Safe bolts for maximum engine performance
Maintaining high-performance industrial and utility vehicle engines requires the utmost precision, efficiency, and ergonomics. This was precisely the challenge MAN faced at its Ingolstadt facility. In collaboration with alkitronic®, a solution was developed that not only significantly optimizes the maintenance process but also noticeably reduces the physical strain on employees.
COMPANY PROFILE
MAN Truck & Bus SE is a leading manufacturer of diesel and gas engines for challenging industrial applications. Its engines have a power range extending from 37 kW to over 1,400 kW. These engines are used in construction and agricultural machinery, rail vehicles and combined heat and power plants for energy generation, as well as in many other applications.
INITIAL SITUATION
During engine maintenance, the bolts on the cylinder heads and crankshaft bearings need to be regularly loosened and tightened again. Previously, this was done manually using long torque wrenches, requiring two employees per bolt. The tightening process itself was a multi-step procedure involving several torque levels and additional rotation increments.
This approach was very time-consuming and inefficient. The combination of partly working overhead and the strain on the wrists made the work physically very demanding. Against this backdrop, a suitable solution was sought in collaboration with alkitronic®.
SOLUTION
To cover both applications, MAN was introduced to the battery-powered alkitronic® EB-S 150 with Mode 2. This model offers a torque range of 150–1,400 Nm and, thanks to the additional software package, enables precise fastening using the torque/rotation angle method. In addition, a special sliding support was designed in collaboration with MAN to ensure secure support on the nearest bolt.
Using this system has halved labour costs, as only one person is now needed to loosen the fasteners. The alkitronic® EB-S 150’s intuitive one-finger operation makes overhead work significantly easier, and its recoil-free performance noticeably reduces physical strain on the user. At the same time, the entire fastening process is accelerated and becomes much more precise, with a repeatability accuracy of ±3%.
