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.
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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.
Technical status January 2018
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Table of contents
6
14
30
32
4 Introduction
6 Body structure
12 Body repairs
14 Body assembly
30 Aerodynamics
32 Interior equipment
40 Occupant protection
47 Glossary
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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. Note 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.
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:
Type of driveWheelbaseRear 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.
Uniform front vehicle (enlarged image)
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Superstructure of closed panel van, long wheelbase with super high roof
Superstructure of fully glazed panel van, short wheelbase with high roof
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Superstructure of partially glazed panel van, short wheelbase with normal roof
Floor assembly for panel vans
Ladder frame for single cabin
Ladder frame for double cabin with increased space for dual tyres
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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*
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Legend: Strength of steel sheets (yield strength “Re”)
The attachments not shown, such as doors, bonnet, mudguards, and side panels are made of soft body sheet < 160 MPa.
< 160 MPa soft
< 220 MPa high-strength
< 420 MPa higher-strength
< 1000 MPa highest-strength
> 1000 MPa highest-strength hot worked
* Legend see page 7
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The increase in strength and weight reduction are achieved by the following design measures:
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Geometrical lightweight construction |
Targeted use of modern processes in |
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the production of steel sheets, e. g. |
Increasing use of high-strength and |
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highest-strength hot-formed steels |
hot forming, bake hardening and |
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tailored blank technology |
Load-appropriate application of joining processes such as resistance spot welding, laser soldering, laser welding and bonding
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Rear roof corner reinforcement area |
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Reinforcement area for A-pillar base and |
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sills |
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Wheel arch area |
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Front transverse wall area
Area of longitudinal member reinforcement in the driver's cab
End part area
Note
Hot-formed sheets must be treated separately during repair. For more information, see the relevant service literature.
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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 |
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In these vehicles it was possible to |
This results in advantages such as |
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lower the loading floor by 100 mm |
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compared to the driving space level, as |
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100 mm greater interior height |
a correspondingly lower entry height |
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no installation space is required for the |
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for vehicles with sliding doors and |
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a resulting larger loading volume |
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cardan shaft. |
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rear doors. |
Floor structure (loading floor -100 mm)
mm
100 -
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Example: short wheelbase
Vehicles with all-wheel and rear-wheel drive
These vehicles have a continuous loading floor at the level of the driving area.
The resulting installation space is required for the installation of the cardan shaft and the rear axle drive.
Floor structure (loading floor at driver's cab level)
Example: long wheelbase with overhang
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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.
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 1
Normal roof (H2*)
Roof height 2
High roof (H3*)
Roof height 3
Super high roof (H4*)
Polyester roof
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* These parameters are explained in the “MAN GUIDE 101 TGE Fundamentals” on page 9.
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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
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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
panel van and is about 193.5 mm lower than the ladder frame for the open superstructure.
The flat frame is optionally available in conjunction with an axle widened by about 200 mm.
Flat frame 3.5 t
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Load paths in the body structure
To absorb high energies in a front or |
In the event of a crash, the energy |
side crash, certain components of the |
absorbed can thus be reduced in a |
body structure are designed accordingly |
defined manner through targeted defor- |
and made of steels with specially |
mations. Other selected areas of the |
selected strengths (shown in brown). |
body structure have a supporting |
Legend
Components for high loads
Components for support functions
function (shown in green). They have the task of stabilizing the driver's cab in the event of a front or side crash.
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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
Outer region |
Door interiors |
Load compartment |
Load compartment, |
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floor, uncladded |
uncladded |
Visible, unobstructed |
Entrance areas for |
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areas above the |
defined exterior |
Bottom and wheel |
Side panels |
main sill flange |
colours |
arch |
Roof |
Legend |
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Cathodic dip painting |
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Base coat |
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Primer |
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Clear lacquer |
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The corrosion protection
The underbody, the front and rear wheel |
The layer thickness values can deviate |
arches and the outer panels of the sill |
upwards (maximum 2000μm). |
are preserved with underbody protec- |
The exterior body panel behind the rear |
tion in layer thickness values between |
wheel arches is sealed with underbody |
400μm to 1000μm. |
protection in the visible area. The PVC |
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.
Example - closed superstructure
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Legend
~ 400μm
~ 700μm
~ 1000μm
Cathodic dip painting
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
are hot-dip galvanised. The remaining galvanized sheets are electro-galva- nized.
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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
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.
Right headlamp
Mounting support
Right airflow
Foam part
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Deformation element
Condenser
Radiator
Additional oil cooler
Left headlamp
Left air flow
Bottom separation part
Bumper crossmember
Front-end service position
Guide bar
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Service position |
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Front-end pulled forward about 100 mm |
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The front bumper
The front bumper essentially consists of |
clip connections. The step and fog |
3 components, the bumper cover, the |
lights are integrated in the bumper |
radiator grille and the panel. These are |
cover. |
connected to each other exclusively via |
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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.
Bumper crossmember |
Reinforcement for step |
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Radiator grille |
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Cover for |
Supporting member |
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step |
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Chrome trim |
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Step |
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Cover for |
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step |
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Bumper cover |
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Panel |
ACC sensor support |
Supporting member |
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(clipped from behind in the lower |
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part of the bumper cover) |
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