MAN TGE Service Manual 106
MAN GUIDE 106
The eTGE
The high-voltage components and the technologies used for the remaining subassemblies guarantee safe and comfortable
mobility. The electric motor boasts a power output of 100 kW and develops a maximum torque of 290 Nm from a standstill.
Depending on the vehicle payload, route and driving profile, the real range is approx. 120 km. According to the NEDC, the range
is 173 km. In the new, more challenging WLTC, the range is 110 / 114 km. The nominal energy of the lithium-ion high-voltage
battery is 35.8 kWh. The recuperation, i.e. the braking energy recovery, has been adapted for the eTGE with three-phase drive.
Under certain circumstances, the three-phase current drive can cause a deceleration when in alternator mode. The power and
control electronics for the electric drive supplies the energy generated to the high-voltage battery. Withthe eTGE, MAN is paving
the way for sustainable, future-proof mobility.
Technical status April 2019
2
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Attention! Dangerous electric voltage!
The eTGE is a battery-driven electric vehicle. It features a high-voltage system with a rated voltage
of 323 volts. This voltage level can be fatal. Only qualified employees may perform work on this
vehicle. The minimum qualification required is an electrically instructed person.
taBle of contents
4 IntroductIon
6 Body
8 Power transmIssIon
10 HeatIng and aIr condItIonIng
16 drIver assIst systems
4
18 HIgH-voltage system
30 electrIcal system
8
38 InfotaInment
41 servIce
43 test your knowledge
18
38
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 eTGE
The electric van is based on the TGE 2017. Like the versions with diesel engines, the new eTGE
isalso equipped with state-of-the-art assistance and comfort systems.
Because the battery is integrated in the underbody, the charging volume of the electric version
withjust under 10.7 m
The payload of the eTGE is approx. 1.0 tonne at a gross vehicle weight of 3.5 tonnes.
3
remains at the level of the conventional models with rear-wheel drive.
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4
The characteristic features of the eTGE
eTGE emblems in the front grille, on the side panels, in front
of the wheel arches and at the rear left of the wing door at
the height of the tail light
e-specific displays in MAN Media Van Advanced
Instrument panel with e-specific displays
Charging socket behind the tank cap
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5
Body
Body structure
The body structure is based on the vehicle body
featured in the TGE 2017. In order to do justice to
crash safety requirements, the necessary changes to
the geometry were implemented in the underbody, and
additional components have been utilised.
Battery frame
Key
Body changes specifically for the eTGE
6
Underbody
The underbody has been extended, which allows
installation of the high-voltage battery, also allowing
thestricter impact requirements this involves to be
satisfied. In the lateral areas, additional crash elements
are installed between the high-voltage battery and the
sill panels. A support frame is located under the middle
of the underbody, which serves as protection for the
high-voltage battery from below. To protect against
dirt, and to improve the drag coefficient, the front of
the underbody features an underbody impact guard
and there are 4underbody covers in the middle.
Crash elements
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7
Power transmIssIon
The 0MD 1-speed transmission
The 1-gear drive 0MD of the eTGE consists of proven
components of the group. Thereby, all components,
especially the lubrication in the gearbox, were optimally
designed to fulfil the high requirements in the
commercial vehicles sector.
Three-phase current drive VX54
1-speed transmission
0MD
Technical data
Transmission designation
Number of gears
Transmission stages
Transmission ratios
Max. input torque
Max. input speed
Weight (with oil)
Oil volume
Driveshafts
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0MD
1
2
Level 1: 3.192 (Z1 = 26; Z2 = 83)
Level 2: 3.609 (Z3 = 23; Z4 = 83)
290 Nm
12,000 rpm
32.2 kg
1.5 l
Splined connection
8
Oil supply system
Oil holes
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The 1-speed gearbox 0MD of the eTGE uses splash
lubrication. To ensure permanent lubrication, the final
drive gear runs in the oil sump. This requires an
appropriate design of the gearbox housing to ensure
lubrication, cooling and oil distribution. Lubrication of
the bearings for the drive shaft, drive shaft and axle
drive is ensured on the gearbox and motor housing
side by 2transverse bores and grooves behind the
bearing shells.
Other necessary measures:
Reinforced tapered roller bearings
Reinforced and larger parking lock
Reinforced toothing of the drive gears
Reinforced differential
Selector lever
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The 1-gear gearbox 0MD and the selector lever E313
are connected by a cable. This mechanical connection
is used only to activate the parking lock. The mechanical and electrical components of the selector lever are
installed in the housing of the selector lever E313. The
locking mechanism for the selector lever E313 is
provided by the selector lever lock solenoid N110. In
the event of a defect or a power failure, the selector
lever E313 remains locked. The manual emergency
release is located on the left of the selector mechanism. To unlock the selector lever lock, pull the locking
lever backwards and press the selector lever lock
button at the same time.
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9
HeatIng and aIr condItIonIng
Overview of components
A 2-zone Climatronic is installed as series standard.
The interior air conditioning of the vehicle is carried out
entirely with a heat pump system via the operating
states “cooling” and “heating”. For cooling, the
refrigerant circuit is switched on in the same way as for
a normal air conditioning system. The system can
switch from cooling to heating via the modified control
of the expansion and shut-off valves. The hot
refrigerant coming from the compressor is passed over
the heating condenser and gives off its heat there to
the air flowing through, which heats the interior. The
Climatronic control unit J255 controls and monitors the
temperature sensors and the air and temperature flaps
in the interior. The thermal management control unit
J1024 controls, regulates and manages the expansion
valves, shut-off valves, high voltage heating (PTC)
Z115, electric air conditioning compressor and
refrigerant pressure and temperature senders.
High-voltage heater (PTC) Z115
Electrical air conditioner compressor V470
10
The high-voltage heating (PTC) Z115 and the electric
air conditioning compressor V470 operate on demand
from the air conditioning control unit for heating/
cooling. The set temperature request is sent via CAN
bus to the thermal management control unit J1024.
The e-Manager can be used to program the auxiliary
air conditioning with three departure times (timer).
e-Manager
Climatronic control unit J255
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HeatIng and aIr condItIonIng
System overview
V470
G395
1
G827
2
G828
Refrigerant circuit
Coolant circuit
N643
G829
N642
N696
N636 G826
3
4
5
N637 N638
6
G785
N632
G789
JX1
V508
G83
9
G110
Z115
V509
G787
8
10
8
AX4
VX54
G788
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12
Key
AX4
Charging unit 1 for high-voltage battery
G83 Radiator outlet coolant temperature
sender
G110 Air conditioning system coolant tempera-
ture sender
G395 Refrigerant pressure and temperature
sender 1
G785 Temperature sender in the high-voltage
heater (PTC)
G787
Temperature sender after heat exchanger
G788 Temperature sender after electric drive
motor
G789 Temperature sender after power and
control electronics for electric drive
G826 Refrigerant pressure and temperature
sender 2
G827 Refrigerant pressure and temperature
sender 3
G828 Refrigerant pressure and temperature
sender 4
G829 Refrigerant pressure and temperature
sender 5
JX1 Power and control electronics for electric
drive
N632
N636
N637
N638
N642
N643
N696
V470
Coolant changeover valve 1
Refrigerant expansion valve 1
Refrigerant expansion valve 2
Refrigerant expansion valve 3
Refrigerant shut-off valve 4
Refrigerant shut-off valve 5
Refrigerant shut-off valve 1
Electrical air conditioner compressor
V508 Coolant circulation pump before power
and control electronics for electric drive
V509 Coolant circulation pump before high-vol-
tage heater (PTC)
VX54
Z115
Three-phase current drive
The high-voltage heater (PTC)
1
2
3
4
5
6
Dryer
Condenser
Evaporator
Temperature flap
Heat condenser
Heat exchanger for heat condenser
7 Internal temperature sender in the high-
voltage heater (PTC)
8
9
10
Non-return valve
Thermostat
Cooler
Refrigerant circuit
Coolant circuit
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HeatIng and aIr condItIonIng
Expansion valves and shut-off valves
The refrigerant circuit has three expansion valves and three shut-off valves.
Expansion valve
The expansion valves are designed as ball valves with a V-shaped
control edge increasing in size. The expansion valves are actuated by
the thermal management control unit J1024 as and when required.
The electric valve is controlled so as to take any position between 0%
(closed) and 100% (fully open). The expansion valves are all identical
in design and are connected to the thermal management control unit
via a LIN bus.
The refrigerant flows through the N637 (EXV2) in one direction or the
other according to the function (heating or cooling).
Coolant
The shut-off valves have been designed as ball valves. They are all
identical in design and are connected to the thermal management
control unit via a LIN bus. The valves can be 0% (closed) or 100%
(fully open).
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Note
When a valve is replaced, it must be readdressed via the
diagnostic software in the thermal management control
unit J1024.
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