Tailored exhaust-gas systems.

Innovative MAN solutions for Euro 4 and Euro 5.

 Engineering feat.
Giving the air a break. The Euro 4 limits are considerably stricter than those of Euro 3.
The share of nitrogen oxides will be reduced by approximately
30 % and the share of particulates by approximately 80 %. The
Euro 5 standard valid from 2009 specifies a further dramatic
reduction of the nitrogen oxide. The major challenge in both
cases lies in the conflict of technical objectives between the
reduction of both nitrogen oxides and the particulate share
in the exhaust gas: modifications within the engine to reduce
only the nitrogen oxides increase the creation of particulates
– and vice versa.
MAN solutions looking to the future.
The required reduction of pollutants in the exhaust gas can be
achieved with two different technologies. MAN has both systems
in its programme and thus offers the customer the perfect
exhaust-gas technology for every region and area of application.
EGR and MAN PM-KAT® filter
Cooled exhaust-gas recirculation EGR combined with the
maintenance-free MAN PM-KAT® filter, which fulfils Euro 4
without any additional additives, is offered exclusively by
MAN. MAN will also offer this system for Euro 5. In view of
its outstanding advantages the majority of customers opt
for this system.
SCR technology MAN AdBlue®
SCR technology fulfils Euro 4 and Euro 5 already today.
To keep the nitrogen oxides within the required limits down-
stream of the engine this technology requires the reducing
agent AdBlue®. Owing to the early fulfilment of the Euro 5
requirements the SCR solution is subsidised by the state
in Germany (toll) and Switzerland. It can therefore be worth-
while for customers who cover high kilometrages on long-
haul assignments.

Nox in g/kWh
14.4
PM in g/kWh

9.0
Trucks are getting cleaner and cleaner. Since 1990 the goal
of the Euro limits has been to achieve a drastic reduction in
7.0
the pollutant emissions from trucks. This must be taken to
fulfil the Euro 4 step by October and Euro 5 by October 2009.
5.0
This is necessary to fulfil the far stricter regulations. For the
3.5
first time it is now technically absolutely essential to combine
measures within the engine with effective systems for the treat- 2.0

ment of exhaust gas. MAN has developed innovative exhaust

0.7 0.4 0.15 0.1 0.02 0.02
gas technologies and offers customers convincing Euro 4 and
Euro 5 solutions for the future. Euro 0 Euro 1 Euro 2 Euro 3 Euro 4 Euro 5
1990 1992 1995 2000 ab 2006 2009 Reduction of limits
from Euro 0 to Euro 5

2 3

A clean edge: EGR and MAN PM-KAT .
Innovative engineering, exclusively from MAN.
The cooled and regulated external exhaust-gas recirculation
(EGR) used by MAN makes it possible to reduce the share of
nitrogen oxides (NOx) within the engine to the extremely low
values required by Euro 4. The PM-KAT® is also used to comply
with the Euro 4 particulate values. The system used is a parti-
culate separation system in the stainless steel silencer which
functions free of maintenance and without clogging and does
not require any additional fluid. The PM-KAT® filter eliminates
an above-average amount of the smallest particulates.
MAN PM-KAT®: Advantages with no disadvantages.
Reliable, maintenance-free system made of stainless steel
No change in fuel consumption
Independent of AdBlue® infrastructure
No restrictions in space; the maximum tank volume
is maintained
Weight advantage of up to 150 kg compared with SCR technology
4 5
In future for Euro 5 too.
The system consisting of EGR and the MAN PM-KAT® filter is
a unique solution with numerous advantages with regard to
economy, reliability and customer friendliness. For this reason
PM-KAT® : Particulates separated
MAN will be offering this exhaust-gas cleaning system with
when flowing through
its advantages for Euro 5 too well before this standard comes
into force. We are already well equipped even for Euro 6. This
exhaust-gas standard, which is expected to come into force MAN is the only manufacturer to offer the low-consumption,
from 2012, can be achieved only by EGR combined with SCR. weight- and space-saving EGR/PM-KAT® solution without
Our competitors too will then have to employ exhaust-gas complex engineering and additives.
recirculation.
®
With the system with common-rail injection, EGR and the
PM-KAT® filter MAN offers a technically and economically
advantageous concept for the TGL, TGM and TGA ranges.
This solution does not require any AdBlue® and thus does not
depend on the AdBlue® infrastructure. There are no costs for
maintenance and AdBlue® fluid. Drivers do not have to make
any extra stops to refuel, and they save up to 150 kg in weight
compared with SCR technology. And last but by no means
least MAN’s engineering requires neither a higher fuel consump-
tion nor any extra space on the chassis and it is considerably
cheaper to buy.
Above-average elimination of the smallest particulates
No restriction on the payload capacity
No complicated metering units and monitoring
systems necessary
Much cheaper than SCR technology
 Pre-catalyst
PM separator

Pre-catalyst PM separator

Exhaust gas flow in the TGA silencer Exhaust gas flow in the TGL silencer

Making the smallest particulates

bite the dust.
The dust is up. Better than any soot filter: the MAN PM-KAT®.
This topic has raised a lot of dust in every sense. The discus- Classic diesel soot filters reduce the particulate emission by up
sion is about how the impact of fine dust can be effectively to 99 %. However, the innovative PM-KAT® filter is currently the
reduced and what can be done to counteract the health risks, only maintenance-free system which is also able to effectively
above all in big cities. Fine dust is made up of minute parti- reduce the smallest particulates that contribute to fine dust.
cles with a diameter of < 10 μm (microns) which – among The separation quota is already 60 to 90 % (dependent on the
other sources – are also produced from unfiltered diesel size of the particulates) - which really gives it a clean edge.
engines of cars and trucks. Since micro-particulates pose a
health risk the European Union has passed a directive on the
maximum permissible values for dust which became effective
as of January 1st 2005. However, the permissible maximum
value of 50 micrograms of dust per cubic metre of air is
exceeded, above all in urban areas. Action must be taken.

1E+14 100
Standardised number of particulates (particulates/kW/h)

9E+13 90

8E+13 80

7E+13 70
Separation (%)

6E+13 60
–– Upstream of PM-KAT®
5E+13 50
–– Downstream of PM-KAT®
4E+13 40
–– Separation (number)
3E+13 30

2E+13 20

1E+13 10

0 0
1 10 100 1000
Fine dust reduction with the PM-KAT® Electric mobility diameter (nm) Measurement with SMPS
Separating efficiency and particulate size

6 7

The MAN AdBlue SCR technology –
®
toll savings into the bargain.
8 9
Euro 5 inclusive.
The exhaust-gas technology that already fulfils Euro 4 and
Euro 5 today is known as MAN AdBlue®. With this so-called
SCR technology the nitrogen oxides are reduced in a second-
ary ceramic catalyst, the SCR-Kat. AdBlue®, a non-toxic and
odourless urea solution, is required for this system.
This urea solution is injected into the flow of exhaust gas and in
the catalyst converts the nitrogen oxide (NO) into water vapour
and elementary nitrogen, a natural element in the air. This tech-
nology reduces the NOx by over 80 %. An on-board diagnostic
system (OBD) checks and ensures that the exhaust gas values
are complied with.
With the MAN AdBlue® system the engine is optimised with
regard to particulate emissions and fuel consumption and the
nitrogen is removed from the exhaust gas in the secondary
removal system. The output of the engine is in no way impaired
and the fuel consumption can even be lowered. A unique
feature among all the suppliers of SCR technology is that the
dimensions of the exhaust silencer are unchanged with the
MAN AdBlue® solution so it does not take up any extra space.
The TGA Euro 5 concept: MAN AdBlue ®
Urea metering
system
AdBlue
mixer
R-KAT NOx reduction
O-KAT NH3 oxidation
The AdBlue® tank forms a unit with the diesel tank (combined
tank) and it is heated to prevent urea freezing in winter.
Driving and saving on long hauls.
If you already operate Euro 5 vehicles today you can save
motorway charges in Germany and in the long term you will
also drive more economically in Switzerland too. This can
be worthwhile for trucks on long-haul assignments with high
annual kilometrages on German motorways or mainly for
service in Switzerland. However, the state benefits for the early
fulfilment of the Euro 5 standard are set off against the higher
investment and operating costs of SCR technology. Since the
SCR technology is worthwhile solely for long-haul assignments
MAN offers this solution exclusively for the TGA range.
Urea
tank
R-KAT
O-KAT
4NO + O2 + 4NH3 4N2 + 6H2O
3NO2 + 4NH3 2N2 + 6H2O
4NH3 + 3O2 2N2 + 6H2O
Frequently asked questions.
MAN answers.
When do the new exhaust gas directives apply? Euro 4 has applied since October 1st 2005 for newly
homologated vehicles and from October 1st 2006 for all
newly registered vehicles. Euro 5 will become effective from
October 1st 2008 or from October 1st 2009.
Why is MAN offering two exhaust-gas technologies for Euro 4 and Euro 5? MAN’s solution with EGR and the PM-KAT® filter is a technically
and economically convincing system. MAN will also be offering
this system for Euro 5 in good time before this standard comes
into force. The SCR technology MAN AdBlue® is available now
for customers who would already like a Euro 5 solution.
Which solution does MAN recommend? MAN’s system with EGR and the PM-KAT® filter is predestined
for customers who drive on motorways only to a small extent,
for whom space plays an important role (construction, public
utility, special-purpose vehicles), whose transport assignments
are payload-intensive (tank and bulk tank branch). SCR tech-
nology is a good idea for vehicles on long-haul assignments
with high annual kilometrages on German motorways and in
Switzerland. They benefit from the lower tolls and road charges
for Euro 5.
How does the PM-KAT® function? In the PM-KAT® filter particulates are separated by the deliberate
creation of turbulence when the exhaust gas is redirected into
the separator and by the passage through the sintered metal
fleece. The disintegration of the particulates deposited in the
fleece is the result of a permanent chemical reaction which is
brought about with the aid of the NO2 in the oxidation catalyst.
What are the advantages of external exhaust-gas recirculation (EGR)?
What is AdBlue®?
How high is the consumption of AdBlue®?
What is the benefit of the OBD 1 on-board diagnostic system?
When the exhaust gas is recirculated externally the cooled
mixture of exhaust gas and fresh air reduces the combustion
temperature. This cuts the share of nitrogen oxide in the
exhaust gas. However, at the same time the share of particu-
lates increases. The PM-KAT® must therefore be installed
downstream in order to achieve the specified values.
AdBlue® is a urea solution which is extremely clean, colour- and
odourless and completely harmless. With the aid of AdBlue®
harmful nitrogen oxides are chemically converted into nitrogen
and water vapour when they emerge from the engine.
An AdBlue® consumption of approximately 3-4 %, of the diesel
consumption has been quoted for Euro 4 vehicles, for Euro 5
vehicles approximately 5-7%.
The OBD is a diagnostic system which monitors exhaust-gas-
relevant components. The purpose of the on-board diagnostic
system, which will be mandatory as of October 1st 2006, is to
ensure the level of exhaust-gas emissions not just at registra-
tion but for the service life of the vehicle. Euro 4 and Euro 5
trucks from MAN are equipped with OBD 1.
11
MAN Nutzfahrzeuge Group
Postfach 50 06 20
D-80976 München
www.man-mn.com
A member of the MAN Group

D 111.3324/E · mu 06054 · Printed in Germany

Text and illustrations not binding.
We reserve the right to make changes in the course of technical progress.