MAN TG model series at the IAA 2018: reliable, ef-ficient, customer-orientated (Press Kit Truck)
At the IAA 2018, MAN presents their TG model series with recent comprehensive upgrades. The clear focus of the Lion brand is placed in proven product virtues such as reliability, efficiency, customer-orientation and branch competence. This is emphasized by MAN with the new comprehensive equipment packages XLION, that make the TGX, TGS, TGL and TGS even more attractive. Moreover, a MAN TGS-TS semitrailer tractor gives an overview of future engine and driver assist applications. In addition, with their new DigitalServices, MAN will show answers to future customer and logistics requirements.
- At the IAA 2018, MAN is showing their reliable, efficient and customer-orientated truck product range
- XLION models make the TG model series even more attractive
- MAN DigitalServices available exclusively for the MAN TG model series
The driveline of the TG model series ensure for an even more efficient fuel consumption at higher performance and driving dynamics as well as the familiar high reliability. The D38 engine offers up to 640 HP in its strongest version and already reaches its up to 3,000 Nm high torque at low engine speed. The D26 engine has been optimised for fleet applications, offers a performance spectrum of 420 to 500 HP with equally low own weight and low fuel consumption. In combination with the tine-tuned MAN TipMatic gearbox with individual driving program for every application as well as the sensitive starting as well as efficient and equally application-orientated switching strategy, the heavy MAN model series TGS and TGX are also equipped with efficient, economical and environmentally protecting drivelines. In the middle truck segment, the MAN TGL and TGM are driving with the new D08 engine presented at the end of 2017 with outputs of 160, 190 and 220 HP in four-cylinder variants and 250, 290 and 320 HP in six-cylinder variants. The new MAN D08 engine generation is characterised by its pure SCR technology based on exhaust gas aftertreatment and a more simple assembly. This extends the application spectrum, serves maintenance-friendliness as well as increases reliability. Moreover, with the new units, MAN could reduce the consumption by a further 5.5 percent. With the extended starting and switching strategy for the TipMatic gearbox with 6 and 12 speeds introduced with the current D08 generation, driving comfort and efficiency are also provided with the TGL and TGM. For the IAA 2018, MAN is also presenting a switching software for the MAN TipMatic 12+2 gearbox which has been optimised even further that, in combination with the D26 engine, is used in the model series TGS and TGX. This reduces the gearshifts with the average speed remaining the same, reduces the average engine speed and uses higher gears more frequently. This contributes sustainably to a further reduction of the fuel consumption. As of the IAA, the MAN TipMatic 12-speed that was only available for the European standard Euro 6 is also available for vehicles of Euro 5 and Euro 6 emission standard. For the model series TGX and TGS of Euro 6 to Euro 2 emission standard, MAN also offers the new version of the manually operated gearbox, Ecosplit 4.
Optimum operating comfort and high living quality for the driver
The new features inside the driver cab interior that were introduced at the end of 2017 and transferred to series in 2018 make working and living for the drivers in trucks of the TG model series even more comfortable. Whereas the optimised interior design of the short C and M drivers cabs places its focus on the application and driver tasks, in particular everything concerning the work place, the drivers of the longer L, LX, XL, XLX and XXL drivers cabs, as used in particular in the MAN TGX and TGS, profit additionally from a redesign of the living area. In addition to the fridges that can be lowered under the bed, this includes an optimised shelf and lamp offer especially for the resting section. All important comfort functions can be controlled via the centralised operating concept. Moreover, an acoustic package ensures for restful sleep in the TGX model series that with the comprehensive insulating measures, noticeably reduces the noise level in the cab. Especially for applications in the traction sector there is also the new cab interior optionally available in the dirt-resistant interior colour Urban Concrete.
Driver relief and safety first and foremost
To ensure that congestion situations and slow-moving traffic do not cause fatigue to the driver, MAN offers the Adaptive Cruise Control ACC with a Stop-and-Go function. It controls the distance to the vehicles ahead and at low speeds, and if necessary, automatically brakes the vehicle to standstill and with short stops, also drives away again independently. This allows the driver to also travel along relaxed and stress-free in Stop-and-Go traffic. In addition to the new Stop-and-Go function, the ACC from MAN in the new generation also offers a convenient approach conduct to vehicles driving ahead. The system also avoids unnecessary braking and acceleration and thus reduces brake wear and fuel consumption when driving with ACC.
ACC and ACC Stop-and-Go ideally supplement the safety system Emergency Brake Assist (EBA 2) and Lane Guard System (LGS) and proactively help to avoid accidents. The Emergency Brake Assist EBA2 already exceeds the more strict legal guidelines for emergency brake systems applicable from November 2018. Due to the highly-mature sensor data fusion of radar and camera, EBA2 can also reliably interpret demanding traffic scenarios, vehicles travelling ahead and identify stationary obstacles with high security in order to trigger an emergency braking if required. Due to the positive experience with this dimensioning philosophy, since spring 2017, MAN has been installing the EBA 2 that can no longer be deactivated using a button in the instrument panel as standard in order to increase the gain in safety by the system even more. In doing so, the driver still has the complete control of the system at all times. Moreover, as of the IAA, EBA 2 is also available for new vehicles of Euro standard 3, 4 and 5.
MAN is introducing the Video Turning System (VAS) for the IAA. This reduces the risk of accidents when turning. It comprises a 150° wide-angle camera that is fixed on the right side of the drivers cab and a monitor that makes the right area of the vehicle side visible. The camera-monitor system with ultrasonic sensors equipped in the front of the vehicle and the in the right side can ensure for more safety. These detect objects and other road users at a distance up to two metres away from the cab.
Safe lightweight: MAN TGS Tank-Silo as innovation leader
At the IAA 2018, with the TGS-TS innovation leader, for the first time MAN will be showing application examples for the new D15 engine in the truck. The D15 is characterised by an outstanding ratio between weight and size as well as consumption. New computer aided construction methods and the use of different materials matched optimally to the use also make it even more environmentally friendly, low-noise and more efficient.
With regard to safety, the MAN TGS-TS innovation leader with the active power-assisted steering MAN Comfort Steering and the lane guard system Lane Return Assist provides an overview of future driver assist systems that actively assist the driver and make driving more safe. The new Video Turning System (VAS) is installed in the MAN TGS-TS innovation leader.
MAN DigitalServices: tailored services and applications
With the introduction of the new group sector MAN DigitalServices, MAN offers tailored services and applications exclusively for MAN vehicles. On the basis of the could-based open logistics platform RIO, mixed fleet operators can network their MAN vehicles and other brands with the comprehensive MAN DigitalServices on all levels and thus use them more efficiently. At the same time, the MAN DigitalServices applications are designed explicitly functional and suitable for everyday use as well as extremely user-friendly. Since August 2017, the RIO Box is a standard part of all brand-new MAN truck model series of the Euro 6 standard in Europe. In this way, MAN truck disposes over the first module of an infrastructure whose services could network the entire transport and logistics branch in the future. In doing so, the RIO box acts as an interface between the vehicle and RIO platform.
MAN XLION – High-performance and reliability as special model
With the XLION special model, for the IAA, MAN is introducing special equipment packages for long-haul transport, distribution and traction vehicles. These combine high-quality segment-specific equipment ex-factory with extras and service packages adopted country-specific. On request, the optic of the MAN XLION can score with an attractive lion design on the sides of the drivers cab. Every vehicle is provided with the lettering XLION on the drivers cab doors. The X in the name of the "Lion truck" stands for "extreme". This associates MAN with the extreme sporty performances of an Ironman triathlete. This is why MAN is an official supporter of Ironman Europe.
MAN Truck Modification for the branch-specific optimised vehicle
The demands for special conversions as basis for an optimum and economical transport solution is increasing constantly, as well as the individual internal and external design. For this purpose, MAN is offering MAN individual designs and versions of vehicle modification on the cab, chassis, driveline and electronics according to customer requirements. This has the benefit of only one contact partner and execution according to the documentation and warranty guidelines as well as the quality assurance of MAN. The vehicle service is possible in every MAN branch.
From professionals for professionals - the tailored branch training course from MAN ProfiDrive
Individual and needs based branch training course for truck and bus drivers - with this offer, since the end of last year, MAN ProfiDrive has been addressing the requirements and needs of their customers more targeted. This could be a comprehensive range on training modules or a combination of training course for your respective transport tasks. The experts from MAN ProfiDrive develop and plan the events together with the customer, organise dates, schedule and location and adopt the contents of the basic training, such as driving safety, technology, cargo lashing, off-road training and efficiency.
MAN introduces practical 26-tonne electric truck at the IAA 2018
At the IAA 2018 in Hanover, MAN Truck & Bus will present a fully electric MAN eTruck based on the TGM for urban goods transport. In mid-September, the 6x2 solo chassis concept from the medium-heavy distribution transport segment was released to nine member companies of the Austrian company consortium CNL for practical testing in real distributor logistics with various bodies.
- At the IAA 2018, MAN will present its TGM-based eTruck concept for urban distributor logistics in the form of a 26-tonne, 6x2 solo chassis
- Nine members of the Austrian company consortium CNL will test the MAN eTGM in real operation
MAN Truck & Bus has been working on new solutions for goods delivery and waste disposal in urban environments since 2009. Cities are increasingly facing the challenge of balancing the need to provide a healthy climate and high quality of life for their residents with the demands of urban goods traffic and delivery logistics. This includes developing concepts to shift high-volume traffic away from city centre areas and out of peak times, as well as new approaches to using available space and new mobility concepts.
eTruck test vehicles based on TGM
During the IAA 2018 from 20th to 27th September 2018 in Hanover, MAN will present a fully electric eTruck solo distributor chassis with a swap body frame and a 6x2 axle configuration. The 26-tonne truck, based on the MAN TGM, incorporates batteries that can be installed under the cab and on the side of the frame, providing a range of up to 200 km. The air suspension on the front and rear axles ensures adaptability to any urban loading scenario. The electric motor, mounted in the centre of the frame, supplies 264 kW of power, transmitting 3100 Nm of torque to the drive wheels without the use of a manually operated gearbox. Designed to handle classic city logistics tasks, the vehicle is suitable for a wide variety of different body applications, from dry freight carrying or refrigerated box vans to refuse collector units. The additional drive systems needed for such applications are also electric. At the IAA, MAN will be offering daily test drives in the eTGM on the outdoor grounds of the trade fair.
CNL practical trials in Austria
The new fully electric MAN TGM 6x2 chassis forms the technical basis for nine vehicles that were released to nine member companies of the Austrian Council for Sustainable Logistics (CNL) for practical trials in mid-September 2018. The vehicles are primarily 6x2 chassis units featuring refrigerated box van units, swap bodies and beverage units. However, they also include a tractor-trailer unit based on the MAN TGM. MAN will incorporate the findings of these practical trials in the development of its future product portfolio of series-produced electric trucks.
The eTruck development and testing programme forms part of the MAN Truck & Bus eMobility Roadmap for urban transport solutions, which are scheduled to be included in the product portfolio starting in 2022. The concept involves trucks and buses using a shared eMobility kit, which will be available in future for a wide variety of applications.
Comprehensive practical experience with electrically powered trucks
MAN Truck & Bus introduced the MAN Metropolis concept vehicle back in 2012. The electrically powered, 26-tonne refuse collector vehicle ran CO2-free in local waste disposal operations and could even be used in the city centre at night, thanks to its low noise levels. An integrated range extender expanded its radius by up to 150 km per day. With the range extender, fuel consumption was reduced by up to 80 percent compared with a regular diesel-powered vehicle. The extensive practical deployment of the MAN Metropolis provided a valuable source of experience for ongoing projects.
At the IAA 2016, MAN Truck & Bus presented a further development of the Metropolis concept: an entirely battery-electric powered tractor-trailer unit for overnight urban delivery services. It was technically based on a MAN TGS 4X2 BLS tractor-trailer unit with an 18-tonne gross vehicle weight rating. Optimised to operate with single or twin-axled City trailers, the concept vehicle fulfilled the demands that will be imposed on vehicles involved in the urban logistics of the future: plenty of load space combined with a light empty weight, zero emissions (CO2, NOX), very quiet and highly manoeuvrable.
MAN XLION – the tried-and-tested, reliable MAN as a special edition
Reliability, high performance and endurance in every aspect – these things are a given for the likes of ironman triathlon star athletes. And that’s what this MAN is about, too. An exciting prospect for businesses and drivers alike: reliable, rugged, long-lasting and practical – the special-edition model, MAN XLION, embodies these traits all day, every day.
- Special equipment packages for long-haul transport, traction vehicles and distribution vehicles
- A combination of premium, segment-specific equipment ex works with country-specific extras and service packages
- Available for Euro 6 MAN trucks as from the IAA in 2018. Production starts at the beginning of 2019.
The MAN XLION is king of the road with an optional eye-catching lion design on the sides of the cab. Each vehicle has the XLION lettering on the cab doors. The X in the name of this powerful truck stands for “extreme”. This is the link between MAN and the extreme athletic performance of an ironman triathlete, and it’s for this reason that MAN is the official supporter of Ironman Europe.
Segment-specific equipment packages
The equipment has been put together so that companies benefit from value for money and drivers can rest easy in the comfort of their MAN vehicles.
The MAN XLION Long-Haul special model is part of the fleet in long-haul transport as the MAN TGX with at least 460 hp. This means the offering includes the D26 as well as the D38 engine series, and even the peak power output of 640 hp. The visual and comfort-enhancing upgrades include comprehensive cab equipment as part of the driver comfort package, the MAN sound system, the LED daytime driving lights and chrome trim on the bumper.
The MAN XLION Traction special model is available for the MAN TGS series with an engine output of 460 hp and 500 hp. The construction site package is included in addition to the MAN sound system, the LED daytime driving lights and the off-road functionality for ABS. This means it helps to boost work safety and transport reliability. Among other things, the package contains a more dirt-resistant interior design in the Urban Concrete colour, an air deflector plate under the engine to prevent dust circulation, a driver’s side construction step with a long support rail on the roof or a stone guard on the front of the radiator.
The MAN XLION Distribution special model is available from MAN for both the TGL and TGM series with two axles and on-road drive, regardless of the engine output and cab size. The air-conditioning system, hands-free system for mobile phones and MAN sound system give the driver added comfort – just like the MAN driver comfort package. This package includes a multi-function steering wheel, driver’s comfort seat, comfort seat covers or central locking, depending on the cab model.
In all three MAN XLION special models, MAN combines a high-quality vehicle boasting industry-specific equipment with special After Sales conditions for the Service Contract Comfort and Comfort Super maintenance contracts.
Regional, market-specific upgrades for the MAN XLION
Depending on local requirements and the model in question, the sales organisations can offer special packages for the equipment, financing terms and maintenance scopes. Customers can select the Style Package, Safety Package, or custom installations from the MAN Truck Modification portfolio such as a wall unit on the cab rear wall, for example.
MAN digital services as an additional benefit
All vehicles are equipped with “MAN Essentials” and “MAN ServiceCare” as standard from the MAN Digital Services offering. As well as this, the “MAN Advanced” package is added free of charge for the first six months. For the same amount of time, there is also the “MAN Perform” package for long-haul transport or “MAN Compliant” for construction and distribution transport.
“MAN Essentials” forms the basis for using the digital services. It also transfers the vehicle's position every 15 minutes and, above all, provides the materials requirement planner and company owner with information for running vehicle analyses. With “MAN ServiceCare”, vehicle data for planning maintenance appointments and servicing work is transferred to the relevant MAN dealership. This helps both parties – the materials requirement planner and the workshop – to be optimally prepared so as to minimise MAN truck downtimes as far as possible. “MAN Advanced” offers even greater access to vehicle data and the corresponding analyses going back over the last 25 months. “MAN Compliant” helps with downloading and archiving driver card and tachograph data.
Reliable lightweight: The MAN TGS tank silo - an innovation driver at the IAA
Tank and silo forwarders focus on payload, safety and profitability in vehicle procurement. MAN is addressing these topics in the innovation vehicle on display, a MAN TGS 18.400 4x2 BLS-TS.
- MAN is showcasing the TGS-TS model at the IAA 2018 - the first possible application example for the new D15 engine in trucks
- With the MAN TGS-TS innovation driver, MAN provides an outlook on fuel-efficient technologies and future driver assistance systems
Countless goods ranging from milk, juice, liquid chocolate, through to heating oil, petrol and cryogenic gas, etc. are transported in tankers. In addition to high manoeuvrability and stable driving characteristics, the payload and safety of the vehicle are some of the most critical customer expectations. For the MAN TGS-TS range of vehicles for tank and silo forwarders, which is already optimally tailored to these requirements, MAN will be showcasing further optimisation potential in these areas with this innovation driver at the IAA 2018. With the TGS-TS semitrailer tractor put on display, MAN is introducing a possible truck application for the completely redesigned D15 engine for the first time. In addition to MAN's proven safety systems, such as ACC Stop & Go, EBA emergency braking system and Lane Guard System, MAN is for the first time also providing an outlook of the active MAN Comfort Steering system and a Lane Guard System, including Lane Return Assist as well as the VAS video turning system with ultrasonic monitoring in the TGS-TS innovator.
MAN D15: more environmentally friendly, quieter, more efficient
The new D15 engine installed in the TGS-TS concept vehicle with 400 hp / 294 kW generates a maximum torque of 1800 Newton metres and thus lies within the ideal performance range for transporting liquids. With an engine capacity of only 9 litres (9037 cm3), it simultaneously offers an excellent ratio between weight and size as well as consumption. New computer-based design methods and the use of different materials that are optimally matched to the application make it even more environmentally friendly, quieter and more efficient.
With the D15 , MAN is relying on exhaust gas aftertreatment based on advanced SCR technology (Selective Catalytic Reduction) in combination with the MAN CRT self-regenerating filter system (Continuously Regenerating Trap). The emission of NOX emissions (nitrogen oxides), which are harmful to the environment and health, is nearly zero due to this type of exhaust gas aftertreatment.
The new common rail injection system atomises fuel particularly finely at injection pressures of up to 2,500 bar and works particularly efficiently and with high fuel economy in conjunction with the space-optimised cylinder head with flatter outlet channels for less charge exchange losses as well as resistant steel pistons and robust camber valves. The single-stage turbo charger ensures optimum performance and very good response. The D15 can thus achieve its maximum torque of 1800 Nm even at low engine speeds. This is reflected in a dynamic "pick-up" feeling when starting off.
MAN developers have also optimised the D15 engine’s thermal management system. An adjustable charge air throttle valve upstream of and an exhaust gas accumulation valve downstream of the engine work together in tandem to accelerate the warming-up process and keep the exhaust gas temperature sufficiently high for ensuring a particularly effective SCR exhaust gas temperature. The new D15 engine already meets the strict requirements of the upcoming Euro 6d standard. The speed-controlled coolant pump, which does not operate permanently, but instead according to demand and the oil cooler, which is also switched on according to demand, and the fan with a speed sensor system provide the thermal management system with additional support and also contribute to consumption efficiency.
MAN also relies on fuel-saving solutions for the D15 engine attachments. Depending on the customer's application requirements, the 1-cylinder air compressors allow the customer to choose between a version that switches off completely after filling the compressed air tanks and a version that does not switch off, but is lighter and equipped with an economy system for backward expansion. A 2-cylinder version is also available for applications with higher air requirements, which also contributes to fuel savings with low power consumption during idling phases. The MAN TGS-TS also is also equipped with another innovative fuel-saving feature: an alternator whose power for charging the vehicle battery is electronically controlled depending on the vehicle's driving condition. While only the consumers in the vehicle electrical system are supplied during starting, acceleration and normal driving operation, the alternator is switched to full power when coasting and braking - i.e. in phases where no fuel is injected. This makes charging the battery extremely fuel-efficient.
MAN Turbo EVBec: Powerful engine brake for even more safety
Part of the requirement profile for liquid transports also includes a high-performance engine brake. This is why MAN has combined the D15 in the TGS-TS innovation driver with the Turbo EVBec controlled engine brake. It is gradually regulated by an electronically controlled and pneumatically operated butterfly valve and supplies up to 350 kW of engine braking power. This valve is positioned upstream of the turbo charger and can thus build up increased back pressure during braking. The braking performance remains constant even on long downhill stretches, which is an important safety benefit, especially for liquid transports.
MAN driver assistance systems: EBA2, Lane Guard System, ACC Stop-and-Go
At the 2018 IAA, MAN will be showcasing other equipment featured in its innovation vehicle that also focuses on safety. The TGS-TS 18.400 offers everything that MAN already offers as standard in assistance and safety systems, which is particularly important for tank and silo transport. The Adaptive Cruise Control (ACC), which MAN has also been offering with a stop-and-go function since 2018, provides critical safety and above all added comfort. The stop-and-go function automatically regulates the distance to the driver in front even at low speeds, brakes the vehicle to a standstill if necessary and also starts up again automatically at short stops. This allows the driver to cruise around relaxed and stress-free even in stop-and-go traffic. In addition to the new stop-and-go function, the new generation ACC from MAN also offers even more comfort when approaching vehicles in front. The system also avoids unnecessary braking and acceleration, reducing brake wear and fuel consumption while driving. ACC and ACC Stop-and-Go ideally complement the Emergency Brake Assist (EBA 2) and Lane Guard System (LGS) safety systems and help to proactively prevent accidents. The EBA2 emergency brake assistant already significantly exceeds the stricter legal requirements for emergency brake systems slated to take effect in November of this year. Thanks to the highly sophisticated sensor data fusion of radar and camera, EBA2 can also interpret demanding traffic scenarios with greater reliability, identify vehicles ahead and stationary obstacles with more certainty in order to only trigger emergency braking when required. Based on the positive experience with this design philosophy, MAN has not been installing the EBA 2 in the instrument panel as standard since spring 2017, so that the system can be switched off even more safely. The driver still has total control over the system at all times.
MAN Comfort Steering: Outlook for the future
MAN will also be exhibiting the TGS-TS innovation vehicle at the IAA featuring two additional active driver assistance systems that will be available in the near future. This includes an active power-assisted steering system, MAN Comfort Steering. Depending on the situation, it increases the steering torque applied by the driver with slight additional torque, thus reducing the steering forces and making steering more precise and comfortable overall. This also includes the second system that complements the function of the LGS Lane Guard System, which is already installed as standard. While it outputs an acoustic warning in case the vehicle drifts out of the lane, the LRA (Lane Return Assist), which will be available in the near future, actively intervenes and guides the vehicle back into the area within the lane markings. The driver can still override the system at any time. LGS and LRA can make a significant contribution to increasing safety, especially in the field of tank/silo transports.
MAN VAS: Video turning system for best view to the right
Despite numerous proactive supporting safety systems, the driver always has responsibility for the driving task. Above all, good visibility for the driver and his unrestricted perception of other road users are essential for this. With the combined camera system with turning warning system already available for the IAA 2018, MAN offers a significant increase in safety here, especially in dense city traffic. The area on the right side of the vehicle is not always fully visible to the driver, especially when turning, manoeuvring or changing lanes. There is a risk that other road users, such as cyclists or pedestrians, next to the truck will be overlooked. The video turning system (VAS) minimises the risk of accidents. It consists of a 150° wide-angle camera that is mounted on the right side of the cab and a monitor that makes the right side of the vehicle visible. The camera monitor system can be equipped with ultrasonic sensors on the front and right side of the vehicle for even greater safety. They register objects and other road users up to two metres away from the cab. When other road users approach, the driver receives a visual warning via LED warning lamps and an acoustic warning via a signal tone. This enables the driver to identify the potential hazardous situation in good time and respond accordingly.
As a further addition to the VAS, the 360° bird view system is available in addition to the camera monitor system and ultrasonic sensors. The system consisting of four HD cameras with fisheye optics provides high-resolution images of the vehicle from a bird's eye view. This makes the entire vehicle environment seamlessly visible, including all blind spots.
MAN is showcasing VAS for the first time on the TGS TS innovation vehicle at the IAA. It is available ex works for all TG truck series vehicles or retrofitted via MAN Truck Modification.
MAN ACC with stop-and-go function and EBA 2 permanently connected as standard
MAN offers a smart ACC stop-and-go function in TGX and TGS vehicles, easing the burden of drivers in congested traffic. The truck brakes to a stop autonomously and starts autonomously after short stops. The standard ACC function also includes a braking and acceleration strategy, providing a combination of comfort, safety, and fuel efficiency with convenient distance control. These functions are an ideal addition to the safety mechanisms of the emergency brake assist (EBA 2) and lane suard system (LGS) and can help to predictively prevent accidents.
- Stop-and-go adaptive cruise control (ACC) enables drivers to “cruise along” in heavy traffic, easing their burden
- ACC function provides fundamental improvements in automatic cruise control
- MAN only manufacturer to install EBA2 (emergency brake assist) as permanently connected standard feature
Whether it's commuter traffic is congested, traffic jams, or long queues of vehicles creeping up the motorway, these conditions mean having to constantly stop and start within a congested area filled with other road users. Stop-and-go driving challenges drivers and greatly increases the risk of rear-end collisions due to lapses in concentration. The stop-and-go function integrated into ACC adds a significant amount of extra safety in these situations. It is currently available for MAN TGX and MAN TGS with a Euro 6 D26 motor and with a MAN TipMatic 12+2 gearbox. The range will be expanded to include other powertrain versions by mid-2019.
Designed specifically for situations such as raffic jams and slow-moving traffic, the stop-and-go function makes it possible to use ACC across the entire speed range – including slowing to a standstill if the vehicle in front stops. Adaptive cruise control can also be used with stationary vehicles in front, but the vehicle with ACC must be moving at less than 50 km/h. If it takes less than two seconds to stop, the truck autonomously starts back up and moves forward. If the stop lasts longer than two seconds, the system automatically shuts off the service brake pressure and the driver can briefly press the accelerator or a button on the multi-function steering wheel to start. This prevents typical stop-and-go accidents involving vehicle body damage and allows the truck driver to deal with the traffic situation free of stress and fatigue. Sensors on the driver’s seat ensure that the function can only be activated when there is actually a driver at the wheel.
Convenience, efficiency, and safety with ACC
Along with its stop-and-go function, MAN’s ACC also makes it convenient to approach vehicles in front. In addition, the system avoids unnecessary braking and accelerating, reducing fuel consumption as well as wear and tear on the brakes during ACC driving. The function can be activated at speeds from 15 km/h and has a high maximum braking deceleration, allowing it to automatically neutralise critical situations with great reliability. A slanted radar system on the front apron virtually prevents snow build-up and the resulting functional limitations in wintry conditions. These features make distance control with the latest generation of ACC highly convenient, efficient, and safe.
ACC uses two sensor systems for the detection of stationary vehicles or vehicles in front. The first task here involves the data delivered by the radar sensor in the airdam. It continuously collects the distance and position of the vehicle in front, using the data to determine its relative speed and analyse it in relation to both the truck in which the system is installed and its own speed. This way, it can brake or accelerate accordingly. The second task is to evaluate the data recorded by the video camera on the windscreen. This features an object and lane detection system independent of the radar and delivers the necessary information to specifically classify the objects on or next to the roadway.
EBA 2 permanently activated
MAN also uses this highly developed sensor data fusion for the emergency brake assist (EBA 2) system. It enables EBA 2 to reliably interpret challenging traffic scenarios, identifying vehicles in front and stationary obstacles with a high degree of certainty so that emergency braking only needs to be initiated when strictly necessary. Dependable and robust object differentiation allows the system to respond uniquely to situations of this kind, reducing vehicle speed faster and bringing it to a stop a number of valuable yards earlier. EBA 2 already goes significantly beyond the stricter legal standards that will apply to emergency braking systems from the end of 2018. MAN offers EBA 2 for the full tonnage range from 7.5 tonnes onwards and has offered it for vehicles at Euro 3, 4 and 5 emission standard levels since early 2018.
EBA 2 is designed according to the maxim “the driver should always be in control”. This MAN-specific warning philosophy guarantees a high degree of acceptance among drivers. The interplay between two technologies for object detection (radar and camera) substantially reduces the risk of unwarranted warnings, achieving MAN’s aim of irritating drivers as infrequently as possible with warning signals.
Based on positive experiences with this design philosophy and a desire to further boost the safety gains from the system, MAN has now been installing the EBA 2 as standard for a year and a half without the former option of switching it off with a button on the instrument panel. This continues to guarantee complete control over the system at all times on the driver’s part.
In the pursuit of increased safety, the two features are supported by others. Along with the brake lights, the emergency stopping signal (ESS) activates the hazard warning flashers with a higher flashing frequency in the event of emergency deceleration. Meanwhile, the lane guard system (LGS) precisely monitors the vehicle position in relation to the lane and autonomously detects changes in lane conditions. In combination with these, EBA 2 and the new ACC stop-and-go function offer all road users added safety and provide significant relief to truck drivers.
Look right: MAN video turning assistant system boosts safety
A camera and ultrasonic sensors in MAN trucks’ video turning assistant systems are helping to expand drivers’ field of view into blind spots. The monitor is located in the field of vision when the driver looks to the right into the mirror.
- Camera on the right-hand side of the cab
- Monitor on the right-hand A-pillar
- Ultrasonic sensors on the vehicle’s front end and right side of the cab
- Installation or retrofitting by the MAN Truck Modification Center for the TGL, TGM, TGS and TGX series
It is difficult to see what is going on to the right-hand side of a vehicle, so if something critical is about to happen when turning, changing lanes or manoeuvring, the driver needs to alerted to this as early as possible. The MAN VAS, a video turning assistant system, helps the driver to see what is happening alongside their vehicle, supporting the view afforded by the rear-view and kerb mirrors. This way, they can identify whether objects or other road users (such as cyclists or smaller vehicles) are in a position directly next to their cab. Obstacles such as bollards, walls or parked vehicles become more obvious when manoeuvring. The system is activated automatically whenever the right-hand indicator is switched on. If required – for instance, while manoeuvring – the driver can also switch the system on manually using a switch.
On request, MAN can install a camera with a 150° wide angle lens on the right-hand side of the cab near to the edge of the roof. This service is provided by MAN Truck Modification. The monitor, which measures 7 inches, is usually installed inside the cab on the passenger side A-pillar. When the driver looks to the right into the mirror, the monitor is visible in the field of vision. Alternatively, the camera signal can be played back on the 7-inch display for the Infotainment system on the instrument panel.
For even greater safety, the camera monitor system can be equipped with ultrasonic sensors at the front of the vehicle and on its right-hand side. These register objects and other road users at a distance of up to two metres from the cab. If other road users are moving closer, the driver receives a visual warning by means of LED warning lamps, as well as an acoustic warning via a signal tone. This empowers the driver to detect the potentially hazardous situation in good time and to respond accordingly.
This equipment can be ordered as a factory-fitted feature or retrofitted.
MAN Truck Modification: Optimising vehicles for industry-specific use
MAN has more than 30 years of experience in modifying trucks to satisfy customer requirements that cannot be met in mass production. The demand for special conversions as one of the basic elements of an ideal and economical transport solution is constantly growing, as is demand for interior and exterior customisation by “MAN Individual” to increase the attractiveness of the driver’s workplace.
- MAN Individual adds emotional value to MAN trucks
- Vehicle modifications designed and implemented for cab, chassis, driveline and electronics
- Benefits for customers: single point of contact, work carried out according to documentation and warranty guidelines, along with quality assurance process
- Vehicle service available at any MAN branch.
Many customers and body manufacturers request adaptations to the chassis, driver’s cab or driveline so they can put their vehicle to industry-specific use. This task of adapting the chassis that rolls off the production line at MAN to the needs of customers is performed by MAN Truck Modification at its sites in Munich and Wittlich, Germany, as well as in Steyr, Austria.
The benefits for customers include having a single point of contact in their sales associate, who controls the implementation of the requirements together with MAN Truck Modification. The work is carried out according to the highest quality standards in line with DIN EN ISO 9001, and includes MAN vehicles’ warranties. Once completed, the modification work is included in the invoice for the complete vehicle. In addition, brand-specific expertise in vehicle engineering has a direct presence in MAN Modification’s technical and production teams.
Modifications to the cab
MAN Truck Modification has been working on cab design at the Wittlich plant for more than 25 years. In driver’s cabs, the focus is on extensions or conversions in the form of flat roofs, roof recesses or sloping roofs. Extensive stability tests have been undertaken before the roof conversions are approved. The installation of a crew cab on the MAN TGS chassis has been a new addition since the IAA 2018.
C-cabin extensions are often ordered by municipal services, disaster protection organisations and fire brigades to provide more interior space. The GRP moulded part used instead of the rear wall of the driver’s cab offers around 265 millimetres of extra space.
The construction of crew cabins made of glass fibre reinforced plastic (GRP) for a crew of nine staff is of huge importance when it comes to emergency services vehicles for fire brigades, first responders and disaster protection services. The doors are raised to the edge of the roof for safe entry and exit. MAN put this crew cabin through comprehensive crash tests before it went into mass production. It has been awarded the ECE R29 test certificate for the protection of cab occupants.
Enhancements to the vehicles are another area of focus. Fitting stainless steel panels (including with lights) on the front, roof and sides of a vehicle helps to customise it. The interior is not just a place for driving lesson equipment or installing seating in place of a bed. The insertion of a storage unit on the rear wall of the cab in the XLX and XXL cabs also adds to the sense of comfort. On request, a microwave, coffee machine, kettle or fold-out 15.6”' LED flat screen can be integrated into the built-in storage units. MAN Truck Modification uses leather trim, along with special designs and their adhesive coverings, to create custom and customer-specific one-offs or small batches.
Modifications to the chassis
On the chassis, the main tasks involve making changes to the wheelbases, shortening and offsetting frame overhangs, mounting additional axles and steered rear axles, reinforcing or offsetting the frame, as well as adding and adjusting attachments on the frame. Especially on municipal works vehicles, low-lying equipment boxes or units mounted on the frame (such as brushes and suction shafts on sweepers) mean that the battery boxes, fuel tanks or compressed-air tanks that would otherwise be mounted there need to be relocated. MAN Truck Modification also offers the option of installing a swap body for container transport.
Modifications to the driveline
On the driveline, the standard gearbox can be replaced by a converter automatic gearbox or power take-offs can be adjusted. For special applications, MAN Modification can add suitably designed reduction gears, power take-offs and retarders to the driveline.
Modifications to the electronics
Work on electronic systems may include installing additional lights, roadwork spotlights, warning devices, reversing video systems, radio technology, or power and air supply systems. But these are also closely coordinated with the other modification tasks, as their retrofitted or converted units need to be integrated into the vehicle electronics.
MAN Modification can offer a complete range of equipment for emergency services vehicles, such as the installation of special signalling devices, radios, a third seat in the driver’s cab and storage boxes on the frame.
MAN provides the “MAN Individual” badge to identify jobs that turn the truck into a unique, customised vehicle. The external and internal enhancements boost the owners’ and drivers’ enthusiasm for their vehicle. MAN Truck Modification works together with the customer to plan the implementation of their individual requests. In terms of the exterior, this may involve special adhesive coverings, stainless steel steps, hub caps, or low, side and highbars with lighting (including on the roof). Interior modifications revolve around upgrading the driver’s workplace and rest space. The range of tasks that can be undertaken to enhance occupants’ sense of comfort and enjoyment include coloured leather trim, rotating co-driver’s seats, LED lighting in various colours, and made-to-order built-in cabinets in the XLX and XXL cabs. Coffee makers, kettles and a fold-out 15.6” LED flat screen can be integrated into the built-in storage units on request.
New at IAA 2018: MAN TGS with crew cab
MAN is now adding its popular crew cab to the MAN TGS series, with MAN Truck Modification seeing to its installation.
- Four-door cab with up to seven seats
- Easy to enter thanks to large, wide-opening crew compartment doors
- Simple order processing with MAN Truck Modification
- IAA exhibition model with box body specially added by MAN Bus Modification Center
The crew cab available in the MAN TGL and TGM series can be counted as a success story. It can be used in many situations that call for a number of other people to travel along with the driver. The parties interested in the spacious, four-door crew cabs include municipal services, disaster protection organisations, fire brigades, first-aid services, mining companies, building contractors, gardeners and landscapers, as well as users of exclusive expedition vehicles and RVs. By autumn 2018, the range of crew cabs will be expanded to include the TGS series, with MAN Truck Modification taking care of implementation. The cab is currently available for two- and three-axle chassis with medium-high and high design height, with 4x2 BL, 4x4 BB, 4x4 BL, 6x4 BB, 6x4-4 BL and 6x6 BL drive configurations. MAN also offers the crew cab as part of the TGS 4x4H BL and 6x6H BL in combination with the innovative HydroDrive drive system.
The dimensions of the crew cab are identical for all three series (TGL, TGM and TGS). Its interior’s width is 2,056 mm, the length is 2,650 mm, the height at the front above the centre tunnel is 1,385 mm and the height at the rear in front of the seat bench is 1,620 mm. The maximum standing height in front of the driver’s seat measures 1,645 mm. There are four seats, including seat belts, attached to the seat bench. Along with a double seat at the front, up to seven people can be accommodated in the cab. The box under the rear seat bench can boast a capacity of 265 litres. Wide doors, which open wide at 85 degrees, make entering and exiting an easy task. The crew cab can be tilted hydraulically for maintenance work.
Off-road exhibition vehicle
The MAN TGS 26.500 6x6 BB with 20″ single tyres, which will be on display at the IAA 2018 in Hanover, has been assembled with a special box truck body as an exhibition model in the style of an expedition vehicle. Its custom interior fittings were installed at the MAN Bus Modification Center in Plauen. The front area is taken up by a group of seats, from which occupants can view a large screen for meetings and presentations. A small kitchenette can be used to supply guests with hot and cold drinks. The centre of the box truck body provides space for product presentations. A staircase leads from the body up to the accessible roof.
In a similar vein, the MAN Bus Modification Center could also conceivably convert externally sourced box bodies into off-road expedition vehicles or made-to-order motorhomes. With the addition of the MAN TGS crew cab supplied by MAN Truck Modification, family, friends and acquaintances can join the driver during trips in comfort and safety.