MAN TGE Service Manual 101
MAN GUIDE 101
TGE basics
With its new TGE, MAN is joining the world of transporters for the first time. What started in the past at
7.5 tons, now begins at maximum permissible weight
of 3.0 tons. Using the new TGE, MAN transfers the
usually customer-focussed truck business to the
category of delivery trucks. The TGE from MAN is a
light commercial vehicle which - flanked by its big
brothers - inspires users with enthusiasm who have
performed professional work with heavy trucks for a
long time. Excellent TGE sales consultants will always
provide a customized solution.
MAN as a full-range offerer
up to 18.4 cubic metres of loading space
engines from 75 kW to 130 kW
standard safety by emergency brake assistants
service and use around the clock
For example, MAN identifies the target groups in the
logistic and construction area. Also, sectoral requirements from handicraft and passenger transportation
businesses can be future applications of the light
“truck” from the MAN Truck & Bus company. All applications have the following in common: Thanks to the
lowest c
its class as well as the lowest maintenance and repair
costs, the best Total Cost of Ownership (TCO) of the
new MAN TGE is inspiring.
-value of 0.33 and the lowest consumption of
W
In addition to the panel van and the glazed estate car,
the chassis with their single-compartment and twincompartment cabs increase the offer of body types.
Two wheelbases, three roof heights and three vehicle
lengths are options. Always available: the loading
space illuminated by LED lamps.
Also, there are lots of drive types. Depending on the
maximum permissible gross weight, front-wheel or
rear-wheel and all-wheel drives are possible, optionally
coupled with a 6-speed manual gearbox or an
8-speed automatic transmission. 2.0L engines with
75kW / 102 HP, 90 kW / 122 HP, 103 kW / 140 HP,
and 130 kW / 177 HP are available.
With its standard emergency brake assist (EBA), MAN
considerably contributes to road-traffic safety. To this
effect, distance sensors review critical distances to the
vehicle in the front, helping reduce the stopping distance. In addition, the integrated city emergency brake
function automatically decelerates the vehicle at low
speeds and thus reduces one of the most frequent
causes of accidents. The adaptive cruise control
system provides great convenience on long highway
distances. The fatigue detection system and the
multi-collision brake have been designed for the safety
of everybody.
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2
CONTENTS
4 INTRODUCTION
14 VEHICLE BODY
16 POWER UNITS
14
22 POWER TRANSMISSION
30 RUNNING GEAR
16
38 ELECTRICAL SYSTEM
22
52 HEATING AND AIR
CONDITIONING
59 RADIO, TELEPHONE AND
NAVIGATION
38
52
The MAN TGE Guide teaches the basics of design and function for sales and after-sales of new vehicle models, new
vehicle components or new technologies.
The MAN TGE Guide is not a sales manual and not a repair guide! The specified values are for the sake of ease of
understanding only and refer to the data status valid at the time the MAN TGE Guide was created.
The contents are not updated.
For customer advice, maintenance and repair work, please use the appropriate technical literature.
59
Note
Reference
3
INTRODUCTION
Die Trucknology Generation
With the newly developed MAN TGE, MAN Truck & Bus is now for the first time making its commercial vehicle expertise in the
range from 3.0 to 41 tons (50 tons) available to all customers, as a full-range supplier.
The TGX, TGS, TGM and TGL series offer the customer the optimum vehicle base for individual transport solutions with total
weights from 7.49 to 41 tons (50 tons) and engine outputs from 150 hp to 640 hp. The MAN TGE now rounds this off between
3.0 and 5.5 tons total weight and an engine output of 105 hp to 175 hp and three drive variants.
MAN TGX To be successful in international long-
distance traffic, to shift up a gear in terms of transport
performance and to put the brakes on costs. This is what
the MAN TGX stands for, setting the standard for maximum
energy efficiency, reliability and economy with its exhaust
gas-optimized engines of up to 640 hp.
MAN TGS The MAN TGS is uniquely versatile:
Whether for heavy-duty local transport, on construction sites,
in municipal transport or as a specialist for special tasks, the
xxx is a versatile truck that is perfectly tailored to every sector
of industry.
MAN TGM In distribution traffic and also in
medium-heavy traction traffic, the MAN TGM is heavily
involved. With tonnages of between 13 and 26 tons and a
first-class payload, it offers economical transport solutions
for construction sites.
MAN TGL The MAN TGL is the solution for fresh
produce, construction, municipal use, furniture transport,
trade and industry. The 7.49 to 12 ton trucks are very
manoeuvrable and combine maximum payload with
dynamic driving characteristics.
The MAN TGE with its powerful commercial vehicle roots is ideally
equipped to meet the diverse challenges of the transporter market from 3.0 to 5.5 tons.
The MAN TGE always offers the right solution for tough everyday working conditions, be
it in the forest, on the construction site or in the confusing urban jungle. With its outstanding driving comfort, numerous assistance systems and a driver‘s cab at passenger car
level, it is the new benchmark in the transporter segment.
MAN TGE
4
The production site
Since the laying of the foundation stone
in November 2014, Europe‘s most
modern plant of this kind has been built
in Wrzesnia, a city with around 30,000
inhabitants about 50 kilometres east of
Poznan, in just 23 months.
The production of the MAN TGE began
here on April 3, 2017, of which 100,000
units per year are to be produced by up
to 3,000 employees, together with the
identical VW Crafter.
In addition to the production halls for
vehicle assembly, a modern paint shop
and a supplier park with logistics areas
were built on the site. The development
of the supplier network and the service
sector has also created numerous new
jobs in the vicinity of the plant.
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5
The product features of the MAN TGE
The following overview shows the 25 most important unique selling propositions and „Best in Class“ characteristics.
The safest transporter in its class thanks to versatile equipment and assistance
systems:
Emergency brake assistant as standard
Automatic Post-Collision Braking System
Automatic Distance Control (ACC)
Trailer manoeuvring assist
Lane departure warning
Lane change assistant with parking assistant
Cornering light
Headlights in LED technology
Side wind assistant
ESC with combination stabilization
Most comfortable driver‘s workplace:
Well designed storage compartment concept
Ergonomic seats with optional massage function
230 V socket in the cab
Innovative media systems
Clear displays and instruments
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Economy to the limit:
State-of-the-art engine-gearbox configurations
Streamlined body shape
Lightweight construction in every detail
Integration into fleet management systems
Versatile solution for every application:
Front, rear and all-wheel drive
Manual and automatic transmissions
Three possible vehicle lengths
Three possible roof heights
Four different body shapes
Universal floor with preparations for built-in
components
Optional longitudinal and transverse rails in the loading floor
Rear end free from technical equipment for various conversion
solutions
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6
The notable characteristics of the MAN TGE
Vehicle front in striking MAN family
design
Modern workstation with ergonomic control panel and clearly
arranged instruments
LED headlights
Adjustable driver and front
passenger seats – also as
swing seat and AGR seat
(with seal of approval from the
campaign for healthy backs)
with electrical lumbar support
Loadspace with universal floor and a
wide variety of installation options
Tail light clusters with connecting character line
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7
Derivatives
Panel van Double cab
Window van Single cab
The MAN TGE has an extensive range
of models to choose the vehicle best
suited to customer requirements. In
total, there is a choice of 69 body and
powertrain variants.
The four basic variants panel van,
window van and platform van with
single or double cab meet the highest
demands in their respective customer
segments.
The individual body shapes can be
further customized with different wheel
bases and roof heights.
In addition to the standard body
shapes, the following derivatives are
also available for extensive customeroriented special configurations:
Carriage with flat frame chassis
Cowl panel
Platform
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8
Dimension variants
Wheelbases
Two wheelbases are available.
Standard wheelbase: 3640 mm (L3)
Long wheelbase: 4490 mm (L4/L5)
Rear overhangs
Two rear overhang lengths are available
for the long wheelbase.
Long: 1346 mm (L3/L4)
Extra long : 1901 mm1) (L5)
Roof heights (panel van, window van)
Three roof heights are available.
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Normal roof: 2355 / 2390 mm2) (H2)
High roof: 2590 / 2625 - 2637mm 2) (H3)
Super high roof: 2798 / 2830 - 2835
1), 2)
mm (H4)
Cabs (platform van, chassis)
Two cab sizes are available for the transport of additional
persons:
Single cab with maximum seat configuration 2+1
Double cab with maximum seat configuration 6+1
Platform lengths
Ex factory, three platform lengths are available with single cab (SC) and a further
platform length for double cab (DC).
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Standard single cab: 3500 mm
Long single cab: 4300 mm
Extra long single cab: 4700 mm
Standard double cab: 2700 mm
Long double cab: 3500 mm
1)
Not with window van.
2)
Single/twin tyres
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9
Technical data
Panel van, window van
3640 – 44901000 1346 – 1901
5986 – 7391
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210 / 214
1773
2425 – 2427
All figures are in millimetres.
Note
The illustrations only show selected variants and their dimensions/dimension areas. For the complete technical data
for the entire model range, please refer to the current sales literature.
10
2355 – 2835
1)
1)
1)
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1766 – 1788 / 1601
2040 / 2069
1)
Single/twin tyres
Single cab, double cab
1000 3640 – 4490 1514 – 1914
3500 – 4700
6204 – 7404
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2321 – 2352 2305 – 2327
2700 – 3500
1000 3640 – 4490 1514 – 1564
6204 – 7004
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All figures are in millimetres.
11
Load compartment measurements
B D
A
Sliding door width 1311
B
Sliding door height 1430 – 1587 / 1668 – 1822
C
Maximum loadspace length 3201 – 4606
D
Maximum loadspace height 1568 – 2196
E
Height of rear wing door 1451 – 1605 / 1684 – 1840
F
Loading height/loadsill 570 – 725 / 1000 – 1050
G
Maximum loadspace width 1832
H
Width between wheel housings 1375 – 1380 / 1030
I
Maximum platform height 400
J
Maximum platform width external 2098
A
C
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1)
5)
1)
2)
3)
All figures are in
millimetres for vehicles
with front-wheel drive.
1)
Normal roof / High roof,
Super high roof
2)
Panel, window / platform
3)
Single / twin tyres
4)
Front and four-wheel drive /
rear-wheel drive
5)
incl. 15 cm subfloor storage
compartment
Window van, panel van Flatbed
E
F
H
G
K
Maximum loadspace area 5,16 – 8,99 m
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Maximum trailer weight 3000 / 3500 kg
Gross vehicle weight 3500 – 5500 kg
K
I
F
J
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2
4)
12
The vehicle concept
Drive system types
Prior to the development of the MAN
TGE, intensive customer surveys were
conducted and market requirements
Front-wheel drive
The drive unit is installed transversally.
Features are:
low loadspace floor (about -100 mm),
thereby increasing the loadspace
volume and reducing the loadsill
height
Rear end without drive technology
Driveline with reduced weight
(approx. 100 kg less), lower fuel
consumption
Applications include courier and
logistics services, joiners/plumbers/
glaziers, etc. and rescue services.
All-wheel drive 4x4
were taken into account in the design
process.
For the first time, three types of drive are
used in the MAN TGE and VW Crafter.
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The drive unit is installed transversally.
Features are:
Electronically controlled multi-plate
clutch
Optimum traction
Particularly suitable for regions with
poor weather conditions or roads
Applications include the building trade
and forestry as well as the police and
military.
Rear wheel drive
The drive unit is in inline installation.
Features are:
Good traction for high loads
Higher gross vehicle weight rating
possible (up to 5.5 t)
Single or twin tyres at rear
Use of auxiliary drives on the gearbox
(e.g. for body manufacturer) possible
Applications include service vehicles
and mobile workshops with heavy
built-in components as well as special
bodies.
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13
VEHICLE BODY
Body structure
The body of the MAN TGE has been
completely redesigned. In addition to
the modular design, the developers
focused on optimizing weight and
aerodynamics as well as crash safety.
These goals were achieved, among
other things, by the use of higheststrength hot-formed steels. Compared
to conventional steels, these are considerably stronger at a similar weight and
thus make the MAN TGE lighter and
safer.
The following components are made
from hot-formed steel:
Front roof side members
Sill panel reinforcement
Corner reinforcement on the rear roof
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A-pillar bottom part
Front bulkhead
Longitudinal member reinforcement
for driver‘s cab
14
Modular structure
Use of as many identical parts as
possible was an important goal during
development of the body structure. The
objective was to allow the numerous
derivatives and variants such as different
wheelbases and roof heights to be
manufactured with great synergy
effects.
Vehicle front end the
same for all variants
Floor structure
The floor structure of the MANTGE is
the same for all variants in the vehicle
front end area. At the rear end, however,
there are significant differences regarding the floor panel, longitudinal
members, wheel housings and the
corresponding connecting parts as well
Vehicle rear end different depending on
the variant, in this case short wheelbase
with low loadspace floor (-100 mm)
as reinforcements. Their configuration
and design are determined by the
following factors:
Type of drive
Wheelbase
Rear overhang
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Type of body
Single or twin tyres on the rear axle
15
POWER UNITS
Engine/gearbox combinations
Transverse
installation
6-speed
Manual gearbox
0AX front-wheel drive
6-speed
Manual gearbox
0AX four-wheel drive
8-speed
Automatic gearbox
09Q front-wheel drive
2.0l Turbo diesel
75 kW
DAUB
2.0l Turbo diesel
103 kW
DAUA
2.0l Biturbo diesel
130 kW
DAVA
8-speed
Automatic gearbox
09Q four-wheel drive
Longitudinal
installation
6-speed
Manual gearbox
0F6 rear-wheel drive
8-speed
Automatic gearbox
0DR rear-wheel drive
2.0l Turbo diesel
90 kW
DASA
2.0l Turbo diesel
103 kW
DASB
2.0l Biturbo diesel
130 kW
DAWB
16
The 2.0 l turbo diesel engines
In the MAN TGE, only 2.0-litre turbo diesel engines from the MDBnutz modular diesel construction kit are used. The use of a
uniform engine geometry with many identical parts creates high synergy effects and reduces manufacturing and maintenance
costs.
Transverse installation Longitudinal installationtion
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The engines of the MAN TGE have been
specially designed for commercial
vehicles to meet the high requirements
in terms of mileage, driving resistance,
driving profile and service life.
Adjustments were made, for example,
to the intercooling, the cylinder head,
the variable-length intake manifold, the
EGR cooler, the turbochargers and the
oil pan.
The installation position is adapted to
the commercial vehicle design.
Depending on the drive concept used,
the engines are installed transversely or
longitudinally - an absolute special
feature within a vehicle series.
In addition, transversely installed
engines are installed at an angle of 8° to
the front in order to make optimum use
of the available installation space.
Longitudinally installed engines have a
larger oil pan and an increased oil
quantity.
Engines with one or two turbochargers
are used. A total of up to four power
stages are available, ranging from 75
kW to 130 kW. The after-treatment of
the exhaust gases is carried out by an
SCR system for nitrogen oxide reduction. Additional options, e. g. different
generators and compressors, are
possible with the accessory drive used.
17
Technical data
The engine is part of the engine series EA288nutz and
is installed in this design – beside the MAN GTE – only
in the VW Transporter and Crafter. The engine is
available in the EU6 plus and EURO VI exhaust emission standards, depending on the application.
Technical features
Liquid-cooled charge air cooler
High-pressure exhaust gas recirculation
Delphi common rail direct injection
Liquid-cooled injector for reducing agent
Injectors with solenoid valve
Single-plunger high-pressure pump (monoturbo),
double-plunger high-pressure pump (biturbo)
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Motor designation 2.0 l Turbo diesel
75 kW
Engine code DAUB DASA DAUA / DASB
Capacity 1968 cm
Type 4-cylinder in-line engine
Valves per cylinder 4
Bore 81.0 mm
Stroke 95.5 mm
Compression ratio 15.5 : 1
Maximum output
at rpm
Max. torque
at rpm
Engine management Delphi DCM6.2
Fuel DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Forced induction Mono turbo Mono turbo Mono turbo Biturbo
75 kW
at 3250 – 3500
300 Nm
at 1400 – 2250
2.0 l Turbo diesel
90 kW
90 kW
at 3250 – 3500
300 Nm
at 1400 – 2250
2.0 l Turbo diesel
103 kW
1)
3
103 kW
at 3500 – 3600
340 Nm
at 1600 – 2250
2.0 l Biturbo diesel
130 kW
DAVA / DAWA
130 kW
at 3600
410 Nm
at 1500 – 2000
Exhaust gas
recirculation
Emission standard
1)
Longitudinal/transversal
2)
EU6 plus: Light duty homologation <2840 kg reference weight (roller test bench)
EURO VI: Heavy duty homologation >2380 kg reference weight (engine test bench)
18
yes yes yes yes
2)
EU6 plus EURO VI EU6, EU6 plus EU6, EU6 plus,
EURO V/VI
Ancillary drive
An ancillary drive with modular expansion capability is used in response to
the wide variety of customer requirements. In addition to the usual units
such as an alternator and air conditioner
compressor, it is also possible to drive
an additional air conditioner compressor
or additional alternator. In vehicles with
bodies such as camper vans or refrigerated vans, this allows the required form
of energy to be provided, e.g. for air
conditioning, cooling or driving electrically operated ancillaries.
An elastic belt alone is used as the poly
V-belt in an engine with alternator. In all
other variants, the poly V-belt is tensioned using a belt tensioner.
Basic drive Air conditioning drive
Alternator
(various
power levels)
Alternator
(various
power levels)
Air conditioner
compressors
Additional drive
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Alternator
(various
power levels)
Air conditioner
compressors
Additional
alternator
(in 180 A version)
Alternator
(various
power levels)
Air conditioner
compressors
Additional air
conditioner
compressor
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19
Exhaust system
The exhaust system of the MANTGE is available in various variants. Its structure depends on the engine or body variant, for
example.
Inline installation, EU6
Transverse installation, EU6
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Exhaust gas treatment
In vehicles with SCR system (EU6 exhaust standard), there is a lambda probe (oxygen sensor) in the front part of the exhaust
pipe as well as three temperature sensors, the injector for reducing agent as well as the corresponding catalytic converters.
Lambda probe
Oxidising catalytic converter
Temperature sensor 3
Temperature sensor 2
Diesel particulate filter
with SCR coating
Trap catalytic converter
Particle mass sensor
sensor
NO
x
20
Injector for reducing
agent N474
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