MAN TGE Service Manual 103

MAN GUIDE 103

TGE - Body

The MAN TGE is a completely new commercial vehicle development. One of the most important goals
in the development of the TGE was to meet the increased requirements for vehicle safety, comfort, and
the optimization of payload and packing dimensions. For the car body, these goals are achieved by
using a modular body concept with a uniform front end, the increased application of adhesive technol­ogy and the use of more body panels of highest material grades. With the TGE, MAN is using highest­strength hot-formed body panels for the first time. Thanks to the completely new development, a large
number of different derivatives in 2 wheelbases, 3 vehicle lengths and 3 roof heights can be realised in
closed and open superstructures.

In addition, the Group's internal busi­ness unit “NC - Customized Solution”
offers numerous bodies and conver­sions such as box bodies, flat beds with
and without tarpaulins and three-way
tippers directly ex works.

Technical status January 2018

m103_160

The new design is based on the design
of the 6th-generation Transporter series
and relies on a consistently aerody­namic basic shape that is implemented
throughout all derivatives.

This chapter of the MAN TGE Guide
series shows you the special features of
the MAN TGE in terms of bodywork and
occupant protection.

2

taBle of contents

4 IntroductIon

6 Body structure

12 Body repaIrs

6

14 Body assemBly

30 aerodynamIcs

14

30

32

32 InterIor equIpment

40 occupant protectIon

47 Glossary

40

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 nor a repair guide! Specified values are for the sake of easy understanding
only and refer to the data status valid at the time the MAN TGE Guide was created.
The contents are not updated.
Please use the appropriate technical literature for customer advice, maintenance and repair work.

Note

Reference

3

IntroductIon

The modular design of the MAN TGE

An important goal in the development of the body structure was the creation of as many identical parts as pos­sible. Thus, the body structure is based on a modular concept. The numerous derivatives and variants, such as
different wheelbases and roof heights, must be produced with high synergy effects.

The floor structure in the front area of the MAN TGE is
the same for all vehicle variants.

The front end consists of the front side members, the
inner mudguards, the spray wall area, the lower area of
the A-pillars and the floor assembly in the area of the
driver's cab.

There are clear differences in the rear section with
regard to the floor assembly, the floor plates, the side
members, the wheel arches, the ladder frame and the
corresponding connecting parts and reinforcements.
Their design and layout is determined by the following
factors:

Uniform front vehicle
(enlarged image)

Type of drive



Wheelbase



Rear overhang



Type of superstructure



Single or dual tyres on the rear axle



Some examples of the modular structure can be seen
in the picture on the right.

4

Superstructure of closed panel van,
long wheelbase with super high roof

Superstructure of fully glazed panel van,
short wheelbase with high roof

m103_110

Ladder frame for single cabin

Ladder frame for double cabin with
increased space for dual tyres

Superstructure of partially glazed panel van,
short wheelbase with normal roof

Floor assembly for panel vans

5

Body structure

The body structure

In addition to the modular structure, the
development of the new body structure
was focused on achieving high crash

safety with low weight and optimizing
aerodynamics.

By achieving these goals, the MAN TGE
has been optimized in terms of payload,
economy and crash safety.

1*

Legend: Strength of steel sheets
(yield strength “Re”)

< 160 MPa soft

< 220 MPa high-strength

< 420 MPa higher-strength

< 1000 MPa highest-strength

> 1000 MPa highest-strength hot worked

m103_161

The attachments not shown, such as
doors, bonnet, mudguards, and side
panels are made of soft body sheet
<160MPa.

* Legend see page 7

6

The increase in strength and weight reduction are achieved by the following design measures:

Geometrical lightweight construction



Increasing use of high-strength and



highest-strength hot-formed steels

3

Targeted use of modern processes in



the production of steel sheets, e. g.
hot forming, bake hardening and
tailored blank technology

4

Load-appropriate application of



joining processes such as resistance
spot welding, laser soldering, laser
welding and bonding

5

Legend

1

2

3

2

Rear roof corner reinforcement area
(shown in graphic m103_161 on page 6)

Reinforcement area for A-pillar base and
sills

Wheel arch area

Note

Hot-formed sheets must be treated separately during repair.
For more information, see the relevant service literature.

6

m103_162

4

5

6

Front transverse wall area

Area of longitudinal member reinforcement
in the driver's cab

End part area

7

Floor structure on closed body

The closed bodies of the MAN TGE are available with two different floor structures depending on the drive concept.

Vehicles with front-wheel drive

In these vehicles it was possible to
lower the loading floor by 100 mm
compared to the driving space level, as
no installation space is required for the
cardan shaft.

Floor structure (loading floor -100 mm)

Example: short wheelbase

This results in advantages such as

100 mm greater interior height



a resulting larger loading volume



a correspondingly lower entry height



for vehicles with sliding doors and
rear doors.

-100 mm

m103_111

Vehicles with all-wheel and rear-wheel drive

These vehicles have a continuous
loading floor at the level of the driving
area.

Floor structure (loading floor at driver's cab level)

Example: long wheelbase with overhang

The resulting installation space is
required for the installation of the cardan
shaft and the rear axle drive.

m103_112

8

Roof variants on closed superstructure

The normal roof and the high roof are
made of sheet steel.
Transverse roof crossmembers reinforce
the roof.

The super high roof is made of polyes­ter. Transverse roof crossmembers are
laminated into the polyester roof for
stabilization. In addition, a reinforcing
frame is integrated in the roof.

Roof height 1
Normal roof (H2*)

Roof height 2
High roof (H3*)

Thesuper high roof is connected to the
body by bonded and screwed connec­tions. After assembly, the resulting gap
between the body and the polyester
roof element is sealed with joint seal.

Roof height 3
Super high roof (H4*)

Polyester roof

m103_113

* These parameters are explained in the “MAN GUIDE 101 TGE Fundamentals” on page 9.

9

Open vehicle superstructure with ladder frame

Vehicles with 3.5 t and 5.0 t have different ladder frames. These are adjusted to the respective
payload and the tyres used.

Ladder frame 3.5 t Ladder frame 5.0 t

Space for

Space for
dual tyres

dual tyres

A flat frame is available for the use of
special superstructures (e. g. motor
homes). It is based on the deep base
frame (without base plate) of the Crafter

Flat frame 3.5 t

panel van and is about 193.5 mm lower
than the ladder frame for the open
superstructure.

m103_163

The flat frame is optionally available in
conjunction with an axle widened by
about 200 mm.

10

m103_164

Load paths in the body structure

To absorb high energies in a front or
side crash, certain components of the
body structure are designed accordingly
and made of steels with specially
selected strengths (shown in brown).

Inthe event of a crash, the energy
absorbed can thus be reduced in a
defined manner through targeted defor­mations. Other selected areas of the
body structure have a supporting

function (shown in green). They have the
task of stabilizing the driver's cab in the
event of a front or side crash.

Legend

m103_165

Components for high loads

Components for support functions

11

Bodywork repaIr

The joining processes

Different joining processes are used in the MAN TGE for design reasons, such as resistance spot welding, laser
soldering, laser welding, and bonding technology.

The paint structure

The MAN TGE is available with solid or metallic paint. Both paint variants finally receive a clear varnish top coat.

Minimum coating thickness values

Legend

12

Outer region

Visible, unobstructed

areas above the

main sill flange

Cathodic dip painting

Primer

Door interiors

Entrance areas for

defined exterior

colours

Load compartment

floor, uncladded

Bottom and wheel

arch

Base coat

Clear lacquer

Load compartment,

uncladded

Side panels

Roof

m103_166

The corrosion protection

The underbody, the front and rear wheel
arches and the outer panels of the sill
are preserved with underbody protec­tion in layer thickness values between
400μm to 1000μm.

The layer thickness values can deviate
upwards (maximum 2000μm).
The exterior body panel behind the rear
wheel arches is sealed with underbody
protection in the visible area. The PVC

Example - closed superstructure

underbody protection is applied directly
to the cathodic dip painting. Cavities and
mounting surfaces, e. g. for the leaf
spring support, are PVC-free. All seams
and folds on the underbody are sealed
with joint seal.

Legend

~ 400μm

~ 700μm

All cavities in the lower part of the body
and on the add-on parts are treated
with cavity wax.
The layer thickness of the cavity wax is
> 30μm. The cavities of the doors are

preserved to a height of 80 mm. The
body of the MAN TGE is galvanised
except for the hot-formed sheets and
some reinforcements inside the body. All
doors, the bonnet and the mudguards

m103_167

~ 1000μm

Cathodic dip painting

are hot-dip galvanised. The remaining
galvanized sheets are electro-galva­nized.

13

Body assemBly

The front-end

The mounting support is made of sheet
steel and serves to accommodate the
radiator, the additional oil cooler and the
condenser of the air conditioning

Right headlamp

Mounting support

Right airflow

system. A reinforcement for the step is
incorporated in the mounting support.
The deformation element serves for
absorbing crash energy in the event of a

frontal impact. The front end can be
brought into service position with the
T10093 guide rods to improve acces­sibility.

Condenser

Radiator

Additional oil cooler

Left
headlamp

Foam part

m103_115

Left air flow

Bottom separation part

Bumper crossmember

Front-end service position

Guide bar
T10093

14

Deformation element

Service position
Front-end pulled forward about 100 mm

m103_114

The front bumper

The front bumper essentially consists of
3 components, the bumper cover, the
radiator grille and the panel. These are
connected to each other exclusively via

Cover for
step

Supporting member

clip connections. The step and fog
lights are integrated in the bumper
cover.

Bumper crossmember Reinforcement for step

The panel is fitted as standard on the
MAN TGE in a painted version, and is
also available as a robust grained
version as an option.

Radiator grille

Chrome trim

Step

Bumper cover

Panel ACC sensor support

(clipped from behind in the lower
part of the bumper cover)

Step Cover for

step

Supporting member

m103_116

15