In the big top! - MAN inmotion

3Temperatures remain at a constant 20°C. During the
test, the engine is lifted off the pallet so that correct
measurements can be made.
The entire test in just three minutes
The last step before the cold test is a leak test on the oil
and water tanks. By pumping these full of air, engineers can
identify weak spots where leaks could occur. Then it’s off to
the testing stand, which is off-limits to humans. The stand
resembles a cleanroom used in chip manufacturing, as
the test can only be successfully carried out when all
environmental conditions are constant. The test is
completely automated. For three minutes, the control unit
measures and assesses various pressures and data while a
laser vibrometer conducts a vibration analysis. As Kocher
says, “In this way, we can precisely determine the quality of
components such as the oil pump and the turbocharger.”
The test is currently being used for D20/D26 engines, built
into the TGS and TGX series, and for D08 engines, used in
the TGL and TGM series.
Committed to environmental protection
The benefits of cold testing are significant. In hot testing,
an engine consumes around 25 litres of diesel per test cycle,
while in cold testing it only uses around two litres. The
process is also much quicker than hot testing, meaning that
the engines can be tested in sync with the assembly line,
which reduces production costs. It’s therefore much more
economical for the company. And the environment also
benefits from cold testing. Since MAN now only runs hot tests
on around ten percent of its engines, it saves an overall
amount of energy each year equal to around 3,000 tonnes of
carbon dioxide. In 2011 this impressive figure brought MAN
an award from the Bavarian Environment Ministry.
“Since 1995 MAN Truck &
Bus has been committed to
developing environmentally
friendly vehicles and engines
as well as energy-efficient
manufacturing and
production processes.”
Dr Heike Sarstedt, Head of Environmental Management
4Vibrometers analyse vibrations and noise and use a
laser (the red light in the picture) to check for faults in
the valve settings. These sensitive devices make the
test results more reliable than ever before.
Dr Heike Sarstedt, Head of Environmental and Safety
Management at MAN Truck & Bus comments on MAN’s
environmental history: “As early as 1995, MAN demonstrated
corporate responsibility by signing a regional environmental
agreement.” Since then, MAN has developed more
environmentally friendly vehicles and engines, made its
production more energy efficient and reduced its
consumption of resources at all its plants. At its headquarters
in Munich, for example, MAN improved the ventilation and
heating systems in the production facilities, saving an average
of around 4,500 tonnes of carbon dioxide a year. MAN Truck
& Bus’s commitment to the environment soon became an
official part of the corporate responsibility strategy of the
entire MAN Group. Its goal is to create sustainable added
value throughout all business strategies and processes in the
belief that businesses, the environment and human beings
can work together in harmony, preserving nature and
resources for future generations. The cold tests at the engine
plant in Nuremberg are an excellent example of this
philosophy in practice. ■
31