MAN at the IAA Commercial Vehicles 2016: a future-proof portfolio
MAN is presenting its new future-proof portfolio at the IAA in Hanover - the world's largest trade fair for commercial vehicles.
With the world première of the new MAN TGE, MAN is extending its product portfolio to include vehicles with a permissible gross weight starting at 3.0 tonnes, making it a full service provider for all transport requirements. MAN’s strong brand presence is rounded off by engines with new power levels, finely tuned transmissions, new interior and exterior design features focussing on the MAN lion trademark, as well as the introduction of the latest member of their coach family, the NEOPLAN Tourliner. At the same time, the traditional Munich-based manufacturer is preparing for the logistics of the future with new digital products and services.
A particular highlight of this year's IAA is the world première of MAN's new transporter product range, TGE. This commercial vehicle for distribution transport and the building trade can handle permissible gross weights from 3.0 to 5.5 tonnes, thus making MAN a full service provider. The new MAN TGE will be available in numerous customisable variants, boasting the best Total Cost of Ownership (TCO) and an impressive payload of up to 1.5 tonnes. The completely new diesel engine generation installed in the vehicles is characterised by its durability, reliability and economy, promising new peak performances for the new MAN TGE when it comes to efficiency and the environment. At the same time, state-of-the-art assistance systems offer maximum safety and the usual professional MAN service is of course always at hand.
More power and a new design
In terms of design, MAN will be presenting a wide range of new features at the IAA. With regard to exterior design, greater emphasis will be placed on the MAN lion as an emotional marker. Appearing in a bold new design against a shiny black background, the lion on the chrome clasp above the grille is now even more prominent. The interior also devotes more attention to the lion, while the newly developed bright colours and fabrics for all textile surfaces create a completely new sense of space. The changes to the exterior and interior will be implemented on all new vehicles in the TGL, TGM, TGS and TGX series. With the new PerformanceLine edition of the TGX with an output of up to 640 HP, MAN combines top performance with equally high design standards in their strongest model.
The third generation of the tried-and-tested TGX EfficientLine was able to demonstrate even further improvements to its economic fuel savings potential during a 4000 km comparison run across Europe against its predecessor. Also on the trip was TÜV SÜD, which confirmed that the MAN TGX EfficientLine 3 provides additional fuel savings of 6.35% compared to the MAN TGX EfficientLine 2.
MAN Truck & Bus will also be presenting a range of measures designed to optimise the D26 and D38 engines at the IAA. The new engines offer more torque and greater performance with lower consumption. The new D26 and D38 engines also feature a new, more reactive catalyst material for the SCR system, which means that combustion and exhaust gas treatment can be optimised so that consumption is reduced even further.
The top engine model with 640 HP, which was previously reserved solely for heavy-duty versions, is now available for almost all variants of the MAN TGX D38. All other power levels have been increased by 20 HP respectively, meaning that MAN now offers 540 HP and 580 HP with the new D38. The tried-and-tested D26 engine also benefits from an additional 20 HP and 200 Nm in its new version, reaching a peak performance of 500 HP. In addition to the numerous emission-reducing measures, this engine now features the electronically-regulated engine brake EVBec as standard.
The two tried-and-tested MAN engine series D08 and D20 also come with a range of new features, which contribute to further reductions in fuel consumption while helping to maintain the engines' proven reliability.
A new member of the family and a wide range of new features
The NEOPLAN Tourliner is making its world debut in the bus sector as a new entry model in the field of premium coaches. The flexible usage possibilities, the large number of assistance systems and the excellent efficiency make the new NEOPLAN Tourliner a real all-rounder in its field. All new bus models also benefit from improved engine and transmission functions that offer increased torque and output as part of the optimised drive train, all whilst retaining the same low levels of consumption.
With its comprehensive bus portfolio, MAN has the perfect solution for every requirement in the field of intercity buses, city buses and coaches. City buses with a variety of available drive concepts already provide solutions for a modern public transport system, with the MAN Lion’s City CNG, for example, allowing for CO2-free operation thanks to the use of biogas. The MAN Lion’s City Hybrid reduces fuel consumption by recovering the kinetic energy used for braking and coasting.
All coach and intercity chassis also feature the latest assistance systems, which contribute to safety, comfort and efficiency. Another innovation in this area that will be presented at the IAA is the latest generation of pre-emptive cruise control systems, MAN EfficientCruise, which now for the first time features the EfficientRoll freewheel function that permits further optimisations to the fuel efficiency of MAN and NEOPLAN coaches. The MAN and NEOPLAN coaches also meet accessibility requirements stipulated for long-distance transport services in each segment.
With its new digital products and services, MAN is paving the way for the logistics of the future. At the IAA 2016, MAN is devoting a special platform to RIO – the new brand in the field of digital solutions from Volkswagen Truck & Bus. RIO is an open, cross-manufacturer business and technology platform that provides individual and uniquely intuitive digital services for the entire transportation and logistics ecosystem. Digital recording and processing and wide-reaching, cross-company utilisation of data forms the basis for the intelligent control of logistical processes. The transport chain is made up of both data providers and data users. As the initiator of RIO, MAN is responsible for its development within the Volkswagen Truck & Bus Group.
With regard to eMobility, MAN will be introducing a number of innovations at the IAA 2016. As well as presenting the fully electric MAN Lion’s City articulated bus as a concept vehicle and introducing different charging infrastructure concepts, MAN Truck & Bus will also be showcasing a TGS semitrailer tractor with electric drive for use in applications relating to inner-city night-time supply. Optimised for use with a city semitrailer, the concept vehicle offers a high load volume with a low tare weight, and is free from emissions (CO2, NOx, noise).
Thanks to its many years of experience with electrified drivetrains and the electrification of further components in the MAN Lion's City Hybrid, MAN Truck & Bus is in an excellent position to provide transport companies with a practical and efficient solution in the electric bus segment. MAN relies on a modular approach, through which charging technology can be selected and combined as needed, with the number of storage modules depending on the required range and transport capacity. In 2018, MAN will be sending a pre-series bus version of a battery electric vehicle (BEV) for field testing as part of its eMobility roadmap. Series production of a 100% electrically-driven city bus will commence before 2020.
The technological expertise from the eMobility modular system in the bus sector will in future also be available for electric truck applications. In addition, MAN’s membership in the Volkswagen Group means that it can utilise synergies within the Group and draw value from the dynamics of the passenger car sector.
MAN Latin America at the IAA
MAN Latin America will also be attending the trade fair, showcasing their truck range with two Constellation type trucks. The first is as a VW Constellation CNG truck with emission levels that meet the Euro 6 standard, the second a VW Constellation anniversary model, which celebrates its 10th anniversary with an improved transmission and high-quality interior details. The focus here is on environmental aspects, with the environmentally-friendly driver's cab partly fitted out with recycled materials. The third trade fair exhibit presented by MAN Latin America at the IAA 2016 is a Volksbus powered by sugar cane diesel.
MAN trucks at the IAA 2016
MAN presents a strong future-proof portfolio of trucks at the IAA 2016. For the 2017 range, MAN combines engines with new power levels of up to 640 HP and higher torque with finely tuned transmissions and switching functions for application-optimised drivetrains. This is accompanied by a strong brand identity. Exterior and interior design innovations in the TG range strongly place the trademark of the lion in the foreground. At the same time, the traditional Munich-based manufacturer is preparing for the logistics business of the future with new digital products and services.
MAN trucks at the IAA 2016: more efficient, more economical, networkedThe new MAN trucks receive impressive innovations in both the exterior and interior, together with an even more efficient driveline. (From the left: TGS, TGM, TGX, and again the TGS)
MAN is taking numerous steps to optimise its engine programme for the 2017 range. These ensure significantly improved fuel consumption with increased performance and driving dynamics as well as the expected high level of reliability. The new generation D38 engine offers up to 640 HP and reaches its greatest torque - up to 3000 Nm - even at low engine speeds. Optimised for fleet applications, the new D26 offers a power spectrum from 420 to 500 HP with a simultaneously low tare weight and low fuel consumption. In combination with the new versions of the MAN TipMatic transmission with individually tuned driving programmes for every area of application, the MAN ranges also have highly efficient, economical and environmentally-friendly drivetrains.
EfficientLine 3 achieves additional fuel savings of 6.35%
Additionally, MAN will be bringing the latest version of the EfficientLine concept to the IAA, which combines all of the technical and aerodynamic fuel efficiency measures into one truck. To clearly demonstrate the fuel saving potential of the new EfficientLine 3 generation, MAN carried out a fuel consumption test journey with an MAN TGX 18.500 4x2 BLS EfficientLine 3 semitrailer tractor in July. The basis for comparison was provided by the truck's predecessor model - an MAN TGX 18.480 4x2 BLS EfficientLine 2 - which travelled with it along the same route. TÜV SÜD monitored how the measured values were determined. The official results confirmed that the EfficientLine 3 saves another 6.35% in fuel over 100 kilometres compared to an identically configured EfficientLine 2.
The new flagship with 640 HP: TGX PerformanceLine Edition
In addition, MAN will also be unveiling numerous design innovations for its TG series at the IAA 2016. Externally, the MAN lion stands proudly in the foreground. TGX and TGS receive newly designed and dynamic cooling air intakes. On the inside, warm colours with new materials and seat upholstery lend all TG models a bright and high quality feel, which is complemented by the distinctive steering wheel design. Furthermore, the driver’s workplace benefits from a new Infotainment system, automatic headlight activation and rain sensors in all models. The new MAN MMT Media Truck Advanced infotainment system is available in 5” and 7” screen versions, and offers a wide range of new features such as digital radio reception, effective traffic information, connection options for different auxiliary devices and a truck-specific navigation function upon request. As its absolute top model in the TGX series, MAN will be presenting the PerformanceLine Edition at the IAA 2016. As well as the numerous exclusive interior and exterior design elements, this special series also boasts the top-of-the-range engine with an output of up to 640 HP.
Looking to the future with connectivity and eMobility
On the topic of alternative drives, MAN will be presenting an electric mobility concept vehicle in Hanover. The purely electrically-powered MAN TGS semitrailer tractor has been designed for inner-city night-time deliveries, such as store deliveries in the food retailing sector. The concept truck offers a generous load volume with a low tare weight, and is free from emissions (CO2, NOx, noise).
As a further focus for the IAA, MAN is putting strong emphasis on new approaches to networking the world of transportation. MAN is paving the way for the logistics of the future, and is devoting a special platform at the IAA 2016 to RIO – the new brand from Volkswagen Truck & Bus in the field of digital solutions.
RIO is an open, cross-manufacturer business and technology platform that provides individual and uniquely intuitive digital services for the entire transportation and logistics ecosystem. The new digital products and services offered by RIO will enable customers to optimise their logistics processes and manage product flows more efficiently thanks to intelligent networking. From 2017, every new MAN truck will feature the technical prerequisites that make it possible to exploit the full potential of these new services. As the initiator of RIO, MAN is responsible for its development within the Volkswagen Truck & Bus Group.
MAN at the IAA Commercial Vehicles 2016: a wealth of product innovations for the truck series
In addition to a number of world premieres, MAN Truck & Bus is also showcasing other vehicles and new technologies at the IAA. A new light hypoid tandem axle increases carrying capacity and reduces consumption. MAN Hydrodrive, a selectable hydrostatic drive in the front axle, boosts traction when needed and is now also available in combination with the MAN TipMatic automatic gearbox. With its new TGS-TS, a lightweight vehicle that can simultaneously handle maximum payloads, MAN is bringing targeted optimisation to the industry.New at MAN: HydroDrive combined with MAN TipMatic and the new D26-Motor in the MAN TGS 18.500 4x4H BLS
With a systematic orientation towards optimising transport within the industry, MAN Truck & Bus develops vehicles and technologies with a focus on delivering the highest possible cost-effectiveness and efficiency. Developments that reduce the unladen weight of the vehicle make it possible to increase the payload and therefore also the transport volume. Systems that can be switched on as and when required allow for a flexible use of the trucks even in unusual situations without having to make any compromise on efficiency and payload advantage in normal operation.
A plus for the payload: new light hypoid tandem axle
At the bauma 2016 earlier this year, MAN presented its new light hypoid tandem axle unit, which is particularly suited to transport operations where the payload is critical. The unit is being presented at the trade fair in the weight-optimised version of the four-axle truck mixer MAN TGS 32.400 8x4 BB, which weighs in at approximately 280 kilogrammes less compared to corresponding planetary axles. The weight advantage achieved over today’s conventional hypoid axles with a 13-tonne load capacity is 180 kilogrammes. In terms of truck mixers, this means, for example, that it is possible to transport 180 kilogrammes more concrete or water. The requirement for the use of thermo-insulated bodies when transporting asphalt adds additional weight. The operator is now able to compensate for this payload loss with a lighter axle unit. With a technical gross train weight of 60 tonnes, there are also applications outside the construction sector in distribution and long-haul transport.
Besides its benefits in terms of improved payload, this tandem axle unit also offers other advantages. The fuel consumption is slightly lower than in vehicles fitted with planetary axles. In a direct comparison, the new hypoid axle construction – designed for a payload of 11.5 tonnes – also offers additional ground clearance of approximately four centimetres. This means MAN now achieves the ground clearance required for N3G approval (off-road vehicle) with 315/80 R 22.5 tyres fitted.
The new axle unit is available for normal-height vehicles up to 480 HP with the leaf-leaf and leaf-air suspension versions of the TGX 6x4, TGS 6x4 and 8x4, but also for the TGM with 6x4 drive configuration. Additionally, the TGX 6x4 and TGS 6x4 and 8x4 also benefit from this equipment alternative in the medium height version with leaf-leaf suspension. The new tandem axle provides a transmission ratio of i = 2.85 to ensure an efficient drive train configuration. The longest ratio offered to date was i = 3.08.
A broader range of applications: MAN HydroDrive combined with TipMatic
With the presentation of the MAN HydroDrive in 2005, MAN introduced a new drive technology variant for trucks to the market. The technical solution of a hydrostatically driven front axle to increase traction when required and to deliver a strong braking effect on steep off-road slopes was received in many sectors with great interest. MAN is offering this system in the widest range of configurations available on the market. It can be provided for two-, three- and four-axle vehicles in the TGS series and for two- and three-axle semitrailer tractors in the TGX series and is ideal for vehicles that are primarily driven on surfaced roads and only occasionally need additional traction.
Typical areas of application are unsurfaced roads and construction sites, farm and forest tracks and unclean roads, or roads covered in ice and snow. The benefit of the hydrostatic front-axle drive really becomes evident if an off-road slope has to be negotiated without a load. A typical example of this is the tipping semitrailer tractor which has unloaded at the bottom of a pit. The rear axle, now under very little load, lacks traction on the incline.
The innovation of the HydroDrive combined with the MAN TipMatic automatic gearbox is now available to order at the IAA. Both the “on-road” and “off-road” gear shifting programmes are available. Milk collection vehicles are one example of the on-road application of the gear shifting software, while tipping semitrailer tractors and timber transporters are typical off-road applications. There are no restrictions on use of the engine and gearbox-dependent power take-offs.
MAN has continued to develop this system and improved its practical operation for users. MAN optimised the routing of the hydraulic lines with the introduction of the Euro 6 design. The clearance around the wheels has been increased to allow for larger rims and tyre widths – even with tyre chains attached.
The driver can activate the MAN HydroDrive using a rotary switch even under load and whilst driving. The system switches off automatically above a speed of 28 km/h. The system re-engages without driver intervention if the speed drops below 23 km/h.
The payload advantage compared to a conventional all-wheel drive is one of the recognised benefits of MAN HydroDrive. The weight advantage is 500 to 750 kilogrammes depending on the vehicle configuration. From a business perspective, the fuel saving represents a further benefit – when the system is switched off, the front wheels rotate freely, as with an on-road vehicle. MAN also offers this additional traction for vehicles with a normal height design. The low frame height makes it easier for drivers to enter and exit the cab. The body's lower centre of gravity has a positive effect on driving stability. All MAN TipMatic and MAN HydroDrive components are located below the top edge of the frame. MAN vehicles are thus distinguished by the unlimited options available in terms of bodies.
On descents, the HydroDrive transfers the engine braking effect to the front axle. This provides safety and lateral traction on slippery ground, resulting in overall improved vehicle control.
The payload heavyweight: the new TGS-TS for tank and silo haulage
The consistent industry-specific focus of the new MAN TGS series supports economic tank and silo haulage operations. In industries where goods are billed according to the transported volume, the payload is of high importance. For this reason, MAN’s focus for the TS version of the TGS range has always been on creating a lightweight vehicle that can simultaneously handle maximum payloads. MAN has optimised the unladen weight of the new MAN TGS-TS, making this vehicle the lightest customer-oriented semitrailer tractor for tank and silo operations in the MAN product portfolio. If all the measures are implemented, the unladen weight of the TGS-TS is no more than around 6560 kilogrammes. This permits an increase in the payload of more than 100 kilogrammes.
The measures that have been implemented include the reduction of the series standard 35 litre AdBlue tank to a capacity of 20 litres. Fastening the side panel in combination with the fender bracket saves both parts and weight. The changeover of the battery box to a version with two 155 Ah batteries instead of two 175 Ah batteries can provide a potential saving of 45 kilogrammes.
The TGS-TS now also features a new, lighter steering gear as standard. In combination with the new weight-optimised front axle and propshaft, these measures reduce the overall weight by up to 24 kilogrammes.
Irrespective of this, the MAN TGS-TS still benefits from the same design upgrade in the interior and on the vehicle front as every new MAN TGS. The aerodynamically optimised radiator fins improve air circulation. The bed behind the seats can be separated from the driver's workplace with curtains in sand beige.
The MAN TipMatic 12 26 DD Profi driveline includes new transmission-side features such as the combination of EfficientRoll with EfficientCruise, smart shifting, shift-support, rocking-free mode and idle speed driving. This means that the new MAN TGS-TS is not only optimised in terms of its payload but also benefits from improved efficiency.
Exclusivity in blue – the MAN PerformanceLine Edition
The flagship of the MAN TGX series with an output of 640 HP is now released in a special limited edition numbering an exclusive 100 vehicles. With its bold blue interior design, this vehicle truly sets itself apart from the standard series model.Exclusivity in blue - MAN presents the MAN PerformanceLine Edition in a steel blue metallic paint colour at the IAA 2016.
The MAN PerformanceLine Edition combines numerous special features in the driver's cab and the external design to create an exclusive premium vehicle. It is only available in the MAN TGX series with the top-of-the-range Euro 6 engine boasting an impressive 640 HP.
On the outside, the vehicle is equipped with mirrors casings and a lower protective radiator grille in elegant anthracite, set off perfectly by chrome applications on the two horizontal radiator fins. A sun visor, two air horns and plaque with the PerformanceLine logo on the doors round off the special edition design.
The interior of the TGX is a particular gem, with numerous applications featuring a distinct blue colour scheme: blue contrasting seams emphasise the contours of the leather multi-function steering wheel, the comfort seats and the floor lining. The lion symbol is imprinted in the head rests and also clearly recognisable as a blue outline on the underside of the top bed. The seatbelts and the inside of the all round curtains are also held in blue, as is the eye-catching brushed aluminium insert on the instrument panel. An additional PerformanceLine plaque on the instrument panel of the passenger side serves to further emphasise the exclusive nature of this special series.
The PerformanceLine logo also appears on the display when switching on the MAN Media Truck Advanced radio and navigation system, which is characterised by its outstanding sound quality and comprehensive additional functions such as digital radio reception as standard.
The leather interior trim and the seat covers in a blend of Alcantara and leather guarantee a feeling of exclusivity and comfort.
At the IAA 2016, MAN will be presenting the PerformanceLine Edition in form of a steel-blue metallic, dual-axle semitrailer tractor with an optional styling package. This package consists of high-shine polished front and side brackets in stainless steel, with integrated LED accent lighting and a solid roof beam with four halogen high-beam headlights.
Customers are, of course, free to choose their desired colour and vehicle design. There is a wide range of different variants, with two and three-axle semitrailer tractors and two to four-axle chassis in combination with cabs in sizes XL, XLX and XXL. Both left-hand and right-hand drive vehicles can be fitted out with the features of the PerformanceLine Edition. The MAN TGX PerformanceLine will be available as from the IAA 2016. Production will begin from January 2017.
New MAN TGX EfficientLine 3 is launched
MAN showcases the third edition of the MAN EfficientLine at the IAA 2016 trade fair. Its economic fuel-saving potential has already been proven in a comparative test drive with its predecessor. TÜV SÜD certifies that the MAN TGX EfficientLine3 delivers a further 6.35% fuel saving against the MAN TGX EfficientLine 2.With an even more efficient driveline, the new MAN TGX EfficientLine 3 is a winner for the model year 2017.
A look back to 2011: MAN show their commitment to increasing transport efficiency with the slogan “Consistently efficient”. MAN’s launch of the EfficientLine semi-trailer tractor took the sector by surprise. A controversial debate broke out among customers regarding some of the methods used to reduce fuel consumption. Passions ran high as the speed was restricted to 85km/h instead of 89km/h and attachments such as sunblinds and truck horns, which interfered with the aerodynamics, were omitted. MAN were proved right due to their success. Over 56,000 semi-trailer tractors with EfficientLine equipment have so far rolled off MAN's assembly lines.
A series of changes all played their part in contributing to this success. These included spoilers and side panels for optimising aerodynamics, lightweight construction in the form of aluminium parts for the compressed-air tank, rims and diesel tank, retarder installed as standard, air compressor controlled to meet requirements (APM, Air Pressure Management) and optional TPM tyre pressure monitoring for maintaining optimal tyre pressure.
MAN launched packages with elements of the EfficientLine design to optimise other basic vehicles such as semi-trailer tractors in the MAN TGS series or chassis such as on the swap body truck. Other European truck manufacturers responded by launching comparable models.
IAA 2016 will see the launch of the new MAN TGX EfficientLine. To clearly demonstrate the fuel-saving potential, MAN performed a consumption tour with an MAN TGX 18.500 4x2 BLS EfficientLine 3 semi-trailer tractor in July. The basis for comparison was provided by the truck's predecessor model - an MAN TGX 18.480 4x2 BLS EfficientLine 2 - which travelled with it along the same route. The TÜV SÜD monitored how the measured values were determined. The consumption tour stretched almost 4,000 kilometres through six European countries: Germany, Austria, Italy, France, Spain and Switzerland. The starting point and final destination was Munich.
The efficiency of the EfficientCruise - the latest generation anticipational cruise control - was demonstrated in particular on the topographically challenging sections of the route. The EfficientRoll freewheeling gearbox function came into effect on gentle inclines or slightly undulating route sections. The reworking of the new D26 CommonRail engine and the driveline redesigned for this with TipMatic gearbox 12+2 27 DD Profi and axle transmission ratio of i = 2.53 also played their part in reducing fuel consumption. On the basis of their trials over the course of the continued development of the driveline, the technicians at MAN had anticipated a fuel saving of at least five percent on this rout.
But even this positive estimation turned out to be too conservative on the consumption tour. According to the in-depth analysis of the measurement report provided by TÜV SÜD, the actual difference in fuel consumption between the EfficientLine 3 and EfficientLine 2 was 6.35%.
In order to illustrate this encouraging increase in efficiency in Europe and to promote the MAN TGX EfficientLine 3 in an eye-catching fashion at the IAA, these two vehicles took part in a promotional tour over the same route as the consumption tour as part of the MAN pre-IAA press conference on 20 July 2016 in Munich. This tour also spanned almost 4,000 kilometres through six European countries. The convoy was scheduled to make eight stops on route in Bregenz-Hohenems (Austria), Milan (Italy), La Junquera and Irun (Spain), La Corrèze (France), Bulle and Birr (Switzerland) and finally in Munich in order to allow customers and truck drivers in these locations to see the new MAN TGX for the first time. Alongside the tour, there were various different activities taking place in the countries such as competitions, the awarding of prizes and expert lectures. The primary focus of this was to post active updates about the tour to the various social media channels such as Facebook, Instagram, Twitter and YouTube. Daily video summaries and animated infographics outlining the features of the new MAN TGX EfficientLine3 kept enthusiasts up to date at all times throughout the tour. The virtual coverage of the tour was rounded off with an emotional look behind the scenes under the slogan “Faces of Europe” and creative collages depicting each country. On the whole, the interest over the course of the tour was very high. With 10,362 likes and 1,641 shares, Facebook was the most successful channel, reaching a total of 5 million people and consequently gaining 2,164 new likes for the MAN Truck & Bus Facebook page. On Twitter, up to 52,000 followers were reached and the account clocked up 37 retweets. On the whole, thanks to the broad, targeted organisation of the promotional tour and various contributions to social media, awareness of the new MAN TGX EfficientLine 3 has increased significantly.
MAN engines: Even greater power and efficiency at the IAA 2016
MAN Truck & Bus is going to great lengths to enhance its range of engines in the lead-up to the IAA Commercial Vehicles 2016. These are set to ensure significantly better fuel consumption, increased efficiency and enhanced driving dynamics without compromising on reliability.
With the requirements of the Euro 6 emission standard about to change in 2017, MAN has taken the opportunity to overhaul its range of engines. The new engines offer more torque and greater performance with lower consumption. Furthermore, MAN has introduced a new, more reactive catalyst material for the SCR system in the new D38, D26 and D20 engines. Combustion and exhaust gas aftertreatment are thus optimised to such an extent that consumption decreases even further and emissions stay low. For the first time, the new D08, D20, D26 and D38 engines in all performance classes can also be operated with paraffinic fuels according to EN 15940, such as hydrotreated vegetable oils (HVO).
The new MAN D38: Up to 640 HP for standard series engines
The 640 HP performance class in the new MAN D38 engine was previously reserved exclusively for heavy-duty designs, but with the new generation of engines, it is now available in almost all versions of the MAN TGX D38. MAN is also offering the new D38 with additional performance levels of 540 and 580 HP – an increase of respectively 20 HP compared to before.
Offering high torque at low speeds, the 15.2-litre, in-line six engine really does stand out from the crowd. Even at as low as 900 rpm, it can reach torques between 2700 and 3000 Nm, depending on the engine power. This makes it ideal to facilitate reduced fuel consumption and thus lower CO2 emissions.
Two-stage exhaust turbocharging
A key element of low-speed engine characteristics is the charging system which comprises two differently sized turbochargers connected in sequence. The smaller high-pressure charger responds even at low engine speeds, with the larger low-pressure charger providing additional support with increasing speeds and loads. When the engine is subject to high power requirements, the low-pressure charger takes over the majority of the compressor activity. This concept leads to an ideal supply of combustion air to the engine and thus an optimal torque curve which means that the maximum torque is available within a wide range of between 900 and 1400 rpm. A range of this size supports low-speed, economical driving on even terrain and less gear shifts on inclines.
Greater combustion and injection pressures
For the new D38 engine, MAN uses a third generation common rail system which injects fuel into the cylinders at up to 2500 bar. This leads to a finer dispersion of the fuel whilst enabling even more accurate pre-injection, main-injection and post-injection processes, making combustion particularly effective and reducing the fuel consumption and CO2 emissions even further. At the same time, the new generation of the common rail system facilitates maximum torque even at low speeds. With its low auxiliary power requirements, the optimised fuel pump further contributes to overall fuel efficiency. A further reduction in consumption is achieved by the air compressor, which can be switched off and also facilitates a quick filling of the air supply with its two cylinders. The Air Pressure Management system only switches on the compressor when compressed air is required, which stops it from running unnecessarily and therefore prevents additional fuel consumption.
Sensor-controlled fan speed
The new air management system keeps the operating temperature constant, ensures that it is reached more quickly, increases the usable drive power, and reduces fan noise.
Optimised oil cooling
The improved overall cooling efficiency is supported by an optimised oil cooling process. A new thermostat controls the engine oil temperature so that the optimal temperature is reached more quickly, and the engine can thus operate faster with the lowest possible friction. In drive mode – for example, on the motorway – the temperature control maintains the oil temperature at a slightly higher level to keep the internal engine friction to a minimum. A further reduction in friction is also supported by the steel pistons. The high strength of the steel alloy makes it possible to reduce the compression height, meaning longer connecting rods can be used to reduce not only the lateral piston force, but also the frictional force of the pistons in the cylinder liner. This serves to increase the service life of the components and simultaneously leads to a reduction in fuel consumption. In addition, the new D38 engine is also equipped with fire rings, which are installed at the top end of the cylinder liners. These minimise the accumulation of oil carbon on the piston crevice and thereby not only reduce wear but also further increase the service life of the engine. Due to its specifically developed plastic oil sump, the new MAN D38 engine is also one of the lightest units in its class.
The new MAN D26: Greater torque and performance with reduced consumption
In comparison to its predecessor, the new MAN D26 engine boasts even more torque and performance. It now comes complete with an extra 20 HP in each class as well as a greater torque of 200 Nm, which means that the D26 engine is available in new performance classes of 420, 460 or 500 HP.
MAN now offers the TGS and TGX series with the new D26 engine to meet customer requirements for the 500 HP class. With its performance range of up to 500 HP, not to mention its high torque, increased fuel efficiency, durability, and low weight, the new MAN D26 engine is one of the most effective drive units in its class.
Like the new MAN D38 engine, the new D26 offers a whole host of different technologies for reducing consumption. It is also fitted with new, low-friction steel pistons and fire rings, optimised oil cooling with thermostat, and sensor-controlled fan speed.
In addition, MAN has also reworked the turbo charger for the new D26, which now responds even faster due to its optimized efficiency in both the high- and low-pressure phases, particularly during mid-range acceleration at moderate speeds. Driving dynamics are vastly improved with the new D26, offering an enhanced torque curve and greater flexibility.
Optimised exhaust gas recirculation
The new D26 benefits from optimised exhaust gas recirculation, which results in a better admixture of the recirculated exhaust gases across all cylinders, along with improved charge cycles and enhanced combustion processes. These measures considerably reduce the level of nitrogen oxide found in the exhaust gas.
Regulated coolant pump
Yet another innovation of the new MAN D26 is a regulated coolant pump. Unlike the previous unregulated and constantly rotating coolant pumps, the fully engine speed-regulated design allows for coolant to be circulated as and when required. The pump performance is regulated continuously between 20 and 95 percent by means of a Visco clutch. This means that when demand for coolant is low – for example in long-haul transport – 80 per cent of the mechanical power required by the coolant pump can be reduced, resulting in significant fuel savings potential. At the same time, the engine also reaches operating temperature more quickly in the warm-up phase, which in turn reduces overall wear.
Electronically controlled EVBec exhaust valve brake as series standard
The new generation of the MAN D26 engine is supplied with the EVBec electronically controlled exhaust valve brake with a brake output of 325 kW (at 2400 rpm) as series standard. Its efficiency and direct incorporation into the brake management system support efficient and fuel-saving operation with a simultaneous reduction in wear on the wheel brakes and drivetrain components. It even makes a significant contribution to driving safety. This enhanced EVBec can be regulated continuously when activated via the brake management system in applications such as additional braking via the MAN BrakeMatic, the standard cruise control function, MAN’s EfficientCruise GPS cruise control, or the ACC Adaptive Cruise Control. If the driver manually activates the sustained-action braking function via the stalk switch, the braking torque can be controlled in stages. The brake management system then automatically controls the exhaust valve brake in five phases. If the vehicle also has a retarder, this is controlled in combination with the exhaust valve brake in six phases.
The new MAN D20 and MAN D08: Tried-and-tested technology with even greater reductions in fuel consumption
In the process of redesigning the truck engine portfolio, MAN has now also kitted out both its D08 and D20 engine series with a wide range of new features.
The new D20 also benefits from most of the innovative equipment found in the new D26 engine, including optimised oil cooling with thermostat, sensor-controlled fan speed, a regulated coolant pump, and improved exhaust gas recirculation. This also applies for the series standard fitting of the electronically regulated EVBec engine brake. It is features like these that make the new MAN D20 more fuel-efficient as well as being exceptionally reliable.
With the new D08, MAN is building on a proven concept, which includes an overhaul of the engine software. A new coolant level sensor prevents the engine from running with too little coolant, allowing any engine damage to be prevented in good time. Further innovations include the sensor-controlled fan speed and a new oil level sensor. Performance classes 250, 290 and 340 HP for the 6-cylinder model as well as classes 150, 180 and 220 HP for the 4-cylinder model remain unchanged. The 6-cylinder design with 340 HP boasts an optimised intercooler system, which reduces the thermal load of the cooling components as well as keeping wear to a minimum.
New MAN engines for trucks in model year 2017
The new engine range in the Euro 6 classification for model year 2017 includes 14 output levels between 150 and 640 hp.
MAN Truck & Bus produces 4 engine series for use in its trucks at its engine plant. The common rail injection system is common to all MAN engines.
The D08 series covers the range from 150 to 340 hp. The 08 figure in the type description indicates a bore of 108 mm. The stroke is 125 mm. Each of the three performance levels are covered by the in-line 4-cylinder and the in-line 6-cylinder engine. These engines are intended exclusively for the TGL and TGM series in the truck range.
In the D20 engine series, the ‘D20’ refers to a bore of 120 mm. The stroke is 155 mm. Both the 320 hp and 360 hp variants are used in the TGS and TGX series.
For the model year 2016, the D26 engines series received new power ratings of 420 hp, 460 hp and 500 hp. The bore is 126 mm and the stroke is 166 mm. These engines, amongst others, are available in the TGS and TGX series.
The D38 6-cylinder in-line engines are reserved exclusively for the MAN TGX series. They cover the output class above 500 hp and, at 640 hp, are the most powerful engines offered by MAN for trucks. The figures for the stroke and bore are 170 and 138 mm respectively.
Table showing the new MAN engines for trucks in the Euro 6 classification for model year 2017
|Series||Cylinder||Cylinder Capacity||Power output||Torque|
|D08||4 in-line||4580 ccm||150 hp (110 kW) @ 2300 rpm||570 Nm @ 1400 rpm|
|4 in-line||4580 ccm||180 hp (132 kW) @ 2300 rpm||700 Nm @ 1400 rpm|
|4 in-line||4580 ccm||220 hp (162 kW) @ 2300 rpm||850 Nm @ 1300 – 1800 rpm|
|6 in-line||6871 ccm||250 hp (184 kW) @ 2200 rpm||1000 Nm @ 1200 – 1750 rpm|
|6 in-line||6871 ccm||290 hp (213 kW) @ 2200 rpm||1150 Nm @ 1200 – 1750 rpm|
|6 in-line||6871 ccm||340 hp (251 kW) @ 2200 rpm||1250 Nm @ 1200 – 1800 rpm|
|D20||6 in-line||10.518 ccm||320 hp (235 kW) @ 1800 rpm||1600 Nm @ 930 – 1400 rpm|
|6 in-line||10.518 ccm||360 hp (265 kW) @ 1800 rpm||1800 Nm @ 930 – 1400 rpm|
|D26||6 in-line||12.419 ccm||420 hp (309 kW) @ 1800 rpm||2100 Nm @ 930 – 1350 rpm|
|6 in-line||12.419 ccm||460 hp (338 kW) @ 1800 rpm||2300 Nm @ 930 – 1350 rpm|
|6 in-line||12.419 ccm||500 hp (368 kW) @ 1800 rpm||2500 Nm @ 930 – 1350 rpm|
|D38||6 in-line||15.256 ccm||540 hp (397 kW) @ 1800 rpm||2700 Nm @ 900 – 1380 rpm|
|6 in-line||15.256 ccm||580 hp (427 kW) @ 1800 rpm||2900 Nm @ 900 – 1380 rpm|
|6 in-line||15.256 ccm||640 hp (471 kW) @ 1800 rpm||3000 Nm @ 900 – 1400 rpm|
The MAN TipMatic gearbox: Faster shifting strategy and customer-specific application optimisation at the IAA 2016
The MAN TipMatic gearbox: Faster shifting strategy and customer-specific application optimisation at the IAA 2016
MAN Truck & Bus introduces numerous driveline innovations in its new TipMatic generation at the IAA 2016, designed to reduce fuel consumption and increase driving comfort.
MAN has optimised the automated TipMatic gearbox in their vehicles with individual moving-off and switching strategies for each specific area of application and added various new functions to enhance efficiency and comfort. The new functions of the gearbox operate uniformly and are available for all 12-speed gearbox versions in the new TG generation. They have been specifically adjusted for the combination with the new D20, D26 and D38 engines in the Euro 6 design and for the respective area of application.
Purpose-built gearbox range
The new gearbox functions can be broken down into various gearshift programmes, which can be selected upon ordering a vehicle and are included as an additional identifier in the gearbox name (such as MAN TipMatic FLEET). Each gearshift programme has its own, specific moving-off and switching strategy. Road vehicles require a balance of enhanced convenience and efficiency, while the emphasis for heavy-duty vehicles is on power, especially when moving off with a high tonnage. As for offroad vehicles, these require improved performance and speed, while emergency services vehicles have to be able to accelerate quickly. With all of these different requirements, the moving-off strategy defines how the truck responds to the accelerator from a standing position. The switching strategy, on the other hand, specifies the gear to be used in each situation.
The following gearshift programmes are available to choose from: FLEET, PROFI, OFFROAD, EMERGENCY, COLLECT.
As the name suggests, the FLEET gearshift programme is specifically designed for fleet vehicles used in long-haul transport. In normal driving mode, it only allows for automatic operation, manual gearshifts are only possible while moving off, when coasting, or as an emergency function. Especially the faster and highly consumptive downshifting via the kickdown function over the accelerator is inhibited. FLEET is specifically designed for fuel-efficient driving, where drivers rarely have to change manually, meaning fewer distractions and a safer driving experience. This gearshift programme is particularly ideal for large fleets with frequent driver changes or for hire fleets.
In contrast, PROFI allows manual gear changes at any time, and the kickdown function for faster downshifting is always active by default. PROFI is primarily designed for comfort and to save fuel. When driving onto an incline, it increases the engine speed and thus makes large power reserves available at a very early stage, reducing the engine speed again at the end of the slope through timely upshifting into a higher gear. This makes it possible to achieve high average speeds without increasing fuel consumption. This gearbox range allows experienced drivers and those trained by MAN ProfiDrive to maximise the efficiency potential of their vehicle even better.
When it comes to driving off the beaten track and in harsh conditions, the OFFROAD gearshift programme is the ideal choice. The gearbox shifts more quickly to higher gears at higher engine speeds, and manual changes are possible at any time. The kickdown function is designed in such a way that upshifts can be inhibited before inclines. OFFROAD makes the maximum power available on inclines through later switching and uses the engine brake line to its full potential on downward gradients.
MAN’s COLLECT gearshift programme offers enhanced gearbox software that has been specifically designed for refuse collectors. Geared towards the operating conditions of vehicles with rear or side loader superstructures, the switching strategy is optimised for longer stop intervals with activation of the power take-offs and frequent moving off. This helps to improve the typical workflows of refuse collectors, which involve a substantial amount of starting and stopping, as well as a high number of gear changes between the collection points at peak times of the day.
The EMERGENCY gearshift programme is specifically designed for emergency services vehicles (such as fire engines, ambulances, or disaster control vehicles). In this programme, the gearbox shifts more quickly and at higher engine speeds. It also has a special downshift logic, which helps to find the right gear faster when accelerating. When heading to an emergency, specialist personnel can therefore count on the vehicle’s maximum acceleration capacity in any situation.
Whilst the FLEET and PROFI gearshift programmes can be considered standard gearbox ranges for normal driving situations, OFFROAD, EMERGENCY and COLLECT are additional programmes that are available alongside the conventional range. Drivers can use the gearbox selection switch to select the appropriate mode as required.
Every gearbox range is complemented by additional manoeuvring features, which can also be called up via the gearbox selection switch. These are specifically designed for low speeds in both normal and reverse mode. The accelerator is characterised by its exceptional sensitivity, which limits the engine speed and restricts the available gears to just the first two. In manoeuvring mode, these can only be selected manually using the stalk switch.
SmartShifting for even faster gear changes
The switching dynamics of the new MAN TipMatic are designed in such a way that gear changes can be made as fast as possible. The new SmartShifting function combines a rapid switching process in all gears to suit every driving situation. Taking the accelerator pedal position, vehicle mass and the calculated driving resistance into consideration, the gearbox software determines the optimum switching speed for every situation. The strategy behind the SmartShifting function is always based on striking the ideal balance between convenience, efficiency and speed.
In the new MAN TipMatic versions, the upshift support (HSU), which allows for gear skips of up to three levels at a time, is additionally supported by the electronically controlled EVBec engine brake. Especially in the case of large gear skips, the EVBec closes the exhaust throttle valve to create a rapid drop in engine speed in the phase where the clutch is open. In particular steep inclines can be tackled in a higher gear thanks to the upshift support.
EfficientCruise + EfficientRoll
With its new generation of gearboxes, MAN is further enhancing the potential to save more fuel. The new version of the GPS-supported MAN EfficientCruise with its anticipatory cruise control is now available in combination with the EfficientRoll gearbox function. This switches the gearbox into neutral on a gentle downward gradient to use the momentum of the vehicle without any drag losses.
EfficientCruise considers the topography of the road ahead so that it can adapt the vehicle’s operation and speed for a more efficient experience. What’s more, it also inhibits unnecessary downshifts in the MAN TipMatic gearbox. In comparison to benchmark vehicles with standard cruise control, the new version of MAN EfficientCruise with EfficientRoll saves up to nine per cent more fuel.
“Coasting along” in idle mode with Idle Speed Driving
The Idle Speed Driving function allows the truck to “coast along” through slow-moving traffic without touching the accelerator when the clutch is engaged. This function is available in the first six gears. While manual upshifting is possible, downshifting is performed automatically when the idling torque is insufficient for a higher gear or when the driver brakes. This allows the driver to let the truck coast along gently through the flowing traffic and increases the protection of the clutch.
Convenient free-rocking function
An added plus for safety and convenience comes in the form of the new free-rocking function in the MAN TipMatic gearbox. It facilitates easier moving off for trucks on snow or other slippery, unstable surfaces. If the toggle switch is activated in the switching strip, the driver can rock the vehicle free from a given situation by pressing and releasing the accelerator alternately. This function opens and closes the clutch according to the actuation of the accelerator so quickly that the vehicle rocks free. As part of this process, TipMatic automatically selects the appropriate gear to reduce