Tailored exhaust-gas systems.

Innovative MAN solutions for Euro 4 and Euro 5.

Giving the air a break.

Engineering feat.

MAN solutions looking to the future.

The Euro 4 limits are considerably stricter than those of Euro 3.

The required reduction of pollutants in the exhaust gas can be

The share of nitrogen oxides will be reduced by approximately

achieved with two different technologies. MAN has both systems

30 % and the share of particulates by approximately 80 %. The

in its programme and thus offers the customer the perfect

Euro 5 standard valid from 2009 specifies a further dramatic

exhaust-gas technology for every region and area of application.

reduction of the nitrogen oxide. The major challenge in both

EGR and MAN PM-KAT filter

cases lies in the conflict of technical objectives between the

Cooled exhaust-gas recirculation EGR combined with the

reduction of both nitrogen oxides and the particulate share

maintenance-free MAN PM-KAT filter, which fulfils Euro 4

in the exhaust gas: modifications within the engine to reduce

without any additional additives, is offered exclusively by

only the nitrogen oxides increase the creation of particulates

MAN. MAN will also offer this system for Euro 5. In view of

and vice versa.

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 downstream 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 worthwhile for customers who cover high kilometrages on longhaul assignments.

Nox in g/kWh
PM in g/kWh

14.4

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

gas technologies and offers customers convincing Euro 4 and
Euro 5 solutions for the future.

0.7
Euro 0
1990

0.4
Euro 1
1992

0.15
Euro 2
1995

0.1
Euro 3
2000

0.02
Euro 4
ab 2006

0.02
Euro 5
2009

Reduction of limits
from Euro 0 to Euro 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
when flowing through

MAN will be offering this exhaust-gas cleaning system with

its advantages for Euro 5 too well before this standard comes
into force. We are already well equipped even for Euro 6. This

A clean edge: EGR and MAN PM-KAT .

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.

Innovative engineering, exclusively from MAN.

The cooled and regulated external exhaust-gas recirculation

With the system with common-rail injection, EGR and the

(EGR) used by MAN makes it possible to reduce the share of

PM-KAT filter MAN offers a technically and economically

nitrogen oxides (NOx) within the engine to the extremely low

advantageous concept for the TGL, TGM and TGA ranges.

values required by Euro 4. The PM-KAT is also used to comply

This solution does not require any AdBlue and thus does not

with the Euro 4 particulate values. The system used is a parti-

depend on the AdBlue infrastructure. There are no costs for

culate separation system in the stainless steel silencer which

maintenance and AdBlue fluid. Drivers do not have to make

functions free of maintenance and without clogging and does

any extra stops to refuel, and they save up to 150 kg in weight

not require any additional fluid. The PM-KAT filter eliminates

compared with SCR technology. And last but by no means

an above-average amount of the smallest particulates.

least MANs engineering requires neither a higher fuel consumption nor any extra space on the chassis and it is considerably
cheaper to buy.

MAN PM-KAT: Advantages with no disadvantages.

Reliable, maintenance-free system made of stainless steel

Above-average elimination of the smallest particulates

No change in fuel consumption

No restriction on the payload capacity

Independent of AdBlue infrastructure

No complicated metering units and monitoring

systems necessary

No restrictions in space; the maximum tank volume

is maintained

Much cheaper than SCR technology

Weight advantage of up to 150 kg compared with SCR technology

Pre-catalyst
PM separator

Pre-catalyst

Exhaust gas flow in the TGA silencer

PM separator

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 m (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

1E+14

100

9E+13

90

8E+13

80

7E+13

70

6E+13

60
Upstream of PM-KAT

5E+13
4E+13

40

Separation (number)

3E+13

30

2E+13

20

1E+13

10

0
1

Fine dust reduction with the PM-KAT

Separating efficiency and particulate size

50

Downstream of PM-KAT

Separation (%)

Standardised number of particulates (particulates/kW/h)

exceeded, above all in urban areas. Action must be taken.

10
Electric mobility diameter (nm)

100
1000
Measurement with SMPS

Euro 5 inclusive.

The MAN AdBlue SCR technology

toll savings into the bargain.

The exhaust-gas technology that already fulfils Euro 4 and

The AdBlue tank forms a unit with the diesel tank (combined

Euro 5 today is known as MAN AdBlue. With this so-called

tank) and it is heated to prevent urea freezing in winter.

SCR technology the nitrogen oxides are reduced in a secondary ceramic catalyst, the SCR-Kat. AdBlue, a non-toxic and

Driving and saving on long hauls.

odourless urea solution, is required for this system.

If you already operate Euro 5 vehicles today you can save

This urea solution is injected into the flow of exhaust gas and in

motorway charges in Germany and in the long term you will

the catalyst converts the nitrogen oxide (NO) into water vapour

also drive more economically in Switzerland too. This can

and elementary nitrogen, a natural element in the air. This tech-

be worthwhile for trucks on long-haul assignments with high

nology reduces the NOx by over 80 %. An on-board diagnostic

annual kilometrages on German motorways or mainly for

system (OBD) checks and ensures that the exhaust gas values

service in Switzerland. However, the state benefits for the early

are complied with.

fulfilment of the Euro 5 standard are set off against the higher
investment and operating costs of SCR technology. Since the

With the MAN AdBlue system the engine is optimised with

SCR technology is worthwhile solely for long-haul assignments

regard to particulate emissions and fuel consumption and the

MAN offers this solution exclusively for the TGA range.

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

Urea
tank

AdBlue
mixer
R-KAT
O-KAT

R-KAT

NOx reduction

4NO + O2 + 4NH3
3NO2 + 4NH3

4N2 + 6H2O
2N2 + 6H2O

O-KAT

NH3 oxidation

4NH3 + 3O2

2N2 + 6H2O
9

Frequently asked questions.

MAN answers.

When do the new exhaust gas directives apply?

Euro 4 has applied since October 1st 2005 for newly

What are the advantages of external exhaust-gas recirculation (EGR)?

When the exhaust gas is recirculated externally the cooled

homologated vehicles and from October 1st 2006 for all

mixture of exhaust gas and fresh air reduces the combustion

newly registered vehicles. Euro 5 will become effective from

temperature. This cuts the share of nitrogen oxide in the

October 1st 2008 or from October 1st 2009.

exhaust gas. However, at the same time the share of particulates increases. The PM-KAT must therefore be installed
downstream in order to achieve the specified values.

Why is MAN offering two exhaust-gas technologies for Euro 4 and Euro 5? MANs 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

What is AdBlue?

AdBlue is a urea solution which is extremely clean, colour- and

into force. The SCR technology MAN AdBlue is available now

odourless and completely harmless. With the aid of AdBlue

for customers who would already like a Euro 5 solution.

harmful nitrogen oxides are chemically converted into nitrogen

and water vapour when they emerge from the engine.

Which solution does MAN recommend?

MANs system with EGR and the PM-KAT filter is predestined

How high is the consumption of AdBlue?

An AdBlue consumption of approximately 3-4 %, of the diesel

for customers who drive on motorways only to a small extent,

consumption has been quoted for Euro 4 vehicles, for Euro 5

for whom space plays an important role (construction, public

vehicles approximately 5-7%.

utility, special-purpose vehicles), whose transport assignments

are payload-intensive (tank and bulk tank branch). SCR technology is a good idea for vehicles on long-haul assignments

What is the benefit of the OBD 1 on-board diagnostic system?

The OBD is a diagnostic system which monitors exhaust-gas-

with high annual kilometrages on German motorways and in

relevant components. The purpose of the on-board diagnostic

Switzerland. They benefit from the lower tolls and road charges

system, which will be mandatory as of October 1st 2006, is to

for Euro 5.

ensure the level of exhaust-gas emissions not just at registration but for the service life of the vehicle. Euro 4 and Euro 5
trucks from MAN are equipped with OBD 1.

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.

11

MAN Nutzfahrzeuge Group

Postfach 50 06 20
D-80976 Mnchen
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.