MAN Nutzfahrzeuge AG WORKS STANDARD July 2005

This supplement contains the permissible upper and lower tolerances for the general tolerances laid down Accuracy of shape
M 3199 B1
for MN in M 3199 for the production processes used most frequently at MN, however no additional
standardised requirements
The tolerances laid down in M 3199 for other production processes and types of parts on general toler- General tolerances for MN
ances are to be found in the individual standards listed in M 3199, depending on the level of accuracy laid
down for MN.
All tolerances are applied to the final condition of a geometric element, including electrolytically applied or
"Old tolerancing principles"
chemical coating, unless otherwise stated in the applicable Standards/drawings.
This ruling is not applied to paint coatings.
Tolerances for the most commonly used production processes
In general, the shape and positional tolerances, apart from symmetry, coaxial and concentricity tolerances,
are limited by the dimensional tolerances. However, the requirements for shape and positional deviations in Dimensions in mm
the table must additionally be noted.

Table 1, General tolerances for the thickness of metallic flats

Footnotes see Page 2
Thickness range in mm Permissible thickness deviation 1) in
mm
≥ < upper toler- lower tolerance
ance
0,10 0,50 +0,06 -0,06
0,50 1,00 +0,09 -0,09
1,00 2,00 +0,22 -0,22
2,00 3,00 +0,30 -0,30
3,00 4,00 +0,80 -0,40
For stamped metal parts, the graphic
4,00 5,00 +0,80 -0,40
5,00 8,00 +1,10 -0,50 diagrams additionally show the most
8,00 15,00 +1,20 -0,50 important shape rulings, in order to
15,00 25,00 +1,30 -0,60 meet the required level of accuracy
25,00 40,00 +1,40 -1,00 according to DIN 6932 without any
40,00 80,00 +1,80 -1,00 problems.
80,00 including 150.00 +2,20 -1,00

Table 2
Standard for general 7
DIN 7168 DIN EN ISO 13920 DIN 6935 DIN 6930 )
tolerances Limit deviations for autogenous, plasma and laser cut
Level of accuracy Abbre- rough C average contours (length and diameter dimensions) according to
AE BF ---
viation (m C) (g C) (m) DIN EN ISO 9013, tolerance class 2
for parts shaped with and without machining 1) made from for welded parts and welded structures 8
1 Bus framework 8 for stamped metal parts created by deformation made from steel and aluminium alloys )
Scope ) construction Cold bending of flat products for flat stamped metal parts made from steel and aluminium alloys ) 9 Control-
metallic materials non-metallic materials 12) ) Level of
12) 13) General type Example Tole- ling
Truck cabs accuracy
Process (Figure rances nominal Remark
Example (Figure-No.) 1 2, 3 4, 9 5, 6, 7, 8 6 9, 10 9 (abbrevia-
No.) for dimen-
tion)
Angle Angle Angle sion
Angle dimensions Angle dimensions Bending radius Length dimensions Length dimensions
Length measure- Radius of curvature Length measure- dimensions dimensions dimensions
Tolerances for 2 3 2 3 5 Diameter dimensions Radius of curvature Diameter dimensions Radius of curvature
ments and slopes β ) ) ments α ) ) ) r 2 3 5 6 2 3 2 3 5 6
β ) ) ) ) Notches β ) ) Notches α ) ) ) )
Auto-
Length of genous 442
Length of the shorter Length of the shorter Length of the Length of the
Controlling nominal dimension d*), fl, l e, r l 4 s a, b, c, d*), e, g, l R a, b, c, d*), e, f, g, h, l R the shorter
shank shank ) shorter shank shorter shank
shank
Length
Minimum tensile strength dimen- For autogenous cutting,
2 Thickness range s in mm Thickness range s in mm the following applies:
Given reference quantities Rm (N/mm ) Plasma 442 sions
11 n – Straightness and
>390 >490 >0,1 >1 >3 >6 >10 >0,1 >1 >3 >6 >10 >0,1 >1 >3 >6 >10 >0,1 >1 >3 >6 >10 )
≤ 390 11 b, d **), L parallelism deviation for
≤490 ≤640 ≤1 ≤3 ≤6 ≤10 ≤1 ≤3 ≤6 ≤10 ≤1 ≤3 ≤6 ≤10 ≤1 ≤3 ≤6 ≤10 Diame- parallel straight cuts
Nominal dimension ter made at the same time:
range of the dimen- limit deviation ±1,5
permissible upper and lower tolerances in mm or degrees and minutes, depending on the level of accuracy
controlling nominal sions
dimension Laser
332
x x x x **)
) above to m g m g m g ) A B A B ) )
1 0,5 3 ±0.1 ±0.15 ±0.2 ±0.2 1 +0,5 +0,8 +1 1 --- 1
±0.1 ±0.15 ±0.2 ±0.3 ±0.4 ±0.2 ±0.3 ±0.5 --- ±0.2 ±0.3 ±0.4 ±0.6 ±0.8 ±0.4 ±0.6 --- --- ---
2 3 6 ±0.1 ±0.2 ±0.5 ±1 2 2 ±1°30’ 2
±1° ±1°30’ +1 +1,5 +2
3 6 8 3 3 ±0.4 --- 3 ---
±0.15 ±0.2 ±0.25 ±0.4 ±0.3 ±0.4 ±0.5 ±0.6 ±0.3 ±0.4 ±0.5 ±0.8 ±0.8 ±0.6 ±1 ±1.2 ±1.5 10
4 8 10 4 ±1 ±1 ±2° 4 4 Limit deviations for nominal dimensions of tolerance class 2 )
+1,5 +2 +3 Work-
5 10 20 ±0.2 ±0.5 ±1 ±2 5 5 ±1.0 5 piece
±0.2 ±0.25 ±0.3 ±0.4 ±0.6 ±0.4 ±0.5 ±0.6 ±0.8 ±0.4 ±0.5 ±0.6 ±0.8 ±1.2 ±1 ±1.2 ±1.5 ±2 ±2.5 thickness
6 20 25 6 6 6 >0 ≥3 ≥10 ≥35 ≥125 ≥315 ≥1000 ≥2000
±30’ ±50’ <3 <10 <35 <125 <315 <1000 <2000 <4000
7 25 30 7 7 ±1.2 ±50’ 7
8 30 40 8 8 ±0.25 ±0.3 ±0.4 ±0.5 ±0.6 ±0.5 ±0.6 ±0.8 ±1.0 8 ±0.5 ±0.6 ±0.8 ±1.0 ±1.2 ±1.2 ±1.5 ±2 ±2.5 ±4
±1°45’
Dimensional tolerances

±20’ ±45’ up to 1 ±0,1 ±0,3 ±0,4 ±0,5 ±0,7 ±0,8 ±0,9

9 40 50 9 9 9
10 50 63 ±0.3 ±0.8 ±2 ±4 10 10 10 above 1
±1°30’ to 3.15
±0,2 ±0,4 ±0,5 ±0,7 ±0,8 ±0,9 ±1 ±1,1
11 63 80 ±20’ ±25’ 11 11 11
±1.6
12 80 120 12 ±1 ±2 ±1°15’ 12 ±0.3 ±0.4 ±0.5 ±0.6 ±0.8 ±0.8 ±1.0 ±1.2 ±1.4 ±25’ 12 ±0.6 ±0.8 ±1.0 ±1.2 ±1.6 ±1.5 ±2.0 ±2.5 ±4 ±6 above
3.15 to ±0,5 ±0,7 ±0,8 ±0,9 ±1,1 ±1,2 ±1,3
13 120 160 13 13 13 6.3
see
±0.5 ±1.2 ±4 ±8 ±10’ ±15’ ±2.0 DIN 6935 above 6.3
14 160 315 14 14 ±0.5 ±0.6 ±0.6 ±0.8 ±1.0 ±1.0 ±1.2 ±1.5 ±1.8 ±15’ 14 ±1.0 ±1.2 ±1.2 ±1.6 ±2 ±2 ±2.5 ±4 ±6 ±10 to 10
--- ±1 ±1,1 ±1,3 ±1,4 ±1,5 ±1,6 ±1,7

15 315 400 15 15 15 above 10

--- --- --- --- ±1,8 ±1,9 ±2,3 ±3 ±4,2
to 50
16 400 1000 ±0.8 ±2 16 ±2 ±3 ±15’ ±30’ 16 ±0.8 ±0.8 ±1.0 ±1.0 ±1.5 16 ±1.6 ±1.6 ±2 ±2 ±3 ±2.5 ±4 ±6 ±10 ±15
±10’ above 50
--- --- ±2,5 ±2,6 ±3 ±3,7 ±4,9
to 100
17 1000 2000 ±1.2 ±3 17 ±3 ±4 17 17 ±2.4 ±3 ±3 ±4 ±4
±1° above
18 2000 2500 18 18
±1.2 ±1.5 ±1.5 ±2 ±2 18
±2 ±4 ±4 ±6 100 to --- --- ±3,2 ±3,3 ±3,4 ±3,7 ±4,4 ±5,7
19 2500 4000 19 19 19 150
20 4000 6300 --- --- ±5’ ±10’ 20 20
±1.6 ±2 ±2.2 ±2.5 ±3 20 above
±3 ±5 ±5 ±8 150 to --- --- ±4 ±4,1 ±4,5 ±5,2 ±6,4
21 6300 8000 21 ±10’ ±20’ 21 21 --- --- --- --- --- 200
22 8000 12000 ±4 ±6 22 ±6 ±10 22 --- 22 --- --- --- --- --- above
200 to --- --- --- --- --- ±5,2 ±5,9 ±7,2
23 12000 16000 ±5 ±7 23 ±7 ±12 23 --- --- --- --- --- 23 250
24 16000 20000 ±6 ±8 24 ±8 ±14 24 24 above
250 to --- --- --- --- --- ±6 ±6,7 ±7,9
25 20000 --- --- 25 ±9 ±16 25 25 300
**) For laser cut bores in diameter range of ∅4.5 to ∅19, the diameter
Straightness, flatness tolerance of +0.2 applies
- to DIN 7168 (Figure 1) and parallelism tolerance - to DIN 6930 (Figure 6, 7, 8, 9 and 10) The diameter tolerance ± 0.1 mm is permitted, if no assembly prob-
according to DIN EN ISO 13920 lems occur or are to be expected as a result (see also NTM
2005.08).
Shape and positional tolerances

- The shape and positional tolerances, apart from symmetry, coaxial and motion Z - The coaxiality and symmetry tolerance (Figure 7, 8, 9) is the same as the difference between the upper and lower tolerances for the length tolerances for the largest nominal dimension (shaped - Shape deviations in the cut surface (Figure 11) to DIN EN ISO 9013
tolerances, are limited by the dimensional tolerances. (DIN ISO1101,DIN 7167) Dimension range Accuracy elements) set in relationship for the given flats thickness.
- Perpendicularity and angularity tolerances are not laid down. The general above to E F - The straightness tolerance applies to strips (Figure 5) and for bent profiles made from strips, relating to each profile longitudinal axis. u - Perpendicularity and slope tolerance
tolerances for angle dimensions apply (β). 30 120 0,5 1 uA [mm] = 0.8+0.02a
The general tolerances for angle dimensions do not limit the shape deviations of 120 400 1 1,5 Nominal length above 2000 3000 4000 5000 These values apply above a uP [mm] = 0.8+0.02a
the shanks or surfaces forming the angle. 400 1000 1,5 3 to 2000 3000 4000 5000 6000 minimum ratio strip width (b) : thickness (s)
- For symmetry tolerances, level of accuracy C =1 mm applies 1000 2000 2 4,5 uL [mm] = 0.4 +0.01a
Straightness tolerance (n) 1 2,25 4 6,25 9 of b : s = 25 : 1
- For the concentricity and flatness tolerances, level of accuracy C = 0.5 mm applies 2000 4000 3 6 RZ = average peak to valley height
- The flatness tolerances must lie within the length dimension tolerances. 4000 8000 4 8 α - The torsion α/l (upright deviation see Figure 5) of strips cut on scissors and profiles bent from strips, may amount to a maximum of 0.5° for each 1000 mm length, if the minimum ratio strip width : RZA [µm] = 110 +(1.8a:mm)
- The longer shaped element applies as the reference element, or for concentricity 8000 12000 5 10 thickness b:s = 25:1. RZP [µm] = 110 +(1.8a:mm)
and flatness, the bearing supports, if these are labelled as such, otherwise 12000 16000 6 12
16000 20000 7 14
RZL [µm] = 70 +(1.2a:mm)
optionally each rotation-symmetrical shaped element.
20000 8 16 - For the evenness tolerance, the eveness tolerance of the semi-finished product applies. A = Autogenous cutting
- The coaxiality tolerances, when added to the concentricity tolerances, must not
exceed the values for the concentricity tolerances. Other shape and positional tolerances are - Other shape and positional tolerances are limited by the dimensional tolerances. P = Plasma cutting
- General tolerances for lines and surface shapes, as well as position, are not laid limited by the dimensional tolerances. L = Laser beam cutting
down. s = Cut thickness in mm

This English version is a translation. In case of doubt or conflict the valid German- Footnotes Page 2, Continuation Page 2 bis 3
language original will govern.

Author: Lapper Clearance: TDN Replacement for: 2005-05 Material group No.:
2005-10, englisch
MAN Nutzfahrzeuge Aktiengesellschaft, Munich Plant - Standards Department (TDN) x All rights reserved in line with ISO 16016.
Dissemination and use of the content is forbidden without the written agreement of MAN Nutzfahrzeuge Aktiengesellschaft.
 Page 2
M 3199 B1 : 2005-07

Remarks
1 If not for certain production processes, which are contained in M 3199, special standards exist for
)
general tolerances.
2 General tolerances for angle dimensions apply independently from the actual dimensions of the
)
lengths.
3 Tangential values to convert the angle tolerances into length tolerances
)

Angle 5‘ 10‘ 15‘ 20‘ 25‘ 30‘ 50‘ 1° 1°30‘ 2° 3°

Tangential 0,0015 0,0029 0,0044 0,0058 0,0073 0,0087 0,0145 0,0175 0,0262 0,0349 0,0524

4 if applicable, take note of reference point

) Standards Referred To
5 the general tolerances for the angle do not limit the shape tolerances of the shanks or surfaces form-
)
ing the angle DIN 6930 Stamped steel metal parts; technical terms of delivery
6 the values apply up to r : s = 4
) DIN 6932 Shape rulings for stamped steel metal parts
For larger values for r : s, larger deviations must be expected due to the spring-back resilience.
7 The general tolerances apply to the polished cut area (see Figure 8, Detail X). If required, the cut flash DIN 6935 Cold bending of steel flat products
)
height and the cut flash direction are to be agreed. (Reference values for cut flash heights see DIN 7168 General tolerances, length and angle dimensions, shape and position, not for new designs
DIN 9830). Production using a nibble machine is to be agreed between manufacturer and orderer. The
DIN 7167 Tolerances, connection between dimensional, shape and parallelism tolerance
wave peaks apply as actual dimension.
For notches, which lie opposite the stop side, the permissible deviations for e change by the permissi- DIN 9830 Cut flash height on stamped metal parts
ble deviations for l (Figure 9). DIN EN ISO 9013 Classification of thermal cuts; geometric product specification and quality
8 If special tolerances are required for stamped metal parts made from aluminium alloys, then these
)
must be agreed with the manufacturer. DIN EN ISO 13920 Welding, general tolerances for welded structures, lengths and angle dimensions, shape and
9 If flat cut shaped elements, which must not be influenced by the deformation process, should have
) position
tolerances conforming to the flat stamped metal parts, then this must be stated in the drawing on the
DIN ISO 1101 Tolerances, shape and positional tolerancing
shaped element. For parts deep drawn in several passes, a rippled condition and larger dimensional
deviations must be expected. M 3199 Shape accuracy, general tolerances for MN, selection
10 For controlling nominal dimensions, which coincide with the progressions, the values of the next larger
)
step-up distance apply.
11
) The dimensional tolerances only apply for aspect ratios l : b ≤4 : 1 or circumferences ≥350. The limit
deviations do not include the proportion caused by the perpendicularity or slope tolerance (u).
12 The entry of throat thickness in engineering drawings could be omitted for fillet welds in non-load- Earlier issues: MG.300.00 / 72-03, 83-07, 84-01, 84-12
)
bearing-joints with throat thickness a < 2,5mm. Generally the following values for throat thickness ap-
M 3199 B1 / 1988-06, 1990-01, 2000-03, 2004-02, 2004-05, 2004-07
ply:
0,7 ⋅ tmin ≥ a ≥ tmax − 0,5
tmax = maximum wall thickness of the parts to be joined [mm] The following changes have been made compared to the 2004-05 issue:
Changes:
tmin = minimum wall thickness of the parts to be joined [mm] - Standard changed over to overview sheet DIN A3
The values of throat thickness are shown at the arithmetic chart in Annex 1.
13 For spot-welded connections in the cab, the following applies:
) The following changes have been made compared to the 2004-07 issue:
Standard spot-welded connection: M 3368 evaluation group II
Standard spot-welded connection: M 3368 evaluation group II - Remark 12 and annex 1 new
*) For bores ∅4.5 to ∅19, the diameter tolerance +0.2 applies
°) The upper and lower tolerances laid down in Table 1 as minimum requirements according to M 3199
The following changes have been made compared to the 2005-05 issue:
conform to the tolerances of the roughest flats - that can be supplied in MN – for the thickness range.
Starting from these minimum requirements, and depending on the required material quality and sur- - Opening clause for deviating diameter tolerance ± 0.1 mm of laser cut bo-
face quality, Work Preparation can select the appropriate technologically most economical flats from res with reference to NTM 2005.08 added
the available range of MN semi-finished products.
If, in special cases, thickness tolerances are required, then either the applicable dimension standards - Footnote 13 added
or, following agreement with the standards office, the required thickness tolerances, are to be stated in
the drawing. - Reference to scope of tolerances for coated and/or painted components
x) Line numbering added
 Page 3
M 3199 B1 : 2005-07

Annex 1: Filled welds, throat thickness

t2

Throat thickness for fillet welds in non-load-bearing-joints (throat thickness a < 2,5mm)

t1
a < 2,5 mm
2,5
throat thickness amin, amax [mm]

2
graph amax

1,5

amax
1
amin Example:
graph amin
tmax = t1 = 2 mm
tmin = t2 = 1,5 mm

0,5 Values of throat thickness from dia-

gram
amax = 1,05
amin = 0,91
tmin tmax

0
0 0,5 1 1,5 2 2,5 3 3,5
wall thickness tmin, tmax [mm]