MAN TGL - universal trucks for urban and regional transport

MAN TGL is a large-capacity truck made in Germany. It is included in the list of the most popular and sought-after trucks of the MAN brand. In this regard, this model is in great demand not only in the European market, but also in many other countries.

MAN TGL is primarily focused on cargo transportation in urban environments. But, despite this, its cabin has a lot of different options, also available in long-range vehicles.

For example, the equipment of the driver's seat is completely reminiscent of the heavy-duty truck tractors of the MAN TGX family, which guarantees increased operating comfort.

The design of the cabin itself does not have a high ceiling, but in some modifications it has a very comfortable sleeping place. Also, when compared with similar trucks, the MAN TGL cabin is more spacious.

The name TGL stands for Trucknology Generation Light, which means a family of light trucks designed for urban use. This family is the third major project developed by the manufacturer in the 2000s with the aim of updating the then existing range of trucks.

Story

The history of such trucks begins in the 1970s. Then MAN, together with the Volkswagen company, developed light commercial trucks with a cabover layout, intended for the distribution of any cargo within the city. The basis for them was the frame of the medium-duty G90 model, and the design from the Volkswagen LT was used as the cab. Since the production of such cars was joint, two emblems were placed on the radiator grille, namely MAN and VW.

In 1994, the manufacturer carried out a fairly deep restyling, after which the updated truck began to be equipped with a more spacious cabin. At the same time, it was renamed L2000 and belonged only to the MAN brand. This model remained in mass production until 2005.

In the 2000s, MAN specialists began developing new families of trucks. Initially, these were heavy versions of truck tractors, called MAN TGA. In addition, the manufacturer began to introduce a new diesel power unit of the D20 brand, which has an electronic CommonRail fuel system, into the range of engines. At the same time, a lighter urban family known as TGL (Trucknology Generation Light) was also being developed. And while the TGA models successfully entered the market, the TGL took another four years to fine-tune. As a result, MAN TGL trucks were introduced to consumers in 2005.

The era of similarists

The event has not yet ended, and comments are already appearing on the Internet: “it feels like Chinese designers are successfully emigrating around the world,” “they look like DAF cars,” “they definitely ripped off design elements from IVECO.” These are comments on social networks by people who are very categorical and equally illiterate; it’s not for nothing that they are called “similarists,” because most of their messages begin with the words “similar to.”

But it’s true that the company can present something radically new to the modern driver. Nothing! As the director of the US National Patent Office, William McKinley, wrote in his memorandum back in 1899: “Everything that could be invented has already been invented.” Therefore, companies are perfecting what they have already worked on in previous years, and this is an absolutely correct strategy.

For its new truck, MAN did not develop a completely new cab, but perfected the successful frame from 2000, presented in the TGA series. But in their search for optimal solutions, the company’s designers did not proceed from some speculative ideas, but based on specific proposals from experienced drivers. To gain such knowledge, we had to discuss prototypes of various solutions with specific specialists, and there were more than 700 of them. We had to visit service centers, because it was there that the service experience was concentrated and those who operate these machines most often appeared. The motto of this generation of MAN vehicles is nothing less than “Simply my Truck” - this is a kind of basis for development. At the presentation, it was repeatedly emphasized that the main task was and is to create an ideal workplace and a cozy living space, and the design of the car should be based on the personal experience of the drivers.

In addition to personal contacts with drivers, MAN specialists organized a special meeting in Munich, where they invited 300 local and foreign customers from 16 countries to determine together the most important segments of the new vehicle line. All data was compared, analyzed, and based on it, key ideas and fresh solutions were identified. This is how a new generation was born.

Modifications

The MAN TGL truck is offered to consumers in several modifications. Cars with vans on board are in greatest demand. This is explained by the fact that such equipment has good load capacity and fairly compact overall dimensions. Thanks to the latter, the truck can easily maneuver in city traffic and limited space. Another advantage of this design is the low loading height, which makes unloading and loading processes easier.

Two main modifications should be highlighted:

• MAN TGL 12.180. This version has an isothermal van and has a maximum load capacity of 12,000 kilograms. Despite this indicator, this truck is the lightest among other vehicles in its class. The main purpose of the modification is to transport any cargo both short and long distances. Moreover, for long trips the cabin has a sleeping compartment;
• MAN TGL 8.180. Just like the previous version, this one is equipped with an insulated van. However, the maximum carrying capacity is already 5000 kilograms. As for the scope of application, everything is similar here: the truck is used mainly in urban environments, but can also travel outside of it. Intercity transportation makes it possible to have a sleeping place.

Add-on options

Trucks can be equipped with various add-ons depending on the needs of the consumer. Most often you can find a truck equipped with:

1. A manufactured goods van;
2. Isothermal van;
3. Refrigerator;
4. Onboard cargo platform;
5. Crane-manipulator installation.

Also, in addition to this, a tank truck and much more can be installed on the truck chassis.

Appearance

The style of this truck is reminiscent of other MAN brand vehicles. There is also a rectangular grille with a large logo in the center. A plastic bumper is installed in the lower part of the front of the cab. There are two rectangular blocks installed in the bumper on each side. The upper ones are responsible for low and high beams, when the lower ones are equipped with fog lights and direction indicators. In the center section, as on many other trucks, there is a wide cutout that acts as both an air intake and a step that allows you to clean the windshield from the outside.

From the side the car looks very simple. There are also plastic wheel arches that protrude slightly beyond the cabin. The arches are combined with a step for access to the cabin.

In modifications where the cabin is equipped with a berth, its side walls closer to the rear have spacious niches in which you can store any tools, wheel chocks and much more.

Cabin

The MAN TGL has a fairly large cabin, at least for the distribution truck class. Due to the increase in the overall dimensions of the cabin, the manufacturer also needed to make some changes to the front suspension.

In terms of equipment, the installed cabin is practically in no way inferior to heavier trucks of the MAN brand. For consumers, this model is offered in four cabin variations. Two of them provide a sleeping place, and the overall dimensions themselves have been increased. The other two are simple options that do not include a sleeping bag. Therefore, they have standard sizes.

The basic cabin is equipped with two seats, but if necessary, another passenger seat can be installed between them. The most innovative version is the double cab, which has a second row of seats. This design allows you to take seven people on board.

Reliable and high-quality plastic is used in many elements of the cabin. The interior trim features aluminum and steel areas in places. In addition, the design includes fabric inserts made from natural fibers. The door handles, like many other cars, have chrome.

The driver's seat is characterized by increased comfort and convenience. It has an air suspension that smooths out road irregularities and lumbar support, allowing you to work for a long time without fatigue and back pain.

The interior of the truck also has various shelves and niches designed to store some things or tools.

In addition to glass on the doors, narrow windows are installed in the cabin design. They do not bring any benefit when performing various maneuvers, but they capture the area of ​​the sleeping compartment.

To protect from the sun when parked, the cabin is equipped with curtains on plastic curtain rods. They protect the side glazing when roller blinds have been installed for the windshield.

As for free space, there is not so much of it here, even despite the rather large overall dimensions of the cabin itself. However, for two people it turned out to be quite comfortable and spacious.

In terms of noise and vibration insulation, the MAN TGL is inferior to many of its analogues, since these qualities are below average. When the engine is running, you can clearly hear it inside.

Options

The truck comes standard with a radio, good heating system, power windows and a manual sunroof.

The driver's seat has air suspension, which significantly increases driving comfort. In addition, the seat is equipped with many position adjustments and armrests.

A static seat with rigid fixation was installed for the passenger, but despite this, it is quite comfortable. There are also adjustments here, but only for the longitudinal position and angle of the backrest.

Together with other MAN brand trucks, this model has a full complex containing various control systems and instruments. The presence of these greatly makes driving a car convenient and understandable. The complex itself consists of:

1. Electronic ABS system, providing more efficient and safe braking:
2. Decent audio system;
3. A small refrigerator that allows you to take various food products with you on the road;
4. Electronic panel in the sleeping compartment, equipped with an alarm clock;
5. Hydraulic power steering, which makes maneuvering more convenient;
6. Effective climate control;
7. A mechanical sunroof provides additional interior ventilation in hot weather conditions.

Additional options

Among the additional options, it should be noted the installation of a button for locking and unlocking door locks. It is installed on the console next to the driver's seat. The power window buttons are also duplicated here.

An EVB engine brake is also optionally installed, which is necessary for braking on long descents and in other similar situations. Thanks to it, the service life of the brake pads is increased.

Engine access

Since the truck has a cabover design, the engine is located directly under the cab. To access it you need to raise the cabin. This operation is performed using a special lifting mechanism, presented in the form of a hydraulic pump and a power cylinder.

Cozy living space

The night cab of a MAN truck tractor has one lower berth as standard, with an optional folding upper berth. The new generation of MAN trucks features a bed with a lattice plane fixed inside a steel frame. The individual elements of the lattice structure consist of different materials with different characteristics. There can be seven zones that adapt to different parts of the body, and this design also ensures good ventilation of the mattresses.

The size of the lower mattress is 2000 mm by 800 mm, in the middle part the width is slightly narrower - 700 mm. The upper berth is smaller: 1970 x 7150 mm. Mattress thickness – 110 mm.

Above the lower berth there is a shelf with a cup holder for small items such as mobile phones or glasses. On the rear wall of the cab there is a large storage compartment consisting of several parts. A net attached to the roof with two straps protects against falling from the upper bed. Raising the bottom bunk opens up additional storage space for large items under the bunk.

In the middle part of the compartment there is an additional remote control. Using it, the driver has access to an endless range of functions right from the bed. It can control the window lifting and door locking mechanisms, activate the auxiliary air conditioning system, autonomous heating and lighting, change the temperature, etc.

Specifications

Engine

The line of installed power units includes modernized D08 diesel engines with four cylinders arranged in a row. They are equipped with an electronic CommonRail fuel system from Bosch, turbocharging and intercooling of charge air.

Basic characteristics of D08:

1. Working volume – 4.6 l;
2. Rated power – 220 hp;
3. Cylinder diameter – 108 mm;
4. Piston stroke – 125 mm;
5. Maximum torque – 579 Nm;
6. Engine weight – 360 kg.

Depending on the modification of the truck itself, the maximum power of such an engine can be 150, 180 or 206 horsepower.

In addition to this option, some versions are equipped with six-cylinder in-line diesel engines with a displacement of 6.9 liters. Their maximum output power reaches 240 horsepower. They are used, as a rule, on the heaviest modifications. In terms of equipment, the engines are identical to the previous ones; there is a CommonRail electronic fuel system and turbocharging with intercooling of charge air.

As for environmental friendliness, both options comply with Euro-4 environmental standards.

Fuel consumption

On average, a MAN TGL truck consumes about 20 liters of diesel fuel per 100 kilometers. The fuel tank has a volume of 200 liters, which is enough for a very long operation without refueling.

checkpoint

The type of gearbox used depends on the installed engine. Thus, for the version with a 150 horsepower engine, a five-speed manual transmission manufactured by ZF is offered.

For models equipped with engines with a power of 180 and 206 horsepower, a six-speed manual transmission from the same manufacturer is offered.

In addition, all four-cylinder power units can be equipped with a six-speed automatic transmission of the MAN TipMatic brand, the development of which was based on the ZF-Ecolite manual gearbox. The selection of the required gear in such a transmission is carried out electronically. Switching is provided by hydraulic cylinders. They also release the clutch.

Paired with the six-cylinder power plant is an Eaton manual transmission, which has eight direct gears and one reduction gear (Crawler).

Practical excellence

According to the company, the ideal combination of powertrains with new, more fuel-efficient drive components and new software will give future model families exceptional efficiency. Thanks to improved aerodynamics, the new cars achieve 8% lower fuel consumption, while naturally reducing CO2 emissions. The new turn assist helps prevent serious accidents in city driving. The Lane Change Assistant warns the driver of vehicles in adjacent lanes. In addition, the presence of additional on-board software that provides practical training while driving helps drivers maintain a more efficient driving style. Optimized maintenance and service reduce operating costs, and the new MAN vehicles also feature improved payload capacity.

Along with new cars, the company decided to introduce new work with customer proposals, entirely focused on their needs. The system follows the logic of an approach to assembling a truck based on its usage profile. According to this idea, at the finish line the car must exactly correspond to the transport task. This approach involves the use of individually coordinated maintenance services. And the MAN Individual program simply offers an extensive range of additional options, allowing the vehicle to be adapted at the factory in accordance with the customer’s special wishes.

Brake system

The manufacturer has introduced all the latest devices into the braking system of the MAN TGL truck to ensure maximum safe driving. There is an EBS electronic control unit that helps the driver in difficult road conditions. The standard equipment is equipped with ABS and ASR systems, which also have a significant impact on increasing the safety and efficiency of the braking system.

The brake system has two independent circuits and a pneumatic booster. Disc brakes are used on the wheels of the front axle, while classic drum brakes are used at the rear.

Environmental component

The reliable MAN engines with exhaust gas recirculation are complemented by MAN AdBlue® emission control technology to meet Euro 6 requirements. AdBlue® consumption is only 2 – 2.5% of diesel fuel consumption. In addition, the new TGL and TGM already have the HCI (hydrocarbon injection) regeneration principle in their base, which ensures the regeneration of the particulate filter even in engines operating at partial load, for example in distribution vehicles or in public utilities. This ensures that the exhaust gas aftertreatment will work even under the most severe operating conditions.

Chassis

The car has a reinforced chassis. Despite the very compact overall dimensions of the truck, it is capable of transporting any cargo of significant weight.

The front suspension uses a pair of single leaf springs. Although the design looks flimsy, its load capacity is 4400 kilograms, and this already inspires confidence. All this is complemented by bi-directional hydraulic telescopic shock absorbers.

For the rear suspension, the manufacturer has already used three-leaf springs that can withstand a maximum weight of 8400 kilograms. However, in some modifications, air suspension with durable rubber cushions is also available.

dimensions

1. Total length – 11260 mm;
2. Full width – 2550 mm;
3. Total height – 3580 mm;
4. Wheelbase length – 3050 mm;
5. Wheelbase length – 3300 mm;
6. Wheelbase length – 4815 mm;
7. Wheelbase length – 4850 mm;
8. Wheelbase length – 6700 mm;
9. Rear overhang height – 1191 mm;
10. Van length – 6230 mm;
11. Van width – 2420 mm;
12. Van height – 2450 mm.

Peculiarities

Despite the presence of various modified versions of this truck, the most popular at present are still the versions with a van. This is due to the fact that, despite its fairly compact overall dimensions, the truck has a very large load capacity. The car is easy to maneuver in urban conditions, as well as in limited free space. In addition, TGL models are characterized by a low loading height, which simplifies the loading and unloading processes.

The front axle uses disc brakes, which are very effective indeed. However, they are poorly resistant to deicing agents and road dirt, and therefore, when used in Russian conditions, these elements fail ahead of schedule. To prolong their service, it is necessary to clean and lubricate the guides, and also to prevent them from overheating.

If on most other modern trucks the gearbox uses either cable or hydraulic drives to change speeds, then in this model only rods are used. The introduction of such a solution is due to higher reliability, simplicity, and durability.

But it is worth noting that there is no telescopic mechanism, which is why there is a large hole in the cabin floor, like in cars produced in the 20th century.

Since this truck has been on the Russian market for quite a long time, almost its entire design, including weak and strong points, has already been well studied by service centers. In this regard, any repair work or simple maintenance will not cause any special problems. In addition, it is worth noting that spare parts are quite widespread.

Invisible helpers

In addition to the well-thought-out, functional and comfortable cabin design, the new MAN vehicles feature many invisible assistants that make the driving task easier for the driver. The most important of these are radar sensors. When turning, the vehicle system monitors the blind side area next to the vehicle on the co-driver's side. When interference occurs, the LED modules in the front pillar begin to blink: the closer the object, the more modules signal.

The new generation cars also have a Lane Change Support (LCS) system - support for safe lane changes. It uses radar sensors and, when driving at a speed of 50 km/h or more, monitors the side zones to the left and right of the truck's lane. If, when changing lanes, the sensors detect a dangerous situation due to a vehicle approaching from behind, they warn the driver using LEDs on the A-pillars.

If the vehicle risks veering out of its lane without activating the turn signal, Lane Return Assist (LRA) is activated and not only informs the driver of the unauthorized departure, but automatically intervenes and guides the vehicle back into the marked lane area.

The new generation of MAN trucks is equipped with many other highly intelligent safety systems. For example, ACC Stop & Go maintains the correct safe distance in front of the vehicle in front in the form of adaptive cruise control. The ACC Stop & Go extension slows the vehicle down when necessary when getting dangerously close to the car in front and even stops and then starts the truck again. Emergency Brake Assist (EBA) intervenes when there is a risk of a rear collision and warns the driver. And the MAN AttentionGuard assistant constantly evaluates the driver’s attention and issues a warning in case of frequent violations.

Flaws

The MAN TGL model is modern and high-tech, which is both an advantage and a disadvantage at the same time. The latter is explained by the fact that the truck must be operated with real care. Moreover, this applies not only to working conditions, but also to the road surface, as well as the diesel fuel being poured. And if you neglect at least one of these points, then any malfunctions can appear quite quickly.

Problems with the fuel system and engine in general are mainly related to fuel economy. Some owners try to save money by filling the tank with cheap fuel, but this option is usually of low quality, which negatively affects the operation of the entire system. The suspension can be damaged by everyday use of the truck on poor road surfaces.

It is also worth noting that it is necessary to overcome any puddles with the utmost care, since elements such as the radiator and plastic tanks are located very low.

Among other disadvantages of this model, one should highlight the high cost, not only for trucks in new technical condition, but even for used equipment. According to this parameter, MAN TGL is inferior to many of its analogues.

Price

The price of the new MAN TGL truck, depending on its version, starts at 5.3 million for the chassis and 6.6 million rubles for the variation with a curtain-sided cargo platform. Van conversions tend to cost a little more.

The secondary market also has many interesting offers. Here this truck can be purchased at a cost ranging from 950 thousand to 4.5 million rubles. The price of a used car is influenced by factors such as year of manufacture, type of modification, type of installed superstructure, technical condition, and mileage.

Project in numbers

The launch of a new generation of MAN vehicles on the market is the company’s most ambitious project in the last 20 years. During the work on it, 12,000,000 working hours were spent, which approximately corresponds to 1,300 years of life. Before entering the market, the trucks completed 4,000,000 test kilometers, which corresponds to four trips around the globe. As part of this project, 2,800,000 lines of program code were written; this figure cannot be compared with anything. 167,000 working hours were spent on developing the design of new cars. About 22,000 new product items have been integrated into all departments of the company. 2,100 MAN employees, the entire team of 36,000 employees, were directly involved in the project. Eight cab variants of different sizes are available for the four MAN model families TGX, TGS, TGM and TGL