18W 81.41250.0133 160x100 Chassis
19W 81.41250.0133 160x100 Chassis
26W 81.41250.0133 160x100 Tipper, chassis, truck mixer
34W 81.41250.0133 160x100 Tipper
49W 81.41250.5187 Without Rear tipper, not for trailer coupling, suitable for tipping-shaft leadt-
hrough
52W 81.41250.0133 160x100 Tipper, chassis
58W 81.41250.0133 160x100 Tipper
85.41250.5000 330x110 Semitrailer tractor, 10-bolt connection for 100-t coupling

Model MAN item no. Hole pattern Comment

no. [mm]
60W 81.41250.0133 160x100 Tipper
73W 81.41250.0133 160x100 Chassis
77W 81.41250.0133 160x100 Tipper
78W 81.41250.0133 160x100 Chassis

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

member [mm] drawbar
trailer load
[kg]
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 9,5 31,5 Trailer-coupling
D value 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 9,5 25,6 Only semitrailer
D value tractor with frame
tapering, no exchange
possible! Replaces
81.41250.0132
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 9,5 50,1 150 mm lower than
D value series
81.41250.5187 Without 0 0 0 0 0 0 0 8 33,6 Not for trailer coupling,
only for rear tipper
D value for 100-t coupling in-
stallation, normal and
lowered, additional
hole pattern 160x100
junction with MAN
nos. 82.41250.5090
and 82.41250.5091
overhang 725 mm.
82.41250.5092 160x100 200 0 0 0 0 0 As per 20 156,6 Normal hole pattern,
D value additional hole pattern
for 10-bolt connection
for 100-t coupling
and lowered, only in
conjunction with MAN
nos. 82.41250.5090
and 82.41250.5091
overhang 725 mm

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

member [mm] drawbar
trailer
load
[kg]
82.41250.5094 330x110 314 0 0 0 0 0 As per 15 50,0 10-bolt connection for
D value 100-t coupling installation
normal, additional hole
pattern 160x100, normal,
only in conjunction with
MAN nos. 82.41250.5090
and 82.41250.5091
overhang 725 mm
82.41250.5094 160x100 200 0 0 0 0 0 As per 15 50,0 Additional hole pattern
D value 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 15 60,4 10-bolt connection for
D value 100-t coupling
81.42030.5116 160x100 190 1.000 24.000 25.000 130 75 As per 22 44,5 Only with MAN
D value low-coupling system
Abbreviations: CAT: rigid drawbar/center-axle trailer: TC: trailer coupling; GW: gross weight
t: sheet thickness of final cross member RC: permissible gross weight of CAT
Table 12: Assignment of trailer-coupling installation drawings to final cross members - TGS/TGX
MAN item no., Hole Trailer- Trailer- 100 t Trailer-coupling Comment

Final cross pattern coupling coupling trailer installation
member [mm] bolts bolts coupling drawing
40 mm 50 mm Bolts MAN item no.
50 mm
81.41250.0133 160x100 X X 81.42000.8152_2 Chamfers required on top and
bottom of trailer-coupling moun-
ting plate
81.41250.5184 160x100 X X 81.42000.8152_4 Lowered by 150 mm
81.42030.5116 160x100 X 81.42000.8152_1 MAN low-coupling system
82.41250.5092 330x110 X 82.42000.8021_1 Heavy-duty trailer coupling, nor-
mal or lowered
82.41250.5092 160x100 X X n/v*
82.41250.5094 330x110 X 82.42000.8021_1 Heavy-duty trailer coupling,
normal
82.41250.5094 160x100 X X n/v*
85.41250.5000 330x110 X n/v* Heavy-duty trailer coupling,
normal

5.0 Ball-type couplings
Like all rear loads, even low trailer nose weights affect axle-load distribution. For this reason, particularly in
conjunction with additional rear loads (e.g. liftgates, rear loading cranes), perform an axle-load calculation to check
whether trailer nose weights are possible.
Other requirements for fitting ball-type couplings are as follows:
• The ball-type coupling must be adequately dimensioned and type-approved (trailer nose weight, trailer load).
• The trailer bracket must be adequately dimensioned and type-approved.
• The trailer bracket must be attached to the vertical webs of the main frame (attachment to the lower flange
of the main frame alone is not permitted by MAN)
• The test center (e.g. DEKRA, TÜV) must check for adequate dimensioning and suitable connection to
the vehicle frame when the trailer coupling is registered.
• Instructions for assembly/guidelines issued by the manufacturers of the trailer bracket and ball-type
coupling must be observed.
• The necessary clearance dimensions, e.g. as per DIN 74058 must be observed (see Fig. 02).
6.0 Fifth-wheel coupling

The weight and size of semitrailers and semitrailer tractors must be checked to see if they are suitable for forming
a tractor-semitrailer vehicle.
The following must therefore be checked:
• Slew radii
• Fifth-wheel coupling load
• Ease of movement of all components
• Statutory requirements
In order to achieve maximum fifth-wheel coupling load, the following measures are required before the vehicle goes
into operation:
• Weigh vehicle
• Calculate axle load
• Determine optimum fifth-wheel lead
• Check front slew radius
• Check rear slew radius
• Check front angle of inclination
• Check rear angle of inclination
• Check total length of tractor-semitrailer vehicle
• Mount fifth-wheel coupling accordingly.
The necessary angle of inclination specified by DIN ISO 1726 is 6° at the front, 7° at the rear and 3° at the side.
Different tyre sizes, spring rates or fifth-wheel heights between tractor and semitrailer reduce these angles so that
they no longer comply with the standard.
In addition to rear inclination of a semitrailer, it is also necessary to consider sideways inclination when cornering,
suspension compression (axle guidance, brake cylinders), anti-skid chains, pendulum movement of the axle unit on
vehicles with a tandem axle and slew radius.
The plane of the fifth-wheel plate on the semitrailer should be parallel to the roadway under a permissible fifth-wheel
coupling load.
The height of the fifth-wheel coupling must therefore be designed accordingly, in order to comply with the statutory
height of maximum 4 m (with semitrailer).

Fig. 07: Dimensions on semitrailer tractors
T_995_000002_0001_G
The distance between rear axle and fifth-wheel kingpin stated in the sales documentation or chassis drawings only
applies to a standard vehicle.
Under some circumstances, equipment that affects the vehicle’s unladen weight or dimensions requires the 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.

Fig. 08: Example of installation with auxiliary frame
T_427_000001_0001_G
1) Fifth-wheel coupling base plate

2) Fifth-wheel coupling
3) Mounting angle
4) Auxiliary frame

Fig. 09: Example of installation without auxiliary frame
T_427_000002_0001_G
1) Fifth-wheel coupling base plate

2) Fifth-wheel coupling
3) 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 AG
Technical Sales Support
Application Engineering
Dachauer Str. 667
D - 80995 Munich
E-Mail: info.manted@man.eu
MAN Truck & Bus AG –a member of the MAN Group

We reserve the right to make changes in the course of technical development.

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MAN Guidelines to fitting bodies Truck

Coupling devices TG Edition 2016 V1.0

Engineering the Future – since 1758

MAN Truck & Bus AG

Technical Sales Support

Fax: + 49 (0) 89 1580 4264

This English version is a translation.

© 2016 MAN Truck & Bus AG

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

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

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

• The necessary final cross member and trailer coupling

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

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 3

Fig. 03: Lowered trailer coupling

Fig. 04: Trailer coupling fitted below the frame

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

The formula for the D value is as follows:

Formula 01: D value

Formula 02: D-value formula for permissible gross weight

Formula 03: D-value formula for permissible gross trailer weight

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 5

The following formulae apply:

DC = Reduced D value when operating with center-axle trailer [kN]

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

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 7

A) Height of plan surface - coupling mounting plate

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

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 9

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

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 11

MAN item no. Hole D S C [kg] Rc=C+S DC V Max. t Weight Comment

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

MAN item no. Hole Trailer- Trailer- Trailer coupling Comment

*not available at this time

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 13

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

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

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

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 15

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

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

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

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 17

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

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

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

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 19

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

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

MAN item no., Hole D S C [kg] Rc=C+S DC V Max. t Weight Comment

MAN Guide to fitting bodies Coupling devices TG Edition 2016 V1.0 21

MAN item no., Hole D S C [kg] Rc=C+S DC V Max. t Weight Comment

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

MAN item no., Hole Trailer- Trailer- 100 t Trailer-coupling Comment