MAN Nutzfahrzeuge AG WORKS STANDARD April 2006

Method for compliance with directives and safety

regulations for MAN products M 3010-3
Parts requiring certification (P-parts)
Dimensions in mm

This English version is a translation. In case of doubt or conflict the valid German-language original will govern.

Contents

1 Scope and purpose

2 Parts requiring certification (P-parts)
3 Marking
4 Clearance (release) procedure
5 Reason for verification management
Appendix A Overview - Ensuring the operational reliability

Important!
New designs and changes for P-parts, especially from Design and Purchasing (see Section 5),
must always be cleared with the materials testing team in acc. with Directive TE 002 prior to
introduction.

1 Scope and purpose

This standard applies to components/modules/systems in MAN commercial vehicles (in acc. with
TE 002) that require functional clearance and whose strength is relevant because of their particular
importance in the vehicle.
For this purpose, a materials strength testing team comprising experts from the areas of calculation,
testing and design was established in MN. This committee checks whether any or which actions are
necessary to ensure operational reliability prior to mass production and clears these parts if suitable.
Since proof (PROOF) of this clearance must documented (certified), such parts are designated as
P-parts.
Changes to parts requiring certification in acc. with Section 5 may be introduced only after clearance by
the material strength testing team.
The purpose of the standard is to avoid damage arising from the use of parts whose operational reliability
has not been adequately verified (by calculation and/or testing).

2 Parts requiring certification (P-parts)

P-parts in the sense of this standard include all
- Types of parts that are listed in Table 1 with an item number stem and name. These types of parts
include parts with safety-related features or requirements, non-compliance with which can have a
critical effect on the roadworthiness or functional safety of the vehicles.
Parts with multiple functions to which one function from Table 1 can be assigned are always to be
treated as P-parts. In cases of doubt, assignment to the function groups and types of parts is to be
agreed upon with the Standards Department (TDN).
- Other parts/modules/system not yet listed in Table 1 that have received a product risk factor P > 8
(with regard to strength) in the course of determining the development risk number (ERZ) during risk
assessment for new developments in acc. with the SE manual, Chapter 01.
Additional parts/systems/modules not mentioned here that must be treated as P-parts are to be
communicated to the Standards Department (TDN) by Design and Testing.

Co-responsibility for the standard: TEF

Continued page 2 to 4

Author: Vielemeyer Release TDN: Replacement for: 2005-05 Material group No.:
2006-05, englisch
MAN Nutzfahrzeuge Aktiengesellschaft, Munich - Standards Department (TDN) All rights reserved in line with ISO 16016.
Distribution and use of the content without the written approval of MAN Nutzfahrzeuge Aktiengesellschaft is strictly prohibited.
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M 3010-3 : 2006-04

Notes regarding Table 1

When establishing item numbers, parts are assigned to a function group and type of part on the basis of their
location in the vehicle and their function there (see function group plan in Supplement 1 to M 3002 and the part
type directory). The item number stem is established in acc. with these criteria.
Parts corresponding to the part types (item number stem) and names listed in Table 1 are classified as P-parts
and must be checked for any necessary certification actions by the material strength testing team in acc. with
Directive TE 002.
If parts are assigned a function and name as listed in Table 1 during the development stage and given testing
numbers (item number stem XX.99XXX-), these must be communicated to the material strength testing
team by the responsible designer at the earliest possible date.

Table1: Types of parts requiring certification (sorted by: function group)

Function Function
Name Name
(item number (item number
stem) stem)

Rear and rigid axle, front wheel drive Front axle, not driven
xx.35401 Axle body,casing, stub (journal) xx.44101 Front axle body
xx.35701 (Rear) wheel hub xx.44201 Control arm
Front axle, driven
xx.44202 Control arm carrier
xx.44205 Control arm bolt
xx.36202 Horn Plate
xx.44301 Front axle flange, hub
xx.36301 Control arm (stub/journal)
Wheels, tyres
xx.36305 Control arm bolt
xx.36501 (Front) wheel hub xx.45501 Wheel fastener
Steering
Frame
xx.46105 Universal joint shaft
06.4611x- Spring band
xx.46110 Steering support
xx.41250 Rear cross member
xx.46110 Steering bracket
xx.41301 Spring support, bearing block,
carrier block xx.46113 Steering column
xx.41306 Spring bolt xx.46122 Steering shaft
xx.41307 (Rear) spring support xx.46440 Steering column holder
xx.41715- Rocker (assy.) xx.46601 Steering column lever
xx.41720- Bearing mount/bracket (assy.) xx.46610 Steering connecting rod
xx.46701 Steering knuckle arm
Frame attachments
1 xx.46705 Steering arm
xx.42020 Coupling ball )
1 xx.46710 Track rod
xx.42710 Fifth-wheel (articulated) coupling )
xx.46715 Drag rod
Axle guide, springs, shock absorbers xx.46720 Operating, reverse, angled levers
xx.43215 (Trailing) arm support, bearing xx.46730 Bearing block
block xx.46731 Bolt
xx.43215 Bearing block Brake assembly for wheel
xx.43220 Axle guide rod
xx.50310 Bearing block
xx.43220 Trailing link
Cab assembly
xx.43250 Transverse control arm
xx.43270 Triangular guide rod xx.61820- Bearer for cab mounting
xx.43270 Ball socket xx.61852- Cab lock
xx.43315 Bolt, holder, control arm
xx.43630 Carrier block
1)
If this is a third-party part it must be cleared to MAN 239-3, i.e. it is not a P part!
+
Parts with product risk factor P > 8 (with regard to strength)
- see p. 1, Section 2, second coat -
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3 Marking
Parts that are to be designated P-parts in acc. with Section 2, must be identified with the letter "P" as described
in Sections 3.1 and 3.2. In this way, these parts will be recognized early as parts requiring certification. The
responsible individual is the designer involved. In cases of doubt, the designer must clarify the designation
for his part with the material strength testing team in advance. The contact partner is the testing/complete
vehicle/strength (TEFF) department.

3.1 Marking in the item master data

When assigning item numbers, a comparison should be made with the specifications in Table 1 and when
designating the item master data for P-parts in the IMS-system MN-SADIS, a "P"-designation should be entered
in the mask TE23A/B in field TK.

3.2 Marking in the drawings

MAN drawings: Entry of the letter "P" in the MN drawing text box in acc. with MG.110.01-2, field 5
By means of sticker in acc. with M 3122

4 Clearance procedure
Parts designated as P-parts are to be communicated to the material strength testing team that tests these parts
by the responsible designer as early as possible. The clearance procedure in this regard is regulated in
Directive TE 002. The contact partner is the testing/complete vehicle/strength (TEFF) department.

5 Reason for verification management

Verification management by the material strength testing team to ensure the functional reliability of P-parts is
required for new clearances and the changes listed in the following. All parts designated as P-parts will be
handled by the material strength testing team in regularly scheduled meetings.
In addition, the material strength testing team is to be informed directly and, above all, in a timely manner in the
following situations, and specifically:

by the responsible designer in the case of:

- P-parts that are to be evaluated by the material strength testing team on short notice (e. g. start of mass
production endangered),
- change of the object features (such as dimensions, material, etc.) specified in the technical documentation
for P-parts,
- changes regarding semi-finished/unfinished parts and changes involving the manufacturing method for P-
parts and

by the responsible purchasing agent in the case of:

- a change in supplier of P-parts,
- relocation of production of P-parts,
- new sub-suppliers of semi-finished or unfinished blanks for P-parts.

Standards quoted
MAN 239-3 Ensuring the operational reliability of externally procured components in MAN products
MG.110.01-2 Text boxes for drawings and drawing changes
M 3122 Table on drawings; identification of drawings for parts with safety-related specifications.
TE 002 Clearance of P-parts

Previous issues: M 3010-3 / 2005-05

Changes: Compared to issue 2005-05 the following changes have been made:
- In Table 1 footnote 1 and individual parts for cab mounts in cab lock have been added
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Appendix A
Overview: Ensuring the operational reliability of parts prior to large-scale use in MAN-vehicles

Ensuring the operational reliability (functionality, reliability and service life) of purchased parts (development and, possibly, manufacturing responsibility
borne by the supplier) prior to large-scale introduction in mass production is regulated in the individual supplier specifications or the plant standard
MAN 239-3 and is the responsibility of the supplier.
Safety-related parts for which MAN bears responsibility regarding development (new designs and changes) are subject to verification management in
acc. with M 3010-3.

Purchased part Propriet

Externally procured part Part manufactured by 3rd party In-house part

Development and, possibly, Development responsibility borne Development and
manufacturing responsibility by MAN, manufacturing manufacturing responsibility
borne by supplier responsibility borne by supplier borne by MAN

Verification of the Requirement "Verification of

operational reliability in acc. operational reliability in acc. If required, any
with supplier specification on with MAN 239-3“ by means of necessary actions
the basis of MAN 239-3“ drawing sticker regarding verification
Part requiring no management are
certification in acc. decided upon by the
with responsible designer in
Supplier submits the form
agreement with the
"Verification of the operational
testing department
reliability in acc. with MAN 239-3"
yes

Clearance (release) by the materials

testing team !
Clearance (release) procedure in acc.
with instructions