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January-February 2013
GLOBAL – PRODUCTS • TECHNOLOGY • INDUSTRY NEWS
DIESEL PROGRESS iINTERNATIONAL
www.dieselprogress.com
Clean EnginE
TeChnologyDoosan’s New Small Diesels
Weichai Finalizes Linde Acquisition
Hyundai SeasAll
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Worldview
The bauma China construction equip-ment show in Shanghai was, perhaps predictably, a rip-roaring success. The showground was packed with impressive exhibits and the aisles overflowing with visitors from all over the globe.
Why predictable? Because China, as well as elsewhere in Asia, has generally reported one spectacular economic news story after another over recent years.
Of course, the economy has boomed and will probably continue to move for-ward over the coming years although the commercial progress has come at some cost — growth, not just in China but also in India, has opened up chasms of inequality, which have led to frequent antigovernment protests.
So assuming that China, India and some neighbors will continue to fare promisingly, where should we look to as the next region to copy their economic transformation?
Africa in 2013, or beyond?Africa could demonstrate the most stun-
ning opportunities for change and devel-opment over the coming years, although the hugely diverse history, fortunes and prospects of the countries that make up Africa could not be more different.
For example, fueled by large natural resources, Ghana’s economy should be solid in the medium term while Kenya is growing, thanks in part to its strong agri-cultural and fishing sectors, although its construction industry was beset by high borrowing costs.
Thus it is unlikely Africa as a collec-tive whole will see across-the-board economic growth, but singular countries could develop, eventually raising the for-tunes of the entire continent.
Other reports paint conflicting pic-tures of the potential for many countries, with literacy remaining a critical issue, although all agree infrastructure invest-ment in roads, rails and ports is essential.
If Africa does copy Asia in a transi-tion combining economic prosperity with equality, we could have another eco-nomic “miracle.” dpi
Over the last few months, it’s been hard to avoid negative talk about the market in China. While its GDP growth remains in the 8% range — a figure that would result in clicking heels and wild dancing just about everywhere else — all we’ve heard of late is how bad things have been.
Yet perspective is called for and the world got a pretty good dose of it in late 2012, courtesy of bauma China.
The biennial show was a terrific example about how a market is more than just numbers. The show itself was stunning, with the highest num-ber of exhibitors (1837), most exhibit space (300 000 m3) and the high-est attendance ever (180 000 from 141 countries).
This time, all the players were there. Caterpillar skipped the last bauma China, but in 2012 put on the largest trade show display in its histo-ry, taking up one entire hall. Anybody who thought Cat’s shift of its Asian headquarters to Singapore from Hong Kong meant it was less focused on China might want to rethink.
Sany was equally as impressive, with huge indoor and outdoor displays. And there were plenty of others.
A lot of the machinery displayed is going to be used, as the coun-try’s 12th Five Year Plan calls for continued infrastructure develop-ment. Much will be constructed with domestic machines, but there will be plenty left over for the imports, particularly since there is a grow-ing emphasis on fuel economy and emissions reduction, technologies that play to the strengths of the in-ternational suppliers.
Looking just at only the numbers, China’s growth is likely to be much more modest than it has been. But these days, modesty of that sort will be an endearing virtue. dpi
Diesel Progress ® International Edition
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Next Up:Africa?
A Market Greater
Than Numbers
DPI516.indd 1 1/11/13 3:19 PM
Technology 4 Thermal Management
For euro 6 20 Tackling The Threat of Water 40 MAn Adds To gas
engine Range52 Driveline Technology
For Tractors 54 Taking The Tough Approach
Technology oF cleAn AiR 10 Meeting Bigger emissions
challenges 12 Keeping The heat on
PRoDucTs 38 new single-cylinder
Kohler Diesel 44 new Flow Directional Valves
And Fan Drive hics 46 cat upgrades c15,
c18 gen-sets 47 generating greater
Protection And control 50 Adding APu Power
member of
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Diesel PRogRess® inTeRnATionAl eDiTion (ISSN 1091-3696) Volume 32, No. 1 — Pub lished six issues/year (January-February, April, June, September, October, November-December), by Diesel & Gas Turbine Publications, 20855 Watertown Road, Suite 220, Waukesha, WI 53186-1873. Subscription rates are $60.00 per year/$10.00 per issue worldwide. Periodicals postage paid at Waukesha, WI 53186 and at additional mailing offices. Copyright 2013 DIESEL & GAS TURBINE PUBLICATIONS. Canadian Publication Mail Agreement # 40035419. E-mail: [email protected]. Return Undeliverable Canadian Addresses to: P.O. Box 456, Niagara Falls, ON L2E 6V2, Canada. POSTMASTER: Send address changes to: Circulation Manager, Diesel Progress International Edition, 20855 Watertown Road, Suite 220, Waukesha, WI 53186-1873 U.S.A.
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EUROMOT
WhAT’s insiDe …
inDusTRy neWs 6 Weichai Finalizes Acquisition
of linde hydraulics 14 small engines Mark Big
Move For Doosan 22 sweeping changes
For lister Petter 24 Brazil notebook — Brazil
Ag Machine sales up 6.2% 32 india notebook — escorts seeks
greater share of Tractor Market 35 Motoring Deeper into
The Marine Market 42 The off-Road Ahead 56 international Business Report —
Mahindra & Mahindra Buys out navistar JVs … Agco Begins African Production … Deutz sells Pipe operation … hyundai heavy Begins Production in Brazil … Turkish order For ZF …
DePARTMenTs 2 Worldview 9 Dateline 21 Diesel hR 30 global Trends 41 Product Briefs 45 Powerlines 48 Advertisers’ index 49 Diesel Dotcom 49 Marketplace
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DPI JanFeb TOC.indd 1 1/11/13 4:42 PM
Thermal ManageMent
For euro 6 New “smart” coolant pumps, EGR valves and coolers can help
deal with increased heat loads in advanced commercial diesels
By RoBeRta PRandi
Pete Kohler, president Borg-Warner Global Commercial Market Development, knows what is ahead. “With upcoming
emissions standards, increasing en-gine output and higher EGR rates raise the amount of heat introduced into the coolant, creating the need for inventive thermal management solutions,” Kohler said. BorgWarner has been working dili-gently on developing “smarter” thermal management systems.
A good example of that develop-ment effort is BorgWarner’s new Heavy-Duty Controlled Coolant Pump (HDCCP) for heavy-duty engines. The new pump system integrates a con-ventional coolant pump with an elec-tronic viscous drive and features high modulation capabilities including op-eration independent of engine speed. It is designed to provide full engage-ment in less than three seconds, with an equally fast disengagement, taking about three seconds at peak power, the company said.
mode allows the required coolant flow, similar to a standard pump.
As far as the management of EGR systems is concerned, BorgWarner is able to offer EGR valves and actuator technologies, together with multiple-core EGR coolers with specially de-signed hybrid tubes to provide supe-rior heat rejection with less soot and hydrocarbon build-up.
BorgWarner has supplied similar multiple-core EGR coolers to Tog-num for its MTU off-highway die-sel engines. BorgWarner explained that the floating core and optimized coolant flow of these EGR coolers increase the durability even with ex-treme thermal loads which are typi-cal for some of the applications for these engines, such as mining vehi-cles, locomotives and pumps for the oil and gas industry. dpi
“The HDCCP is mainly used in trucks and will be commercially launched in the course of 2013,” said Karl Wagner, vice president Sales at BorgWarner Thermal Systems in Markdorf, Ger-many. “The market launch will start in Europe and aim at both heavy-duty commercial vehicles and off-highway machinery. Meanwhile a version for light-duty commercial vehicles is ex-pected to be launched starting with the U.S. market.”
Wagner said the HDCCP could boost fuel efficiency by up to 1.4% in a heavy-duty engine, compared with a standard water pump. Its precise con-trol of the impeller speed produces the desired coolant flow rate with av-erage lower pump speed.
BorgWarner Thermal Systems said it is also developing a Dual Mode Cool-ant Pump featuring electric and me-chanical mode to exactly control the coolant flow. The electric mode pro-vides the required flow rate even when the engine is off, while the mechanical
Diesel Progress international 4 January-February 2013
Technology
For More inForMationwww.borgwarner.com
The new Heavy-Duty Controlled Coolant Pump by BorgWarner is designed to provide as much as 1.4% fuel savings in heavy-duty
trucks when compared to standard water pumps.
DPI525.indd 1 1/11/13 10:52 AM
Weichai Finalizes Acquisition of Linde HydrAuLics
Deal adds hydraulics to Weichai’s engine-powertrain portfolio, along with stake in global lift trucks business
By Mike Osenga
Weichai Power Co., Ltd., KION Holding 1 GmbH, along with various subsid-iaries of the two compa-
nies, have announced the successful completion of their previously an-nounced strategic partnership.
This agreement is also the latest in a string of deals in which Chinese companies have bought all, or part of, German and EU industrial manufac-turers, such as Sany’s acquisition of Putzmeister and Weichai’s own acqui-sition of the French engine manufac-turer Moteurs Baudouin S.A. in 2009.
Weichai Power is part of China’s Shandong Heavy Industry Group, and Germany’s KION Group is a manu-facturer of industrial trucks and hy-draulics. The bottom line of the deal is that Weichai now owns the majority of
clude transmissions, axles and now with Linde, hydraulics.
The goal of the whole deal, first an-nounced in late August of 2012, is for Weichai Power and KION to strengthen their industrial base in the European markets, create additional opportuni-ties for expansion for their Asia-Pacific businesses and build a platform for fu-ture joint growth, according to the an-nouncement of the agreement.
The hydraulics business will now be operated and managed as an in-dependent company called Linde Hy-draulics. Linde’s fluid power products will continue to be branded under the Linde Hydraulics trademark.
The business plan for Linde Hy-draulics includes relocating the exist-ing hydraulics activities in Nilkheim,
Linde Hydraulics, as well as a share of Linde’s lift trucks business.
KION is involved in forklifts, ware-house equipment, industrial trucks, hydraulic pumps and motors and tractors for construction, agricultural, commercial and manufacturing sec-tors. It markets its products under Linde, Still, Fenwick, OM, Baoli, and Voltas brands.
KION also provides services, such as fleet management, logistics, finan-cial, warehouse equipment systems, consultancy and IT solutions for truck and material flow management.
To this point Weichai has been pri-marily a diesel engine and powertrain manufacturer with engines used in buses, construction equipment, ma-rine and power generation applica-tions. Its powertrain components in-
Diesel Progress international 6 january-february 2013
Industry neWs
With changes in off-highway driveline technologies beginning to come into the market, Weichai, and by extension its Shandong construction equipment man-ufacturing parent, now add systems from Linde designed to reduce CO2 and in-crease the efficiency of the drive system. This concept, first shown at Agritechnica for electronic overall vehicle manage-ment, uses Linde’s LINC 2 ECU with the MPR 50 electronically controlled, medium- pressure hydraulic pump and flow- optimized valve blocks.
continued on page 8
DPI517.indd 1 1/11/13 10:56 AM
Kubota.indd 1 1/3/13 9:11 AM
Aschaffenburg, to a new hydraulics plant nearby and increasing capacity at other hydraulics production sites. Further, the existing strategic sales agreement between Linde Hydrau-lics and Eaton Corp., which has been amended, remains in place.
Linde specializes in hydrostatic or electric drive technology, powered by a diesel engine or batteries, with prod-ucts including hydraulic pumps, motors and valves, as well as swing drives and compact drive units. On the electrical side the portfolio includes electric mo-tors, power modules and integrated subsystems, electronic control units, sensors and machine interfaces.
The financials of the deal has Wei-chai Power, through its Luxembourg based subsidiary Weichai Power Holding S.a.r.l., acquiring a 25% stake in KION by way of a capital increase, making it an anchor investor in KION Group along with KKR and Goldman Sachs Capital Partners.
In addition, Weichai Power now holds a 70% majority stake in Linde Hydraulics GmbH & Co. KG, the former hydraulics busi-ness activities of Linde Material Handling GmbH. The remaining 30% continue to be held by Linde Material Handling GmbH.
In addition there is a call option through which Weichai Power can in-
crease its share in KION to 30% on a fully diluted basis, upon the completion of a potential future IPO. Further, Wei-chai Power has an option to acquire an additional 3.3% stake in KION from the current shareholders until June 30, 2013 or within three months after completion of a potential future IPO. If Weichai holds at least 33.3% of KION, the parties will support the election of a Weichai Power representative to chair-man of the supervisory board of KION.
Weichai Power has invested a total of €738 million, including €467 mil-lion paid in to acquire its 25% stake in KION through a capital increase and €271 million paid to Linde Material Handling GmbH for its 70% majority stake in Linde Hydraulics.
“We will now make an immediate start to implementing our common growth strategy in the area of hydrau-lics,” said Tan Xuguang, chairman and CEO of Weichai Power. “The new As-chaffenburg-based Linde Hydraulics plant is set to start operations in 2015.
“Also, teams from Linde Hydraulics and Weichai Power have already
started to explore a wide range of ap-plications for Linde Hydraulics tech-nologies in Weichai Power products. Our options to increase our overall shareholding in KION up to 33.3% demonstrate our strong commitment to the common goals of KION Group and Weichai Power.”
Gordon Riske, CEO of KION Group, said: “The closing of this long-term strategic partnership is a milestone in our strategy to continuously expand our forklift truck business in the grow-ing Asian and Chinese markets. More-over, the additional enhancement of our capital structure provides exciting opportunities with which we can build on our growth strategy.”
The long-term strategic partner-ship between Weichai Power and KION Group will also be reflected in the governance structure of KION and Linde Hydraulics. Jiang Kui, president of Shandong Heavy In-dustry Group and director of Wei-chai Power, will join the supervisory board of KION, which will continue to be led by Chairman John Feldmann.
The supervisory board of the newly established Linde Hydraulics will con-sist of Jiang Kui as chairman, Sun Shaojun and Jeffrey Chen, all of whom were nominated by Weichai Power, as well as Theodor Maurer, who was nomi-nated by Linde Material Handling. The respective employee representatives have yet to be nominated.
Jorg Ulrich, speaker of the man-agement board and head of finance and administration; Steffen Appel, head of operations; and Thorsten Van der Tuuk, head of products and
markets, have been appointed to the management board of
Linde Hydraulics. dpi
Industry news
Diesel Progress international 8 january-february 2013
Gordon Riske (left), CEO of the KION Group and Jiang Kui, general man-ager of the Shangdong Heavy Industry Group, and board member of Weichai Power Co. Ltd. at the signing of their strategic partnership.
Among the product lines coming to Weichai in its acqui-
sition of the Linde Hydraulics group are electronic control units, such as the LINC 2 line,
designed to control a mobile hydraulic system.
DPI517.indd 2 1/11/13 10:56 AM
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*Sept 24-March 22Diesel Progress Online Show XIAt www.dieselprogress.com and Diesel Progress Magazine Diesel Progress 20855 Watertown Road, Suite 220 Waukesha, Wisconsin 53186 U.S.A.Tel: +1 (262) 754-4100Fax: +1 (262) 754-4175E-mail: [email protected]
*Feb 5-8bC IndiaBandra Kurla Complex Mumbai, IndiaThe Association of Equipment Manufacturers6737 West Washington Street Suite 2400, Milwaukee Wisconsin 53214, U.S.A.Tel: +1 (414) 298-4176Fax: +1 (414) 272-2672E-mail: [email protected]: www.bcindia.com
*Feb 17-19M.E.E. Middle East Electricity 2013Dubai International Convention & Exhibition CentreDubai, United Arab EmiratesIIR Middle East Office 301, Sultan Business CentreP.O. Box 28493Dubai, U.A.E.Tel: +971 4 3365161Fax: +971 4 3353526E-mail: [email protected] Web: www.middleeastelectricity.com
April 8-12Hannover MesseExhibition GroundsHannover, GermanyDeutsche MesseMessegelände, 30521Hannover GermanyTel: +49 511 89-0Fax: +49 511 89-32626E-mail: [email protected] Web: www.hannovermesse.de
*April 15-21 bauma 2013New Munich Trade Fair Centre Munich, GermanyMesse München GmbHMessegelände, 81823 München GermanyTel: +49 89 949-11348
Fax: +49 89 949-11349E-mail: [email protected]: www.bauma.de
April 25-2634th International Vienna Motor SymposiumCongress Center HofburgVienna, Austria
ÖVK Austrian Society of Automotive EngineersElisabethstrasse 26/24A - 1010 Vienna, AustriaTel: +43 1585 27 41-0Fax: +43 1585 27 41-99E-mail: [email protected]: www.oevk.at
Diesel Progress international 9 January-February 2013
Jan_Dateline.indd 1 1/11/13 11:46 AM
Meeting Bigger Emissions ChallEngEs
One size definitely doesn’t fit all when it comes to SCR system technology on larger engines
By Raimund mülleR
When it comes to emissions control, much of the focus for diesel and gaseous-fuel en-gine manufacturers in recent
years has been on off-highway mobile equipment, and the U.S. and Europe have developed similar stringent NOx and PM limits in emissions regulations covering engines up to 560 kW. In Europe, regula-tions for engines above that range have not been implemented while the U.S. has established requirements, though with less-stringent limit values. There are also separate emissions regulations covering locomotives, marine vessels and station-ary generator set engines.
pressed air is utilized for atomization in the injection nozzle.
In case of a liquid-only solution, the atomization is done by liquid pressure in a pulse width modulated (PWM) in-jection valve mounted in the exhaust stream upstream of the SCR catalyst.
Airless/liquid-only systems are preferred in applications where com-pressed air is not available on the ve-hicle, machine or installation. The full evaporation and chemical reaction of the urea to ammonia in the exhaust and homogenous mixing can be a challenge, but are important factors in attaining optimum NOx conversion rates and safe operation that avoids formation of deposits.
Emitec has developed a compact universal mixing pipe, incorporating the injection valve and a downstream
As in the case of smaller engines, selective catalytic reduction (SCR) is expected to be the prime tech-nology used to help larger engines meet Tier 4 final emissions regula-tions. SCR has shown that emis-sions of nitrous oxides (NOx) can be very efficiently reduced in the pres-ence of a specific catalyst with the aid of a reducing agent, typically an aqueous urea solution.
The reducing agent — typically known as AdBlue or DEF (diesel ex-haust fluid) — is injected in small, pre-cise quantities calculated according to the momentary NOx mass flow of the engine and the required NOx reduc-tion rate. The quantity of urea solution is typically done by a metering pump or metering valve. Urea dosing pumps and injectors are used when com-
For large engines equipped with SCR systems, special manifolds incorporating multiple injectors such as this one developed by Emitec, can be used to distribute the aqueous urea reductant to the injectors and achieve a homogenous spray pattern in the exhaust stream.
Diesel Progress international 10 January-February 2013
TECHNOLOGYof clean
Dr.-Ing. Raimund Müller is general manager, Technical Sales of the heavy-duty truck and nonroad business at Emitec GmbH, Lohmar, Germany.
DPI520.indd 1 1/11/13 4:04 PM
TECHNOLOGYof clean
Diesel Progress international 11 January-February 2013
installed hydrolysis catalyst (with the special Emitec MX-structure), which can be used in various exhaust system configurations without further validation testing required.
As the urea demand for a large diesel engine may exceed the capacity of pumps and injectors made for automotive applications, Emitec’s solution is to combine two or more pumps with specific control software.
For larger engines requiring multiple injectors, a high- capacity industrial pump has been modified to meet the re-quirements of large stationary and mobile engine applications. Combined with a special manifold, the reducing agent is dis-tributed to the multiple individual injectors, providing a homo-geneous spray pattern in the exhaust pipe. In one design study concerning a 3 to 4 MW diesel engine, Emitec combined six individual mixing pipes which had been already proven in a variety of nonroad mobile and stationary applications.
Capitalizing on the extensive validation testing done with the individual injection and mixing pipe components used in serial production machines, manufacturers of larger engines, which are typically produced in lower numbers, are able to use a proven technology without further testing investment.
Catalysts can be selected to meet the specific demands for large engines which have in general high intrinsic performance requirements, which typically include reduced space and weight, low backpressure for best fuel consumption and mechanical and thermal robustness.
Metallic substrates, which can be produced in various shapes and cell densities with very thin foils, have been applied successfully in many applications and can be serial produced with round, squared, oval or hexagonal frontal faces. The size can be tailored — some applications use substrates with di-ameters greater than 600 mm, while others prefer a modular approach with parts of serial production with diameters up to 450 mm. Hexagonal shaped substrates allow building an array with an outer shape which is almost round, which can enable a very cost-effective, lightweight structural outer housing shell and thermal insulation.
Depending on design priorities — for example, space alloca-
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tion versus backpressure — and fuel quality, the cell density of the substrate is adjusted to higher surface or more open frontal area. Metal substrates allow a wide variety and feature the possibility of further increases in efficiency by turbulence-inducing structures, such as Emitec’s LS-structure.
Several proven catalyst coating material variants are avail-able on metal substrates. Most commonly used is the TiO2-V- technology or the iron zeolite or copper zeolite technologies used in automotive, off-highway machines and stationary applications.
Currently, large engines above 560 kW with SCR systems are being used in locomotive, marine and stationary applications. While large construction and mining equipment presents specific challenges, suppliers to the industry will be able to offer proven solutions to the market. dpi
Urea demand for large diesel engines with SCR can exceed the capacity of pumps and injectors developed for smaller engine applications. One solu-tion is to combine two or more pumps, such as Emitec’s UDA2 urea pump, with specific control software.
For More inForMationwww.emitec.com
DPI520.indd 2 1/14/13 1:58 PM
Keeping The heaT On
New CB2 thermal system from HJS designed to keep aftertreatment at proper temperatures
By RoBeRta PRandi
HJS, the Menden, Germany-based specialist in exhaust gas aftertreatment technology, has developed a new system designed to assure that exhaust gas tempera-tures required to make aftertreatment systems work
properly can be effectively reached and maintained. The com-pany said its new Catalytic Bypass Burner (CB2) is especially useful in urban vehicles such as city buses, where cold ambi-ent operating temperatures and stop-start duty cycles can pre-vent exhaust gas temperatures from reaching the temperatures needed for catalytic reduction exhaust gases.
The CB2 is a two-stage catalytic burner with a capacity of 5 kW and greater, along with infinitely variable control. It can be used with diesel engines with rated output power up to 560 kW and does not need an external supply of compressed air, HJS said.
The principle of the CB2 operation is based on dividing the exhaust gas mass flow between a primary and a by-pass flow pipe by means of an exhaust flap. The exhaust
bypass flow is routed away from the mass flow downstream the turbocharger and diverted into a separate pipe, where a hydrocarbon (HC) dosing takes place. Exhaust and the injected hydrocarbon pass through a first, prediesel oxida-tion catalyst (DOC) where part of the injected HC is already converted, bringing the bypass gas flow to a temperature greater than 600°C. The hot, hydrocarbon-rich gases then mix with the cooler exhaust gas from the primary exhaust mass flow, upstream a second DOC. The mixture at this point is still hotter than the DOC light-off temperature and a further temperature increase due to catalytic oxidation is assured, HJS said, as well as the filter regeneration.
In case the exhaust gas temperature from the turbo-charger is lower than the light-off temperature of the two DOCs, the system can be fitted with an electrothermal heating element before the pre-DOC, so that the necessary temperature is reached before the first catalytic reduction. This electric assistance is usually required only in the en-gine start phase, the company said. Afterward the heat is developed only by the fuel conversion in the two DOCs.
The exhaust gas flap controlling the volume flow is installed in the primary exhaust gas flow and is designed to assure that the pre-DOC works efficiently even after a long operating life.
HJS added that the CB2 has also the advantage of a low thermal load on the materials, since the temperatures are raised to the necessary levels but do not exceed 700°C. The system also has a beneficial effect on eventual down-stream SCR for which it also assures the necessary ex-haust temperatures.
As a complement to its exhaust gas aftertreatment sys-tems, HJS also offers an Aftertreatment Control Unit (ACU) that acts as the brain for the complete system. The com-pany said the ACU measures temperature, pressure and gas concentrations and uses the information to automati-cally determine the proper moment for filter regeneration and calculate dosing. The unit does not interfere with the engine management system and can be easily configured to operate any aftertreatment technology, HJS said, even with more combined components. dpi
Designed for diesel engines up to 560 kW, the Catalytic Bypass Burner (CB2) from HJS is a two-stage thermal management system engineered to assist aftertreatment components to maintain proper operating temperatures.
Diesel Progress international 12 January-February 2013
TECHNOLOGYof clean
For More inForMation www.hjs.com
DPI524.indd 1 1/11/13 10:46 AM
Small EnginES Mark Big Move For Doosan
Production starts on new range of Tier 4 final/EU Stage 3b compact diesels at new South Korean engine plant; company aims to become top tier engine builder
By Ian Cameron
Doosan Infracore has started production of its new range of Tier 4 final/EU Stage 3b and 4 compliant compact
diesel engines at its newly developed factory at Incheon, South Korea.
The move marks a significant step for the company as it aims to establish itself as a global top tier engine maker with the new compact range designed for installation in a range of com-pact and midsized equipment such as loaders, tractors, portable power units, excavators and forklifts.
L diesel rated up to 74 kW at 2400 rpm. Both the D24 and D34 are in-line, four-cylinder engines.
Bore and stroke dimensions for the D18 and D24 diesels are 90 x 94 mm while the larger D34 has a bore x stroke of 98 x 113. Maximum torque ratings for the engines is 165 Nm at 1600 rpm for the D18, 280 Nm at 1600 rpm for the D24 and 430 Nm at 1400 rpm for the D34. Respective low-end torque ratings are 113 154 Nm for the D18, 235 Nm for the D24 and 410 Nm for the D34, all at 1000 rpm.
With the new addition to its line, the entire Doosan engine range now spans models from 1.8 L to 22 L. The first units of the new compact engine range will be installed in Doosan In-dustrial Vehicle forklifts, replacing the existing engines.
The new range of compact engines consists of three models. The new D18 is a 1.8 L, three-cylinder engine producing up to 37 kW at 2800 rpm. At 2.4 L displacement, the D24 deliv-ers a top rating of 55 kW at 2600 rpm, while the top of the line D34 is a 3.4
Diesel Progress international 14 January-February 2013
Doosan Infracore has developed a new series of small diesel engines designed for a broad range of applications in compact equipment. Among them is the 2.4 L D24 shown here, a four-cylinder engine available in ratings up to 55 kW.
INDUSTRY NEWS
DPI513.indd 1 1/11/13 1:28 PM
While all of the new engines incorporate diesel oxidation catalysts (DOCs), none requires the use of diesel particu-late filter (DPF) technology, which was a key design target for Doosan.
“Common industry design practices call for the use of both DPF and DOC technologies to meet new emissions regulations,” said Hyung Taek Lim, chief research engineer Doosan Infracore Engine Business Group. “Maintaining our design philosophy of simplicity and robustness we eliminat-ed DPF whilst meeting the strictest emissions standards.
“Our research showed that dealers and customers want and prefer a non-DPF solution which offers clear advantages in terms of high quality, low maintenance and easy installation.”
Doosan, which already produces two Tier 4 interim en-gines — the 5.9 L DL06 and the 7.6 L DL08 — invested heavily in its new compact engine facility alongside its exist-ing plant in Incheon. The first engines rolled off the produc-tion line in early October 2012. This year, the company will also start building the D18 and D34, with the company esti-mating that around 6000 engines of all three models will be built in 2013. By the end of the year, the capacity of the new compact engine plant will be 50 000 annually, which will grow to 100 000 a year by the end of 2015, with the major volume of engines going into certain models in the range of Bobcat compact equipment.
The project to develop new compact engines was started by Doosan in 2008 in collaboration with engineering consultants FEV and Ricardo. The new compact diesel engines were de-veloped with the experience and know-how Doosan had with small size engines, but was based on a new design concept. The advanced fuel injection system utilizes Delphi common
continued on page 16
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INDUSTRY NEWS
“The next two to three years may be challenging, but we aim to counteract
this by strengthening our product portfolio and by developing new products.”
Hong Goo Lee, senior vice presidentDoosan Infracore Engine Business Group
Diesel Progress international 15
DPI513.indd 2 1/11/13 1:28 PM
rail technology with injection pressures of 1800 bar and a compression ratio of 17:1. The wastegate turbocharger and external cooled exhaust gas recircula-tion (EGR) systems help to ensure best performance, even in the most chal-lenging conditions in any application, the company said. All of the new mod-els are turbocharged and intercooled.
Outside of the DOCs used on all of the new engines, only the D34 adds any additional aftertreatment, in this case a selective catalytic reduction (SCR) system. All of the engines have an oil separator-integrated closed crankcase ventilation system.
The D18 and D24 are Tier 4 final/EU Stage 3b compliant, while the D34 meets Tier 4 Final/EU Stage 4 stan-dards, Doosan said.
“The conventional way to achieve Tier 4 emissions compliancy is to adopt DPF, but our non DPF way gives us and the end users many benefits,” Lim said. “Because we adopted the Delphi common rail system, this gives us low-er emissions, better fuel consumption and lower noise and vibration. This is important because our new compact engines are user friendly and so by adopting this fuel injection system
we can achieve the ultimate goal for each application.
“Also, the integrated polymeric cyl-inder head cover module means that no external oil separator is needed. The wastegate turbocharger gives us a better fuel efficiency and perfor-mance and we can also achieve ex-cellent low end torque which is a big requirement from the customer.
“We also introduced a reliable EGR system which has reduced NOx emis-sions and the EGR system is electroni-cally controlled as is the EGR valve. Furthermore, all of the components are well proven because they come from the automotive industry where they are in mass production. The optimized pis-ton ring package means we can also achieve ultra-low oil consumption and extend the oil change intervals up to 500 hours without oil top up.”
Another key feature targeting emis-sions reduction is Doosan’s Ultra Low Particulate Matter Combustion (ULPC) technology. “Simply, it is the optimized combination of the combus-tion bowl shape, the injector nozzle, cylinder head swirl and EGR mixing to minimize raw exhaust emissions,” Lim said. “The ULPC system is very clean
with no soot visible. In this ULPC sys-tem the low particulate matter emis-sions are around one sixth that of a conventional system. Because of this, we need to only apply DOC to reduce the PM level below the Tier 4 emissions levels.
“Our non-DPF system uses DOC technology solely to meet the emis-sion regulations. This simple and easy aftertreatment system removes con-cerns about installation, maintenance and quality issues that might have arisen in a more complicated system. The compact sized, flexible aftertreat-ment system can also be either en-gine or chassis-mounted.”
Dry engine weight for the D18, D24 and D34 is 163, 204 and 265 kg, respectively.
Regarding maintenance, recom-mended oil/filter change, fuel filter change and valve adjustment intervals are all 500 hours, the company said.
Along with the new engines, Doo-san focused on the development of the new compact engine plant, which is designed to be operated with a minimum of highly skilled and trained workers.
The facility covers around 14 000 m2
Diesel Progress international 16 January-February 2013
INDUSTRY NEWS
Doosan’s new range of compact engines consists of three models: The D18 rated up to 37 kW, the D24 that delivers up to 55 kW and the D34 that tops out at 74 kW.
DPI513.indd 3 1/11/13 1:29 PM
Diesel Progress international 17 January-February 2013
and includes a head and block machining line, a main and sub assembly line, storage area, testing section and two paint areas for washing and final coating.
Chulhyun Roh, factory manager of the engine facility, said that key leading-edge production aspects include an Electronic Identification System, which allows workers to monitor and have all access to data and production pro-cess. There is also a “Vision Check” system enabling robots to check the final assembly, which enhances product qual-ity, he added. Overall at its two engine factories at Incheon, Doosan plans to have a capacity to produce 172 000 en-gines a year by 2015, including its existing range of larger compact engines and medium and large engines.
The company’s other engine building interests include a 50-50 joint venture established in 2008 with Chinese construction equipment machinery maker XCMG in Xuzhou City, Jiangsu Province, China with a production capacity of 50 000 units an-nually; and its Doosan Infracore America (DIA) Engine Divi-sion established in 2007 in Suwanee, Georgia, U.S.A.
Globally, Doosan Infracore has 226 engine dealers and OEMs in Asia (71), China (62), Europe (40), North, Central and South America (30) and Africa/Middle-East (23).
Hong Goo Lee, senior vice president of the Doosan Infra-core Engine Business Group, said that although the company has supplied diesel and natural gas engines since 1958 for commercial and military vehicles, construction equipment, generators and marine vessels worldwide, its aim “is to be-come one of the world’s top three machinery companies and a global top tier engine maker by 2020.”
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Doosan has invested significantly in its engine manufacturing plant at Incheon, South Korea, as part of the new compact engine development.
DPI513.indd 4 1/11/13 1:30 PM
INDUSTRY NEWS
The company added that as well as being a mass producer of Tier 4 Final engines for Bobcat and Doosan machines, Doosan Infracore Engine Business Group is aiming to capture a significant market share in the under 74 kW market by developing products for use in air compressors, agricultural machines, forklifts and generators.
It said its Xugong Doosan business, a joint venture with China’s Xugong construction machinery group, pro-vides a strategic base for the Chinese engine market. It currently supplies Tier 2 engines for wheel loaders to XCMG and is developing engines to meet Tier 3 regulations in China after 2014.
Doosan said it is also developing new large engines and Tier 4 medium sized engines for Doosan’s Construc-tion Equipment Business Group and improving the medium sized engine for Tier 3 for the Chinese market.
Lee said Doosan’s engine business has achieved sustained global sales growth of 7.8% between 2007 and 2011, but added that with some mar-kets experiencing recession that would be difficult to repeat in the short term.
“The next two to three years may be challenging, but we aim to counteract
this by strengthening our product port-folio and by developing new products,” Lee said. “Sales of engines for genera-tor sets account for the biggest sales volume in our overall Engine Business Group. China is one of our biggest mar-kets and with the downturn there, total sales have been sluggish even though other markets have been steadily grow-ing in 2012. A modest economic recov-ery is forecast in 2013 but it still remains unclear how much it will be.
“The Korean economy has re-mained flat in 2012 but Korean do-mestic product market share is ex-pected to grow owing to a restriction of imported Chinese products so we see an opportunity to increase sales here. The other Asia and Pacific markets have not been impacted so much by the recession and the de-mand for generators remains stable and continuous.”
He said Middle East and African markets have been “more settled” in 2012 and the gradual recovery will boost generator set demand. Although the financial crisis hit the European markets there was soaring demand for biofuel, which had resulted in in-creased sales of natural gas engines.
“Due to the efforts of the U.S. government to boost recovery fol-lowing the financial crisis of 2008, overall generator markets have been steadily growing,” Lee said. “We aim to boost sales by supporting OEMs and developing products to meet their specific requirements.”
Concerning the new compact en-gine, Lee said “our main targets are agricultural machinery and small con-struction equipment. The agricultural machinery market in Korea is about 40 000 units.
“Since there only a few engine makers able to provide Tier 4 final solutions for emission regulations that take effect in January 2016 in Korea, Doosan Infracore is in a fa-vorable position in this market,” Lee said. “We aim to gradually broaden markets starting with our domes-tic market and then proceeding to markets around the world. We are also targeting forklift truck manu-facturers who do not produce their own engines.” dpi
Diesel Progress international 18 January-February 2013
For More inForMationwww.doosaninfracore.com/engines
Doosan’s new compact engine plant covers around 14 000 m2 and includes a head and block machining line, a main and sub assembly line, storage area, test-ing section and two paint areas for washing and final coating.
DPI513.indd 5 1/14/13 2:23 PM
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Dana_construction.indd 1 1/4/13 10:26 AM
TacklingThe ThreaT Of WaTer
Conductivity-based sensor from Gems Sensors designed to detect moisture in engine fuel and lube oil systems
By Ian Cameron
Fuel is subject to the relentless and unceasing hazard of con-tamination, and moisture is one of the most common dangers.
Water in fuel that reaches the fuel sys-tem can affect the operational perfor-mance and life of engine components. Worse, it can lead to early and some-times catastrophic failures. Controlling the ingress of moisture in fuel systems is therefore of vital importance.
Gems Sensors and Controls has developed a conductivity-based sen-sor designed to detect the level of water in fuel and lubricating oil and prevent mechanical damage as a re-sult of lubricant property degradation. The WIF-1250 is a no-moving-parts solution for use with fuel filters, and in
efficiency engines, especially modern ones, where moisture in the form of condensation is a common problem,” Dockendorff said.
“In general, contamination from the ingress of water is often more prob-lematic in diesel engines than in petrol engines because the subsequent cor-rosion can cause serious damage to the injection pump and injectors. Die-sel engines require fine fuel filters and water traps to alert operators when there is too much water in the trap, so that it can be drained before the en-gine is damaged.”
Conductivity-based sensors use electrical conductance principles to detect the presence of water in fuel and lubricating oil. “Conductive level measurement is achieved via the electrical conductance of the process material, typically a liquid with a low-voltage source,” Dockendorff said. “In a tank of liquid, simple conductive sensors can be positioned at high and low points in the tank to detect maxi-mum and minimum levels. When the level of process material rises to reach the upper probe, a switch closes to activate a discharge pump. When the process material makes contact with the lower probe, the switch opens to stop the pump.
“However, there are now more sophisticated components available that can detect the presence of water in fuel. Because water is electrically conductive and fuel is not, conductiv-ity sensors such as those produced by Gems Sensors and Controls can be mounted in any position and with-stand extreme temperatures. Their output can be used to actuate re-
compressor crankcases to determine if water is present in the lubricating oil, the company said.
Founded in 1955, Gems manufac-tures liquid level, flow and pressure sensors, solid-state relays and bar-riers, liquid and pneumatic miniature solenoid valves and pre-assembled fluidic systems. With its headquar-ters in Plainville, Connecticut, U.S.A., the company also has facilities in the United Kingdom, China, Germany and Japan.
According to Jim Dockendorff — chief engineer, Level Products at Gems, cases of water ingress lead-ing to engine failure have become in-creasingly common. “However, there is a particular urgency to protect high-
Diesel Progress international 20 January-February 2013
SenSorS
The new WIF-1250 sensor from Gems Sensors and Controls is designed to detect water in diesel fuel and lube oil systems, preventing potential damage to engine components.
DPI523.indd 1 1/11/13 3:23 PM
SenSorS
lays, indicator lights or LEDs, as well as to interface with CMOS/TTL logic, PLCs or microprocessors. Also, since water is heavier than oil, it tends to sink to the bottom of fuel tanks. These sensors can be positioned strategically in the tank bottom for water detection.”
The WIF-1250 sensor contains integral, high-temper-ature-rated electronics that generate an alternating volt-age to a probe tip. The probe tip is electrically isolated from the housing via a fused glass seal, providing a her-metic, high-pressure capability suitable for fuel system use, the company said. The presence of water completes the circuit, which in turn, changes the condition of the transistor output.
“For detecting water in fuel, conductivity-based sensors have proved very successful in applications such as off-highway vehicles, locomotive and generator sets,” Docken-dorff said. “However, the marketplace is expanding as the sensors become more resilient.
“For example, in a conventional conductivity probe, where a single potential dc voltage is applied to a probe submerged in conductive liquid, metal from that probe will be lost over time via electrolysis. However, the WIF-1250 contains extra circuitry to produce an alternating potential. By using this technique, no electrolysis occurs, resulting in virtually zero probe material loss.
“The WIF-1250 is a new solution to detecting the pres-ence of water in fuel, but customer feedback tells us that this is proving to be an ideal solution for fuel filters, com-pressor crank cases, lubricating oil tanks and diesel fuel storage tanks as it has high reliability and long term stability in oil.” dpi
www.hjs.com
“Diesel engine exhaust fumes are unequivocally carcinogenic!”On the 12.6.2012, research scientists at the World Health Organisation (WHO) made the following announcement:“Today, the International Agency for Research on Cancer (IARC) classified diesel engine exhaust fumes as carcinogenic for humans.”
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CB2 – Catalytic Bypass Burner
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HJS.indd 1 1/2/13 9:32 AM
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dieselhrChueire New President Volvo CE Latin America President
Afrânio Chueire has been named president of Volvo Construction Equipment Latin Amer-ica. He succeeds Yoshio Kawakami, who held the position 12 years and is leaving the company to pursue other professional oppor-tunities. Chueire, 53, has worked for Volvo CE since 2000, when he was named chief finan-cial officer. Volvo CE Latin America’s head-quarters is in Curitiba, Paraná State, with a factory in Pederneiras, São Paulo State.
New COO For JCBJCB has announced that Arjun Mirdha
has been appointed chief operating officer of JCB, Inc. overseeing Sales, Commercial Operations, Parts and Service, Manufac-turing, Marketing Communications and Product Marketing.
Mirdha joined JCB in 1996 and through his 17 years with the company has gained substantial experience in various roles that include dealer development, parts, service, sales, marketing and new product development. He has also held various management positions in the U.K., India and North America.
New VP For Yanmar EuropePeter Aarsen has been appointed vice president of Yanmar Eu-
rope BV. He will share management responsibilities with current president Geert Jan Mantel. Aarsen will also retain his position as president of Yanmar Marine International.
Arsen joined Yanmar in the Engineering department in 2007 and held several jobs until he became president of Yanmar Ma-rine International.
A. Chueire
A. Mirdha
continued on page 31
DPI523.indd 2 1/11/13 3:24 PM
Sweeping ChangeS For Lister Petter
New products, global expansions and investments in machining and distribution target continued growth
BY IAN CAMERON
Engine, generator set and pump manufacturer Lister Petter has unveiled sweeping changes across its business
worldwide, which include new prod-ucts, a significant expansion in North America and heavy investments in both its distribution network and ma-chining capabilities.
Since its acquisition by private in-vestors eight years ago, the company based in Dursley, Gloucestershire, England, has embarked on a swift pro-gram of acquisitions, closures, dispos-als and expansions — all amid tem-pestuous economic circumstances.
Lister Petter said its order intake last year rose to approximately £59 million worldwide. Orders climbed an-other 6% during the first half of this year, the company said. While that lev-el is below the company’s ambitious 20% growth projections, it represents a healthy return when considering the volatility of the markets.
tions. We expect to relaunch the gas version of the Alpha this year and cer-tainly will have EPA compliance by the start of 2013.”
Part of the engine’s longevity has been its increase in output, Draper said, adding it is “now much more powerful than previously rated.
“We have developed the Alpha Max by effectively increasing the capacity of each cylinder from 450 to 500 cc and changing the fuel injection to en-able us to put more power into the en-gine at the fixed speed nodes,” Draper said. “The net result has been to take the direct injection Alpha up one pow-er node. The LPWX4 at the 20 kVa (16 kW) node has been launched into the market, with the LPWX2, 3 and T4 to be released by the end of 2012. This will give a maximum output of 25 and 30 kVa (20 and 24 kW) at 1500 and 1800 rpm respectively.
“In addition, both the Alpha water-cooled and the air-cooled engines are
“Traditionally we have run Lister Pet-ter as one business,” said Bryan Drap-er, Lister Petter’s chief executive. “Now we are running it as three very different businesses — a conventional engine company, a generator manufacturer and also a distribution business.”
The company’s Alpha engine has pro-vided much of the recent solid showings for the 140-year-old company. “Probably the thing that surprises most people is that the Alpha engine has stayed as strong as it has,” Draper said. “Eight years ago when we bought the busi-ness, the Alpha was regarded as being a spent engine and no one thought we would be around for very long.
“Eight years later the Alpha is strong and still satisfies current EPA emissions. Obviously it won’t go to Tier 4 final but we have a product in the pipeline to deal with that.
“We have put a lot of engineering investment into the Alpha, an engine that thrives on prime power applica-
Diesel Progress international 22 january-february 2013
INDUSTRY NEWS
A new LWA acoustic generator set powered by a Lister Petter Alpha diesel engine is one of several new or updat-ed products Lister Petter is launching into the market this year as it aims to grow its business worldwide.
DPI531.indd 1 1/11/13 1:45 PM
now capable of 2000 hours service in-tervals, which is a market differentia-tor. As more and more end users are expecting manufacturers to be able to supply generators with that capability so we have seen almost a doubling in the enquiries for the Alpha.”
Lister Petter said the new range of Alpha generator sets goes from 4 kW at 1500 rpm through to 32 kW at 3000 rpm at 50 Hz with corresponding rat-ings for 60 Hz.
Coupled to these will be the Lister Petter Energy Centre, a stand-alone hybrid unit designed to offer 30 com-binations of outputs, six power nodes and four levels of autonomy from 12 to 48 hours in a single compact unit.
Over the longer term, Lister Pet-ter said an Alpha replacement will be launched in 2014 with a common rail, EPA-compliant version due in in 2015. The company also said it is developing a new engine to provide a gen-set in-crease from 32 to 112 kW, noncompli-ant by 2016 and a common rail, EPA-compliant version by 2017. It will also launch a new air-cooled engine to take its air-cooled range up to 37 kW.
Lister Petter has also changed its production profile over recent years, now basing it around four key locations. In England all generator set production has been in Dudley in the West Mid-lands since Jan. 1 2012, while the parts distribution center has been relocated to Hardwicke, Gloucestershire. The company has expanded component manufacturing and now makes 15% of all parts by value for its engines and generator sets internally through a ma-jor investment in CNC equipment at its machining plant in Sheerness, Kent.
It is in the United States where some of the most interesting develop-ments have taken place. Lister Pet-ter said it has upgraded its factory in Olathe, Kan., to not only remanufac-ture Alpha engines but also to build the engines to service U.S. contracts.
“Currently in Kansas we are doing 5000 units a year,” Draper said. “Two thousand are new-build Alphas and 3000 are rebuilds. But we have in-
stalled capacity from a single shift of 10,000 a year.
“There are currently 40 people em-ployed in Kansas and we have also opened a distribution center in Miami with 12 people there. We are ready for the fight. The job numbers in Kansas will rise — we haven’t aggressively at-tacked North America, so it is going to be a big focus for us over the next six months.
“Mike Shell is our new president of Lister Petter Americas Inc. in Kansas and Pablo Nunez has taken over the running of the distribution operation in Miami. They have great ideas and energy so we are expecting to see a big difference in North America, es-pecially when we put the gas product back into the market there.”
Looking at the broad scope of its business throughout the global mar-ket, Draper said “the territories that were hit the hardest during the last recession are proving to be more re-silient in this one.”
“We are doing well in Latin America — the Mercosur countries of Argen-tina, Brazil, Paraguay and Uruguay,” Draper said. “North America is steady
and the Gulf countries, now they have got through their issues, and the South Pacific are doing well.
“It seems to be that anybody who is European dependent in terms of their sales is getting a hammering. What we are also seeing is that it is product related, so our engine busi-ness is 18% up but our generator set business is 19% off. We expect India and China to be stronger particularly as the Alpha is CPCPll-compliant and our spare parts and remanufacturing businesses are very healthy.
“We have also taken on the problem of pirated products, especially in Af-rica. We have been more aggressive in some parts and increased our business there. On the back of Africa we are go-ing to attack pirating in South America.
“The other thing we have done qui-etly is to strengthen our distribution so where we have had poor distribution in key areas or we have had a prob-lem finding decent distributors we have opened up ourselves.”
Draper said the first place the company opened was in Miami, to service Florida and South America. “We followed this with Auckland, New Zealand, and then Cape Town, South Africa, last year,” Draper said. “The purpose of the hubs is to ser-vice the local markets and provide both commercial and technical sup-port to master distributors in neigh-boring territories, significantly re-ducing their lead times and working capital pressures.
“We are planning to open at least four new hubs over the next 12 months. UAE and Singapore first and then one in each in South America and China where there are a lot of OEMs that would like access to en-gines. A Lister Petter engine landed in China is still a considerably bet-ter economic proposition than some Chinese engines produced by other Western manufacturers.” dpi
INDUSTRY NEWS
Diesel Progress international 23 january-february 2013
For More inForMationwww.listerpettergroup.com
“The other thing we have done qui-etly is to strengthen our distribution so where we have had poor distribution in key areas or we have had a problem finding decent distributors we have opened up ourselves.”
Bryan Draper, Lister Petter chief executive
DPI531.indd 2 1/11/13 1:48 PM
Diesel Progress international 24 JanUarY-FeBrUarY 2013
brazilnotebook
by Mauro belo Schneider
Sales of agricultural machin-ery rose 6.2% in 2012 over the previous year, according to information from Brazil’s
National Association of Motor Vehicle Manufacturers (Anfavea). Anfavea said domestic sales of equipment — both locally manufactured and import-ed — totaled 69 374 units compared to 65 323 in 2011.
In December, 5728 machines were sold, a decrease of 2.3% compared to November (5861), but a 41.8% rise compared to the same month in 2011 (4040).
Agricultural machinery production registered a growth of 2.6% in 2012 compared to 2011, reaching 83 640. In December, 5716 machines were manufactured, an increase of 4.4% compared to December of 2011.
The exports totaled R$5.89 billion
(US$2.91 billion) in 2012. The result rep-resents a decrease of 10.6% compared to 2011. In December, exports reached R$400 million (US$198 million).
The number of farm machines ex-ported in 2012 from Brazil reached 16 896 units, a drop of 7.8% compared to 2011.
Soprano Hidráulica Expands Factory
Marking its 35th anniversary, Soprano Hidráulica, the hydraulic component specialist based in Caxias do Sul, Rio Grande do Sul State, Brazil, announced an investment of R$7 million (US$3.5
Brazil ag Machine SaleS Up 6.2%
A report from the Brazilian association Anfavea puts the country’s 2012 sales of farm equipment at 69 374 units, an increase over 2011.
Mauro Belo Schneider is a Diesel Progress correspondent based in Porto Alegre, Brazil. His e-mail is [email protected].
An investment by Soprano Hidráulica in its hydraulic component factory is expected to double the company’s cylinder output.
continued on page 26
DPI522.indd 1 1/14/13 2:27 PM
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SCI15376_Ad_203x267_Volmar.indd 1 1/11/2013 9:11:55 AMScania.indd 1 1/11/13 8:49 AM
million) in its manufacturing facilities. The company said it also expects to double its billing in four years.
Under a plan called Projeto DH 2013, the company has expanded and modernized its facilities. Soprano Director Paulo Eduardo Ruschel de Souza said the goals of the project were to create an area for assembling cylinders, increase manufacturing ca-pability, improve production flow and achieve a level of excellence in prod-uct quality and processes.
“DH 2013 places Soprano Hidráu-lica as a top company with modern productive and management systems and innovative hydraulic products of high quality,” Souza said.
Soprano has a new industrial plant of 4000 m², expanding its factory com-plex to 12 000 m². The company said its manufacturing capacity will increase from 150 000 to 300 000 cylinders a year, covering the mobile, agricultural, road and construction segments. So-prano had invested primarily in products for cranes and is now expected to start supplying special vehicles assemblers, such as backhoes and loaders.
Gustavo Miotti, vice president of Soprano, said the market for cylinders is strong, much of it because of the country’s agricultural industry. Data supplied by the Organization for Eco-nomic Cooperation and Development (OECD) shows Brazil is expected to be the biggest exporter of chicken, pig and cattle products, as well as of or-ange juice, soy, coffee, corn, banana, cocoa and sugar, through 2020.
“Our agriculture industry has been growing since 1995 at an average in-dex of 10.5% a year,” Miotti said. “We are feeding the world and will be more and more. India and China’s emer-gence will keep boosting our agricul-ture. It means more combines, trac-tors, sprayers and as a consequence, hydraulic cylinders.”
The company said it expects its 2012 fiscal year sales to be approxi-mately R$33 million (US$16.5 million), down 15% to 20% compared to 2011. Soprano’s main export markets are Ar-
gentina, Uruguay, Chile and Peru. The company also has a plant in Mexico.
Agrale, Marcopolo Invest In Argentina
Agrale S/A, the Brazilian manufac-turer of trucks, bus chassis, military vehicles, tractors and diesel engines, announced an investment of R$25 million (US$12.5 million) at its Argen-tinean plant in the city of Mercedes. The company said it plans to manu-facture tractors there.
Marcopolo, which manufactures bus bodies in Caxias do Sul, Rio Grande do Sul State, Brazil, has also made an investment in Argentina in the form of an acquisition. The company said it has acquired Metalsur Carrocerias, a manu-facturer of long-distance buses in Rosa-rio, for R$18 million (US$9 million).
Agrale said it aims to start produc-tion in Mercedes during the first half of 2013. It plans to develop its content from local suppliers totaling more than 50% initially and has set a second-stage goal of 70% local content.
The manufacture of bus chassis in Argentina will be increased in 2013 with the production of chassis for ar-ticulated buses on a second-vehicle assembly line. In Argentina, Agrale is one of the leaders in the chassis segment and expects to enhance its exports with the new products, the company said.
Agrale’s plant in Argentina began operations in 2008 with the production of bus and light truck chassis. It has
already reached 3300 units, in addi-tion to the vehicles imported from its operation in Brazil. The company has been part of the local market for more than 40 years.
Working through its affiliate, Met-alpar Argentina, Marcopolo acquired 51% of the shares of Metalsur Car-rocerias. Carlos Zignani, investor rela-tions director, said that the purchase is intended to enhance Marcopolo’s presence in Argentina and enlarge its range of models.
Through Metalpar, the Brazilian manufacturer supplies the urban bus segment, while with Metalsur it will reach the long-distance bus market. Metalsur is an expert in the production of double-decker buses, vehicles that have less sophistication than those exported by Marcopolo to Argentina. Founded in 1989, Metalsur has an an-nual production of 200 units.
Metalpar has worked with Marcopolo since 2010 and has been a significant supplier of urban buses. It built 1387 units during the first 11 months of 2012 and claims a 50% market share. The company has 700 employees at its plant in Loma Hermosa, Buenos Aires.
Toyota Plans Lift Truck Plant Toyota Industries Corp. said it would
build its first Brazilian lift truck plant in Artur Nogueira city, São Paulo State.
Diesel Progress international 26 JanUarY-FeBrUarY 2013
brazilnotebook
Agrale S/A has announced an invest-ment of US$12.5 million at its Argentin-ean plant, where it plans to manufac-ture tractors.
DPI522.indd 2 1/11/13 2:04 PM
Late last year, it said that its United States unit in Columbus, Indiana, called Toyota Industrial Equipment Mfg. (TIEM), has been chosen as the model that will be followed in South America. The U.S. plant was chosen in part for its strict quality control process and its 22-year history of building more than 400 000 lift trucks in the U.S.
“The selection of TIEM as the ‘moth-er-factory’ aims to give agility in the process of manufacturing’s implemen-tation without the need of great profile changes, specification and quality in our flagship, which has wonderful rep-utation in the Brazilian market,” said Hi-royuki Ogata, president, Toyota Mate-rial Handling Mercosur. “We are trying to gather the best characteristics of the Takahama, in Japan, and the Colum-bus plants.”
The Brazilian factory will occupy a site of 93 000 m², with 31 000 m² under roof. The investment was of R$101 million (US$50 million). Pro-duction is expected to start in October 2013 in the plant the company said would have 120 employees.
Production of 5000 units is ex-pected in the first year of operations, Toyota said. Studies are being held to analyze the possibility of exporting the products to Argentina. “In the first stage, the plant will attend to the Bra-zilian market,” Ogata said.
The machines expected to be man-ufactured in Brazil are the Toyota 8 series internal combustion lift trucks, powered by Toyota 4Y-ECS four-
cylinder, OHV gasoline engines, with lift capacities from 1.63 to 2.72 tonnes. “These models are of great-est demand in the market nowadays,” Ogata said. “In a first step, we won’t manufacture electric machines in Bra-zil, although the market’s demand will be monitored and we will study the availability of producing them locally.”
Other models sold in the coun-try will continue to be imported from U.S., Japan and Europe. From the U.S. comes pallet and counterbalance types branded Raymond and from Sweden, BT. From Japan comes the internal-combustion models with ca-pacities higher than 3.18 tonnes as well as electric lift trucks.
With the construction of its first Bra-zilian plant, Toyota will have 11 lift truck manufacturing plants worldwide. The
company also operates in Sweden, Italy, France, China as well as the U.S.
“We see Brazil as an expanding market and our aim is to continue investing in this sector, establishing the best production and distribution structure to attend the demand with innovative and highly technological products,” Ogata said.
Hyundai To Start Production in Brazil
Hyundai Heavy Industries (HHI) announced it would start manufactur-ing machinery in Brazil in March. The plant is under construction in Itatiaia, Rio de Janeiro State.
The investment will be of R$369 million (US$180 million) and is a part-nership with Brasil Máquinas de Con-strução (BMC). The joint venture BMC-Hyundai was created a year ago.
The plant will supply equipment such as excavators, wheel loaders and forklifts. Approximately 80% of the production is destined for the domes-tic market, said the company.
This will be the second HHI plant outside of Korea, with the other facility in China.
Scania Launches Car Hauler In Brazil
Scania has introduced the first 6x2/4 truck in Brazil, targeting the
Diesel Progress international 27 JanUarY-FeBrUarY 2013
brazilnotebook
Toyota plans to put its first lift truck factory in Brazil in the city of Artur Nogueira.
Scania’s P 360 6x2/4 truck is targeted toward the car hauler market.
continued on page 28
DPI522.indd 3 1/11/13 2:05 PM
vehicle transportation market with the model P 360.
“Scania has the philosophy of con-stant production evolution, services and technologies,” said Victor Carval-ho, Scania’s sales manager in Brazil. “We are launching a range of trucks that elevates the profitability of the op-eration. We follow our tradition of lis-tening to the market requirements and with this unique configuration, 6x2/4, Scania offers a new efficiency base-line to customers in road transport.”
The company said the 6x2/4 en-hances the load capacity and manag-es longer trailers, besides moving in a smaller turning radius and with fewer wheels on the ground (two fewer com-pared to the traditional 6x2), avoiding unnecessary wear and tear. The turn-ing radius makes handling easier with deliveries in big cities, it said.
“In many services, the traction of the 4x2 doesn’t satisfy the customer’s demands and the 6x2 is more than what’s needed,” said Celso Mendonça, post-sales manager for Scania. “So we thought about 6x2/4, which provides the tractor with six control points, two for traction and four directional ones.”
The new model leaves the factory with an axle spacing of 4050 mm, with a support axle and traction axle distance of 1250 mm and directional axle at 2800 mm. The load capacity is 17.7 tonnes.
The P 360 6x2/4 truck is powered by a Scania DC13 diesel engine rated 268 kW with 1850 Nm of torque.
Ammann Announces New Factory
Rio Grande do Sul State’s govern-ment has announced that the Swiss company Ammann will invest R$15 million (US$7.5 million) in a plant to manufacture compactors and pavers in Gravataí city, Brazil. The factory is to be located on a 5000 m² site.
“The choice for Rio Grande do Sul is because of its already developed machinery and equipment production chain, available local suppliers and qualified workforce,” said Develop-ment and Investment Promotion Sec-retary Mauro Knijnik.
The company was founded in 1869 and is a leading supplier of construction machines with exper-tise in asphalt and road building. It had a billing of approximately R$1 billion (US$500 million) in the fiscal year of 2011. Ammann has been es-tablished in Brazil since 2010, with a subsidiary in Gravataí and dealers in Porto Alegre, Belo Horizonte, Recife and Sorocaba.
Gilvan Medeiros Pereira, who was chosen to be CEO for Ammann Lat-in America, said “starting from our Brazilian unit, the goal is to position
Ammann as a leader in the segment of road construction equipment in Latin America.”
Initially, the plant will create 40 jobs, said the company.
Deere Launches Sugarcane Simulator
John Deere has launched a simula-tor for training operators in Brazil on the company’s 3520 sugarcane harvester. The simulator, which replicates the ma-chine’s cab, is portable, reducing the time to train the staff and eliminated fuel consumption as a training cost.
Besides preparing new operators, the simulator also enhances the skills of experienced employees, said Car-los Newton Graminha, Deere’s ac-count manager. The equipment was developed in partnership with a lead-ing company in simulator technology.
The demand for such training is growing in the South American mar-ket, especially since after 2014 the burning of sugarcane for the harvest will not be allowed. It is said that mechanization minimizes the environ-mental impacts.
Being portable, the simulator can train several groups, even during the sugarcane off-season, said Cristiano Trevizam, from Deere’s sugarcane mar-keting department. A new harvester in-volves at least four employees. dpi
Diesel Progress international 28 JanUarY-FeBrUarY 2013
brazilnotebook
John Deere has introduced a simulator to train operators of its new sugarcane harvester.
DPI522.indd 4 1/11/13 2:06 PM
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By DaviD PhilliPs
Last year, mobile cranes were among the leading products in terms of volume in the con-struction equipment market in
India. In the first half of 2012, back-hoe loaders, crawler excavators and mobile cranes accounted for approxi-mately 84% of the market, similar to the 83% share they held during the corresponding period of 2011. Though falling slightly from 17% of the market in the first half of 2011 to 14% in 2012, they still remain one of the bell weath-ers of the market in India.
The market for mobile cranes has an interesting history. After growing for four years, it declined marginally by 3% in 2008 and then plunged near-ly 17% in 2009. However, demand re-covered strongly in 2010 when sales were up by 43% and peaked at 11 306 units in 2011, representing a 22% growth over the previous year.
Sales of mobile cranes are domi-nated by the locally manufactured pick-and-carry cranes, which account for 93 to 94% of the market. This class of machines has rated capacities of 3 to 23 tonnes, but those rated at 12 to 14 tonnes are the most popular. Demand increased from 8755 units in 2010 to 10 604 units in 2011, a growth of 21%.
Sales of conventional cranes, which include truck-mounted, all-terrain, rough-terrain, crawler and industrial
cranes, fell from 547 units in 2008 to 457 units in 2009. However, their sales increased by 18% to 536 units in 2010, and peaked at 702 units in 2011.
The crawler crane market grew from 13 units in 2005 to 295 units in 2008, but fell sharply by 36% in 2009. However, it recovered strongly with a growth of 49% to 284 units in 2010. Sales peaked at 463 units in 2011, representing a 63% growth over the previous year.
The market for rough-terrain cranes has remained stable between 115 to 126 units since 2007, barring 2009, when it dropped to 91 units. The 20 to 50 tonne capacity range constitutes the major part of the market, which is dominated by local manufacturers. Demand for truck-mounted cranes has varied between 100 to 135 units during this period.
The mark for industrial or yard cranes remained in the range of 11 to 34 units
from 2005 to 2010, but declined to five units in 2011. All-terrain cranes have always had a very limited market in India because of their high price. Only three units were sold in 2007 and sales peaked at 16 units in 2011.
Mobile cranes are utility machines, which are used extensively in all ma-jor sectors of the economy. Sales de-clined by 20% during the first half of 2012 and trends indicated a 16% de-cline for mobile cranes to 9500 units in 2012.
However, the outlook for these ma-chines remains optimistic in view of ongoing industrial and infrastructure development, and the high level of con-struction activity future projects are like-ly to generate. Current trends indicate a steady growth in demand, with sales likely to touch 13 000 units by 2016.
While local manufacturers are sig-nificant players in many of the crane segments, some familiar global equip-
David Phillips is managing director of Off- Highway Research, a London-based manage-ment consultancy that specializes in the re-search and analysis of international construc-tion equipment markets. Phone: (44) 020 7404 1128; E-mail: [email protected]
Diesel Progress international 30 January-February 2013
MobiLe Cranes in india see Ups and downs
gloBaltrends
The Mobile Crane Market In India By Type, 2007-2011 Units
Crane Type 2007 2008 2009 2010 2011
Truck-Mounted 121 101 134 108 101
All Terrain 3 12 6 13 16
Rough Terrain 126 115 91 120 117
Crawler 220 295 192 284 463
Industrial 24 24 34 11 5
Total 494 547 457 536 702
Pick-And-Carry 7621 7323 6048 8755 10 604
Segment Share Of Pick-And-Carry (%)
94 93 93 94 94
DPI530.indd 1 1/11/13 4:15 PM
Diesel Progress international 31 January-February 2013
globaltrends
ment names are also competing effectively. JCB strength-ened its range of pick-and-carry cranes in 2012 with the introduction of an indigenously developed model, the Liftall 1553. The machine has a three-stage boom and is powered by a 36.5 kW Kirloskar diesel engine and has a maximum lift capacity of 15 tonnes.
The machine comes with a slotted boom, which is de-signed to provide greater working radius and productivity due to its auto rope self-compensation mechanism. The cabin has an insulated ceiling, and is spacious enough for its operator to sleep inside, a feature that is particularly im-portant for plant hire (rental), whose operators often have stay for months on remote sites.
This launch was part of JCB’s strategy to increase its share in the mobile crane market, which stood at 11 306 units in 2011 and is expected to reach 15 500 units by 2016. Though JCB is the third largest mobile crane supplier in the country, its market share has remained below 5%. The company entered the market in 2008 with the sale of 39 units, which increased each year to reach 387 units in 2011, but its market share peaked at 4% in 2010.
Demand for the mobile cranes in the country is highly skewed in favor of the low-cost, pick-and-carry crane, which is essentially a material handler with a rigid (as opposed to a revolving) superstructure, and is propelled by what looks very much like the front half of a backhoe loader chassis. It is used on a wide variety of light lifting tasks, which in other countries would probably be done by an industrial crane or a telescopic handler.
Pick-and-carry cranes typically represent 93 to 94% of total mobile cranes sold in the country. This type of crane is extremely cheap (about one-third of the price of an industri-al crane) and as a result, it is overwhelmingly popular in the price-conscious Indian construction equipment industry.
The rated capacity is typically under 15 tonnes, although cranes up to 25 tonnes are available. Almost all compo-nents used on these cranes are either sourced from local suppliers or are produced in-house. Pick-and-carry cranes are allowed to travel on the road, and as a result they are registered with the road transport authorities.
Until the launch of the Liftall 1553, JCB was offering two models of pick-and-carry cranes, both with a maxi-mum lift capacity of 12 tonnes. Though the company had positioned itself at the higher end of this segment, it was facing stiff competition from the other locally produced machines with similar specifications. Despite increased sales, the business remained unprofitable as the compa-ny struggled to extract some premium for what it claims to be a superior product.
The 15 tonne class pick-and-carry crane was launched with a view to enhancing JCB’s market presence and to improve its business profitability. The over 12 tonne class is without doubt a growing subsegment, as its share has increased steadily from 10% of pick-and-carry crane sales in 2007 to 34% in 2011. dpi
dieselhrLima New Parker LatinAmerican Group President
Parker Hannifin Corp. appointed Candido Lima, 47, to vice pres-ident and president - Latin America Group, which became effective Nov. 1. Lima succeeds Ricardo Machado, 64, who will retire at the end of January after 20 years of service. Until retirement, Machado will work to ensure a smooth transition of responsibilities to Lima, the company said.
Lima is responsible for growing sales of all Parker technologies and products in the Latin American region. He began his career with Parker in 2002 as a controller for multiple divisions in Brazil, serving in financial management positions of progressively greater responsibility until 2009, when he became the general manager of the Seal Division based in Sao Paulo, Brazil.
Machado joined Parker in 1992 as the Latin America Group’s continuous improvement manager with the additional responsibil-ity of establishing operations for Parker’s Fluid Connectors Group in the region. Within two years, he became general manager of the Brazilian Automation Division where he successfully helped Parker establish a leading position in Brazil for pneumatics, the company said. In 2000, he was promoted to vice president and president – Latin America Group.
New Education Director For EGSAThe Electrical Generating Systems As-
sociation (EGSA) has named Robert (Bob) Breese as the association’s new director of education. Breese has more than 30 years of experience, most recently working as the lead service trainer and technical writer for Generac Power Systems. In that position, he developed the course curricula for Generac’s factory and field service training programs. He also served as an EGSA Advanced and
Basic school instructor for the past three years.Breese’s responsibilities will include directing the association’s
educational programs, such as the Basic and Advanced Power Schools, the EGSA Technician Certification Program, as well as the David I. Coren Scholarship Program. Breese will also have full responsibility for the eLearning Program as it is developed and implemented.
Tognum Board Gets New MemberJörg Schwitalla, 51, has been named to the Tognum AG ex-
ecutive board, responsible for Personnel and Integrity. Tognum said it has created the new position to meet future require-ments — such as the planned integration of Bergen Engines AS and the group’s growth targets — and to bring the Person-nel, Legal Affairs and Compliance divisions closer together and underline the growing importance of ethics in corporate man-agement. He will also perform the duties of Industrial Director within the group.
Schwitalla was chief human resources officer on the executive board of MAN until July 2012 and has since acted in an advisory capacity for the Volkswagen Group.
R. Breese
DPI530.indd 2 1/11/13 3:37 PM
Diesel Progress international 32 January-February 2013
IndIanotebook
By T.C. MalhoTra
Indian tractor maker Escorts Limited is aiming for a 10% market share in Gujarat during the next fiscal year, up from its current 7% as the company
seeks to become the top manufacturer in the high-end tractor market segment in India over the next three years.
Chief Executive Officer S. Sridhar said the company wants to achieve 25% market share in the segment of 50 hp and above tractors. Sameer Tandon, head of sales, services and spare parts for Escorts Agri Machin-ery, said the company is third in that segment with a 12% market share.
“While we are eyeing the number two slot nationally, we want to have at least double digit market share in the western state of Gujarat next fiscal,” Tandon said.
Escorts reports it sold 63 000 trac-tors last year. Reports suggest the de-
mand in India is for 525 000 tractors per annum, with market size estimat-ed at Rs250 billion (US$4.62 billion).
The company has recently launched its Powertrac DS Plus tractor series in the Gujarat market. The Powertrac DS Plus tractors, with a 10% power upgrade across the range, caters to the emerg-ing “commerce-minded” segment, In-dian farmers who use their tractors not just for regular farm work but also as a source of generating additional income, the company said.
Upgraded to 27.5 kW, 30.5 kW and 37 kW categories, the new Powertrac DS Plus tractors have new Escorts-built engines and are designed to pro-vide efficiency as well as best-in-class power ratings, the company said.
“These tractors are designed to not only save 10 to 15% of diesel to more than negate the impact of diesel price increases, these will also enable farmers to substantially increase their productivity and hence their incomes,” Sridhar said.
Force Motors Aims For GrowthCommercial vehicle manufacturer
Force Motors expects to increase vehicle sales by 25% in the 2012-13 fiscal year. Naresh Kumar Rattan, the company’s president and chief operat-ing officer, said that Force is forecast-ing sales of 40 000 vehicles in the cur-rent fiscal compared to 32 000 units sold in the previous year.
Force Motors also announced the launch of the Traveller 26, a light com-mercial vehicle (LCV) that seats 26 passengers. The Traveller 26, which was released in October, is powered by a Force Motors’ four-cylinder diesel engine rated 95 kW at 3800 rpm.
Force Motors is an Indian manu-facturer of three-wheelers, multi-utility and cross-country vehicles, light com-mercial vehicles, tractors, buses and now heavy commercial vehicles.
Mahindra and Mahindra Reports Gains
Mahindra and Mahindra Limited
Escorts sEEks GrEatEr sharE of tractor MarkEt
Escorts Limited has ambitious goals for its products, including the recently launched Powertrac DS Plus tractor series.
T.C. Malhotra is a technical journalist based in Dehli, India. His e-mail is tc_malhotra@ rediffmail.com
DPI527.indd 1 1/11/13 2:13 PM
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saw gross revenue and other income in the second quarter increase 32.6% compared with the same period in 2011.
For the quarter ending Sept. 30, the company reported gross revenue
of Rs108.914 billion (US$2.01 billion) compared to Rs82.12 billion (US$1.52 billion) during the corresponding peri-od last year. Net Profit after tax for the quarter was Rs9.018 billion (US$167 million) compared to Rs7.374 billion
(US$136.5 million) in the same period last year for an increase of 22.3%.
The domestic tractor industry, in the wake of a below normal monsoon sea-son, witnessed a 12% drop in sales dur-ing the second quarter. The company sold 47 065 tractors in the domestic market, compared to 54 585 tractors during the second quarter last year. The company also reported its engine business revenue grew by 11.1% to Rs2.313 billion (US$42.8 million) in the same period.
Gross revenue and other income during the half-year was Rs210.072 billion (US$3.89 billion) compared to Rs155.306 billion (US$2.87 billion) in the corresponding period in 2011, a growth of 35.3%.
Study: Tractor Volumes Likely To Rise
The domestic tractor industry is like-ly to grow from 500 000 units to about 860 000 units by 2015, according to the
Volvo Trucks has launched the new five-axle FM480 dump truck for the Indian mining industry.
continued on page 34
DPI527.indd 2 1/11/13 2:13 PM
Associated Chambers of Commerce and Industry of India (ASSOCHAM).
Northern India accounts for more than 50% of the tractor market, with states like Punjab, Haryana and Uttar Pradesh enjoying significantly higher penetration levels, followed by the western region, according to a study released by ASSOCHAM.
“Rising rural liquidity together with high disposable income of farmers due to government social schemes like Mahatma Gandhi National Rural Employment Guarantee Act (MNRE-GA) are collectively contributing to growth of the tractor industry which has provided the necessary push for greater farm mechanization,” said D.S. Rawat, national secretary gen-eral of ASSOCHAM.
Increasing application of tractors for nonfarm operations like infrastructure and construction projects, transporta-tion and increasing farm labor costs due are key growth drivers of the trac-tor industry, he said.
An increased domestic demand in the replacement market is another sig-nificant reason behind strong tractor demand as average life cycle of tractors has reduced from over 10 to 12 years to just about eight to nine years.
The domestic tractor industry has traditionally been a medium horse-power market, with 31 to 40 hp trac-tors accounting for about 42% of in-
Diesel Progress international 34 January-February 2013
indianotebook
Daimler India Commercial Vehicles, the Indian subsidiary of the truck manufacturer Daimler AG, has started production of several light-duty trucks (LDT) at its plant in Oragadam near Chennai in the south Indian state of Tamil Nadu.
dustry volumes. But the ASSOCHAM study points toward a shift in the trend with a higher growth in the up-per and lower horsepower segments and moderate growth in medium horsepower segment.
India has about one-third of the global tractor production. According to the ASSOCHAM study, the Indian tractor industry has 13 national play-ers and few regional players. The in-dustry is dominated by Mahindra and Mahindra (M&M) with a share of about 40%, followed by Tractors and Farm Equipment (TAFE) with a share of about 23%, Escorts (13%), L&T-John Deere (10%) and International Trac-tors Limited (about 8%).
Volvo Trucks Launches Mining Truck
Volvo Trucks in India has launched a new dump truck geared toward the Indian mining industry. The five-axle FM480 truck powered by a 13 L Volvo D1 3A480 diesel engine rated 358 kW with 2400 Nm of torque.
“This is the biggest truck ever in In-dia,” said Philippe Divry, managing di-rector of Volvo India Private Limited. “It looks like a truck, but produces like a machine. The Volvo FM480 10x4 dump truck is slated to be the next big game changer in the mining industry.”
The truck has a struck volume capacity of 24 m3 and delivers a
power-to-weight ratio of 7.38:1, the company said, which allows it to provide high performance along with enhanced fuel economy. “The Volvo FM 480 is the first 10x4 dump truck in the Indian market for mining appli-cations,” said Vinod Aggarwal, CEO of VE Commercial Vehicles Ltd. “The higher capacity rock body enables customers to derive best-in-class productivity thereby reducing their fleet size and helping them achieve increased profitability and higher operating efficiency.”
Daimler Starts Light Truck Production In Oragadam
Daimler India Commercial Ve-hicles, the Indian subsidiary of the truck manufacturer Daimler AG, has started production of its 9-tonne rigid, 12-tonne rigid & 12-tonne con-struction BharatBenz light-duty truck (LDT) range at its plant in Oragad-am near Chennai in the south Indian state of Tamil Nadu.
The company said the LDT offerings are based on the Fuso Canter platform, which was bought into India via a joint venture with Mitsubishi Eicher.
The LDT vehicles will be manufac-tured at the Oragadam manufactur-ing plant, which has a capacity of 36 000 units.
Cummins Increases Gen-Set, Engine Prices
The power generation business of Cummins India Limited has in-creased the price of its diesel gener-ator sets and generator set engines in the range of 7.5 kVA and 3000 kVA by up to 3%.
The price increase became effec-tive Jan. 1, 2013. Cummins powered generator sets, transfer switches and paralleling systems are used for continuous, prime and standby pow-er in a variety of commercial and in-dustrial applications. Cummins said it would continue to deliver the high-est quality and value to its custom-ers while remaining competitive in the market. dpi
DPI527.indd 3 1/11/13 4:28 PM
By Ian CameronOne of the world’s youngest marine
engine companies, a spin-off from a giant global carmaker, is gearing up for further growth.
Based in Gyeonggi-do, South Ko-rea, Hyundai SeasAll is backed by the country’s Hyundai-Kia Motor Co. And while the first production marine engines only came off the line in De-cember of 2009, the company now has five base engines from which 22 engine models, ranging in output from 92 to 280 kW, are derived.
Hyundai SeasAll develops marine engines from base automobile, bus and truck engines supplied by its par-ent company. But the company has already outlined plans to add at least one new engine family in the next 12 months and two more within the next three years. It is also steadily growing its distributorship network with four re-cent appointments.
Hyundai SeasAll has mainly sup-plied the global pleasure-boat sector.
and, along with several colleagues, convinced the corporation’s senior ex-ecutives to back the new venture.
Development work started in 2007 and the company was officially formed in August 2009, with the first engines produced four months later.
“Our engines are the same base engine which is used in our cars,” Jeong said. “To compete in the car business you have to use the very latest developed engines, so our policy is to use the same car engine technology and not an old style en-gine for our marine offerings.
“All of our marine engines are very new and meet emissions regulations. Torque is very good and low noise and vibration levels are better than expected in the marine sector. Our price is also cheaper than our com-petitors because our brand is not so strong yet and the customers don’t know our engines so well.”
In its home market, most of its en-gines go into commercial fishing ves-sels, as the recreational market has only recently started to gain momen-tum in Korea.
In Europe, most Hyundai SeasAll en-gines are destined for pleasure boats, one interesting exception being water taxis in Venice, where the company’s local distributor, Socoges, has gained a significant slice of the business.
The burgeoning marine busi-ness stems from the ambitions of Seungkab Jeong, Hyundai SeasAll’s president and chief executive officer. A keen boater, Jeong was working as a senior development engineer in Hyundai’s luxury car division in Korea responsible for noise, vibration and harshness attenuation in the Equus and Genesis models.
Confident the diesel engines used in the company’s cars could be suc-cessfully adapted for marine use, Jeong put together a business plan,
Diesel Progress international 35 January-February 2013
Industry news
Just over four years since the launch of its first marine diesel engine, Hyundai SeasAll has developed a growing range of 22 marine engines based on five engine platforms. They include five 3 L, V6 S-Series diesel engines (left) and one of the most recent additions to the lineup, the H-Series diesels.
Motoring Deeper Into the MarIne Market
Four years after launch of its first engine, Hyundai SeasAll growing marine diesel range, distribution network
continued on page 36
DPI528.indd 1 1/11/13 3:08 PM
Industry news
Diesel Progress international 36 January-February 2013
strongly on expanding its international sales footprint. Like most engine suppli-ers the company was hit by global eco-nomic uncertainties over recent years and sold around 500 engines in 2012, around half of its original forecast.
Not surprisingly though, it has a strong sales presence in its home Korean mar-ket and a growing profile in Europe, the primary market for recreational diesel engines. It has distributors in most major European countries except for Norway where it is seeking to appoint a repre-sentative. In the past seven months, the company has appointed distributors in western Canada, Colombia, Ecuador, Egypt, Singapore and Thailand and ex-pects further representation to be final-ized soon in Russia, which the company said has “great potential.”
The company is also active in Chi-na, South-East Asia, Australia, New Zealand and several Pacific Islands.
Hyundai SeasAll also serves the Safety of Life at Sea (SOLAS) market through its partner Bukh Diesel, which offers the D and S engine families for fast rescue boats. Hyundai SeasAll added that Bukh is considering ex-panding its range to use the U-Series.
“We are hopeful our new engines will be successful especially as many distributors are interested in the 10 and 12.7 L engines,” Jeong said. “Up to now we have only really sold in the pleasure market but some of our distributors have great experience in the commercial market as they already sell Doosan en-gines for the commercial marine market.
“Like all players in the marine industry, we hope that we have seen the bottom of the recession. So while we believe that 2013 will be flat overall, we are an-ticipating that the market will start to im-prove in 2014. That said, as a fairly new player, starting from zero three years ago, we have seen significant volume increases year-on-year since we began.
“Our recent addition of the H and L families of commercial engines will also add to our growth as the commercial engine market is more resistant to eco-nomic cyclicality than the pleasure en-gine market.” dpi
and stroke is 77.2 x 84.5 mm. Dry weight is 220 kg.
Available in five models, the S-Series are 3 L, four-stroke, V6 engines incor-porating a Bosch piezo-controlled, com-mon-rail fuel system. CGI cylinder blocks are lighter and quieter than conventional cast iron blocks and demonstrate “at least 85% higher tensile strength, 45% higher stiffness and approximately dou-ble the fatigue strength of iron and alu-minium,” the company said.
The S250S, S250P and S250J en-gines are aimed at the pleasure and special light-commercial markets and have an output of 184 kW at 3800 r/min full load. The S220S and S220P engines have a 162 kW output at 3200 r/min and are targeted at the light-duty commercial market. All five models have a bore x stroke of 84 x 89 mm and a dry weight of 334 kg.
Completing the current product offer-ing is the D-Series family of five, 2.2 L, inline four-cylinder, four-stroke engines that have Bosch solenoid-controlled common rail fuel injection systems and variable geometry turbochargers.
Again aimed at the pleasure and light-duty commercial markets, all five engines have an 87 x 92 mm bore x stroke with a 261 kg dry weight.
The D170S, D170P and D170J en-gines are rated 125 kW at 3800 r/min full load, while the D150S and D150P en-gines produce 112 kW at 3200 r/min. All five engines weigh in at 261 kg.
Along with boosting its product offer-ing, Hyundai SeasAll is also focusing
The two most recent additions to the Hyundai SeasAll line-up are the H and L families of engines aimed at the heavier commercial marine market.
The 10 L, six-cylinder inline H Se-ries provides 280 kW at 1800 r/min at full load. It incorporates a Denso elec-tronic unit injection system with the company and a one-piece compacted graphite iron (CGI) cylinder head, which makes it lighter and quieter than conventional heads for more on-board comfort, Hyundai SeasAll said.
Also featuring Hyundai electric vari-able geometry turbochargers the H-Series engines have a bore and stroke of 122 x 142 mm, a compression ratio of 16:1, torque is 1667 Nm at 1100 r/min and dry weight is 1120 kg.
The four-stroke, four-valve, heavy duty L-Series produces 368 kW at 1800 r/min, has six cylinders and has a 12.7 L displacement. Bore and stroke is 130 x 160 mm and maximum torque is 2275 Nm at 1200 r/min. Maximum fuel consumption is 88 L/hr and dry weight is 1310 kg.
Hyundai SeasAll said its three-model U-Series engines offer the benefits of diesel power for boats which were pre-viously limited to using petrol engines.
The 1.6 L, in-line four-cylinder, four-stroke engine has an output of 93 kW at 4000 r/min full load. Aimed princi-pally at the pleasure boating and light-duty commercial markets, the engine has a Hyundai variable geometry tur-bocharger with a Bosch common rail direct fuel injection system and bore
Seungkab Jeong, Hyundai SeasAll president and chief executive officer.
DPI528.indd 2 1/11/13 4:20 PM
M I D D L E E A S T
TRIZACH O L D I N G
DEWA.indd 1 1/10/13 1:18 PM
New SiNgle-CyliNderKohler Diesel
KD15 replaces Lombardini’s single-cylinder 15LD diesel; KDI diesels go into production
By RoBeRta PRandi
There was a lot to celebrate at Lombardini’s headquarters in Reggio Emilia, Italy, recently, as the company unveiled its
newest air-cooled, single-cylinder diesel engine range and marked the startup of a new assembly line for its Kohler Direct Injection (KDI) engines, first unveiled just over a year ago.
Starting with the company’s new-born, the KD15-440 is the first unit to be presented within a range that will be ultimately composed of four single-cylinder engines — the KD15-350, KD15-350S, KD15-440 and KD15-440S models — delivering 5.0 to 8.0 kW power outputs at 3600 r/min. The latter two models were to be available beginning in February, while the oth-
According to Massimiliano Bonanni, Lombardini’s director of engineering, a bigger cartridge and the high fil-tration capacity of the filter’s paper element assure the best protection for the engine, while maintenance is much improved thanks to higher in-tervals (up to three times greater than the current version) and an easy sys-tem for replacing the filter cartridge.
“The fuel tank is a new development with a primary filter housed inside the tank and a pre-filter for additional safe-ty,” Bonanni said. “The two filters work-ing in tandem efficiently block particle contamination during fuel refill.
“The primary filter inside the tank can be easily accessed and replaced without using special tools, while a new drain tap allows users to remove water and impurities collected at the bottom of the tank without disassem-bling other components.”
The new KD15 diesel also utilizes a new rubber-coated recoil pulley, curbing noise by 1dB(A), along with a bigger oil sump to increase standard maintenance intervals from 250 to 500 hours.
Also noteworthy was the inaugura-tion of the new assembly line for the KDI engines, which mark the Reggio Emilia plant as the center of excel-lence for diesel engines within the Kohler Group.
Lombardini’s director of operations, Gianluca Paini, explained that the new assembly line is composed of three main parts with an initial capacity of 33 000 engines per year. That number can be doubled without major invest-ments, the company said.
“The KDI assembly line is subdivided into two major parts,” Paini said. “The
ers are scheduled for release at the end of the year.
The KD15 family — KD “Kohler Die-sel” — will replace the current 15LD (Lombardini Diesel) engine family while offering a series of enhance-ments, mainly in the area of air filtra-tion and fuel tank. The new engines will maintain the same footprint and mounting points of the engines they replace, the company said.
Lombardini, which led the KD15 de-sign update from the existing single-cylinder series, said the new engines incorporate a new air filter system composed of a high-efficiency cy-clonic separator with prefilter and an accumulated-dust drain valve in the primary filter.
Diesel Progress international 38 january-february 2013
indusTry news
The KD15-440 is the first version in Kohler’s
new KD15 range of air-cooled, single-cylinder die-
sel engines. The new engines are a revamp of the existing
Lombardini 15LD diesels.
DPI518.indd 1 1/11/13 3:42 PM
first, called Short Block, assembles those elements which are common to all engine models, such as crankcase, bedplate, oil pan, camshaft, crank-shaft, connecting rods and pistons.
“The second subline, called Long Block, completes the upper section of the engine and customizes the unit according to the different engine ver-sions. A third subline runs parallel to the Long Block and is dedicated to the assembly of the cylinder head, essen-tially feeding the main line.”
The whole assembly line covers a length of 236 m with 39 stations, 14 in the Short Block area and 25 in the Long Block. Eleven stations are fully automated. Six more stations com-pose the cylinder head line.
“This is a highly automated assem-bly concept, based on the theory of objectification,” Paini said. “Objectifi-cation is an approach aiming at cre-ating an industrial design finding a best practice for every operation. This leads the operator to execute the op-eration correctly.”
The assembly line applies stan-dard error prevention techniques that ensure an engine will not move to the next step unless sophisticated computerized controls prove that the checkpoints at the previous station were passed.
Great efforts have also been put in minimizing acceptance testing on the bench, thus eliminating a poten-tial bottleneck. “We will adopt a mixed testing process, with short accep-tance tests on hot running engines for all those units featuring mechani-
cal injection and externally driven cold tests for all those units with a common rail system,” Paini said.
Along with the new assembly line, the Lombardini plant also upgraded production capacity that now sits at 33 000 KDI engines per year in two shifts, but can be easily doubled in a time span of eight to 10 months, the company said.
Among the newly installed produc-
industry news
Diesel Progress international 39 january-february 2013
The new highly auto-mated line at the Lom-bardini plant in Reggio Emilia, Italy, has begun production of Kohler’s new KDI diesel range. The 1.9 and 2.5 L ver-sions are already in pro-duction. The 3.4 L mod-el will follow in 2014.
FXS.indd 1 1/4/13 10:40 AM
tion machines, are some latest gen-eration machining centers for the fin-ishing of the crankcases. Two of these machines cover a production output of 26 000 units/year of the three- or four-cylinder crankcase at the same time, while five centers will handle up to 65 000 units per year.
Cylinder honing is also an opera-tion that Lombardini decided to keep in house, as well as the machining of crankshafts and camshafts.
KDI engines in the 1.9 and 2.5 L displacement versions started to roll out of production at Reggio Emilia in October, while serial production of the 3.4 L engine will start in 2014.
Lombardini has announced the com plete migration to the Kohler brand to be carried out along the completion of all the new ranges. The engines, however, will still be available with the Lombardini brand upon cus-tomer’s request. dpi
DPI518.indd 2 1/11/13 3:42 PM
MAN Adds To Gas EnGinE RanGE
220 kW output power for new six-cylinder gas engine by MAN Truck & Bus based on diesel truck engine
MAN Truck & Bus has devel-oped a new gas-powered engine for power genera-tion applications. The new
E2676 LE202 engine targets combined heat and power generation installations such as swimming pools, hospitals and housing complexes, the company said. The engine is also suitable for applica-tions using agricultural biogas, in waste- disposal sites and water treatment plants, the company said.
The E2676 LE202 is a gas-powered four-stroke spark ignition engine with six cylinders inline (126 mm bore x 166 mm stroke) for a total displace-ment of 12.4 L and a power output of 220 kW at 1500 r/min for 50 Hz power generation applications. MAN Truck & Bus said the new engine complies with current emissions limits and has a mechanical efficiency over 40% and a thermal efficiency of more than 50%.
The E2676 LE202 gas engine is
In accordance with MAN’s minimum requirements for gas quality, it is pos-sible to use natural gases at a com-pression ratio of 12.5:1 as well as spe-cial gases at 14:1. The E2676 LE202 engine was designed especially for decentralized, continuous power sup-ply and optimised for operation with natural and special gas, MAN said.
MAN Truck & Bus said it would de-liver the natural gas or biogas variant from the fourth quarter of 2013.
The new engine completes the MAN range of gas-powered engines for oper-ation in CHP plants, with outputs rang-ing from 37 kW to 550 kW at 1500 rpm for 50 Hz applications powered by natu-ral gas and from 68 kW to 550 kW for biogas versions. Five series with a total of 19 gas engines are available. dpi
based on a newly developed engine block with monoblock four-valve cylin-der head. For many years, the base engine has been installed as the die-sel power unit of choice in MAN trucks.
The company said the D2676 diesel engine offers a constant load profile with low operating costs, above all in long-distance transport. This high level of efficiency is confirmed with the new-ly developed six-cylinder gas engine, MAN said, noting that the reduction of pressure losses in the cooling circuit of the E2676 LE202 made it possible to decrease the size of the external en-gine coolant pump, thus increasing the system’s overall efficiency.
“The combination of four-valve tech-nology and a new combustion cham-ber geometry increases the specific power output, optimizes economy and reduces emissions,” said Reiner Röss-ner, vice president and head of sales at MAN Engines in Nuremberg, Germany.
Diesel Progress international 40 january-february 2013
POWER GENERATION
For More inForMationwww.man-engines.com
The new E2676 LE202 six-cylinder gas engine by MAN Truck & Bus delivers 220 kW at 1500 r/min burning natural gas, biogas or other special gases.
DPI529.indd 1 1/11/13 4:24 PM
productbriefs Diagnostic Display
FW Murphy introduced the PowerView model PV25, a diagnostic display designed for Tier 4/Euro Stage 3b/4 and below en-gines. The PV25, which displays engine parame-ters and diagnostic trouble codes, is part of the com-pany’s existing PowerView display portfolio.
The display provides equipment operators with a way to see how the engine is perform-ing by revealing 20 J1939 parameters broadcast from the ECU. Operators can use the up and down push-buttons to scroll through the parameters, and be alerted by the device’s LED lights, which indicate warning and shut-down conditions. It also can instrument mechanical engines with an additional MeCAN module, as well as replace the existing hour-meter function.
Other features include displaying DEF and soot levels, as well as active DM1 and store DM2 faults using the suspect parame-ter number (SPN), failure mode indicator (FMI) and occurrence count (OC).
www.fwmurphy.com
Fuel FiltersRacor, a division of Parker Hannifin Corp., has released the DFBO-
14 Series, duplex fuel filters for industrial or marine applications. The FBO filters have a duplex design that ensures fuel is filtered without interruption, Racor said. The cast-iron head and steel bowls allow the filter to be used in marine applications that require ABS certifica-tion. A prefilter, water separator/particle filter, or water absorptive filter can also be used, according to the company.
www.parker.com/racorproducts
bc India.indd 1 11/6/12 4:11 PMProducts.indd 1 1/11/13 3:47 PM
The Off-ROad AheAd
How the creation of the Off-Highway Systems business unit continues the evolution of global powertrain specialist ZF
By RoBeRta PRandiEditor’s Note: In business, it is an
accepted fact that nothing stands still. Whether it is a company’s structure, products or processes, successful global suppliers continue to define and refine what they do and how they do it. A good example is ZF Friedrich-shafen AG, the German specialist in driveline and chassis technology for off-highway, on-highway, automotive and marine applications.
Less than two years after rolling out a completely new corporate structure intended to “present one face” to all of its customers, the company has continued to develop that strategy. On the off-road side, that develop-ment has resulted in the creation of the Off-Highway Systems business unit within the Industrial Technology Division, which bundles the com-pany’s off-highway operations into a single entity.
Diesel Progress International spoke
easily find the right contacts indepen-dent from the requested technologies, be it axles or transmissions.
DP: Dr. Mohr, you are now respon-sible for construction machinery. What are your main tasks and goals in this new structure?
Mark Mohr: As a global-acting sup-plier for drivetrain components, the main challenge for the future will be managing the spread between high-tech drivetrains for the Western mar-kets and best-cost drivetrains for the growing markets.
In the Western markets, efficiency is the main target today. The overall optimization of the driveline system does require different approaches for the individual driveline components. Components considered as being of minor importance also offer consider-able potentials at limited efforts. After optimization of the individual compo-nents, additional potentials can only be achieved by a system approach.
This system approach will play a ma-jor role in our future strategies. In com-bination with our axle and transmission expertise, we see fuel saving of 20 to 30% for our products. Our ZF Efficien-cy Package is the recent technology to address this system approach.
Based on our long-term experience in
with Dr. Hermann Beck, head of Off-Highway Systems, and Dr. Mark Mohr, head of ZF’s Construction Machinery Systems segment, about the new or-ganizational developments and future product plans.
DP: ZF reorganized its structure in the off-highway business segment — what’s behind that?
Hermann Beck: In order to improve our “One face to the customer” strat-egy and to benefit from internal syner-gies between our cross-functional de-partments, we decided to create a new business unit, Off-Highway Systems. Under its roof you find three strategic market segments — construction ma-chinery, agricultural machinery and material handling systems.
This new structure gives us the chance to bundle know-how and equal standards and allows the customer to
Diesel Progress international 42 January-February 2013
Powertrain specialist ZF, see-ing an increasing emphasis
on fuel economy and machine productivity, has developed what
it calls the ZF Efficiency Package, which is being used by JCB on its
Model 457 HT wheel loader. The package includes a five-speed ZF Ergopower 5 WG
210 transmission with lock-up option and ZF Multitrac L 3095 2 front and rear axles.
Industry news
DPI526.indd 1 1/11/13 4:01 PM
the agricultural sector we already made the next step in this evolution, CVT tech-nology for construction machinery.
Hybrid modules for all relevant ap-plications will be a final step as soon as markets, customers and environ-mental/political scenarios request that technology.
DP: With bauma in Munich not far ahead, what will your message be at the world’s biggest trade show for construction machinery?
Mark Mohr: Efficiency! This will be the main driver for the construction machinery market today and for the years coming. I think ZF has all the right answers, both in axle and trans-mission technology. Bauma Munich for us is the perfect platform to pres-ent these “Innovations of Great Value,” as our bauma slogan says.
DP: What are your current mar-ket and product strategies for off-highway?
Hermann Beck: Design to market is one key element in ZF’s global strat-egy. It means adjusting the design to expectations of local customers and the possibilities and demands of the local industrialization market.
We are trying to meet this demand by creating global product platforms so we can adjust specific techno-logical steps exactly to the according market requirements; from basic pow-er-shift transmissions and dry brake axles to CVT transmissions, electric drives and hybrid solutions.
DP: What are the primary emerging markets for construction machines? What are your expectations in Chi-na after the economic slowdown? And Russia?
Mark Mohr: The biggest market for constructions machines is China and it will still grow in the coming years. In 2012 we saw a big decrease and the outlook for next year is not clear yet.
But the market is developing step by step into a higher technology level. We are able to deliver different levels of technologies and thanks to this ca-pability we are able to increase our volumes also in a flat market.
Russia is also a country with a big potential. The market is mainly domi-nated by Western companies for the high-end machines and Chinese com-panies for the lower level of technol-ogy. The Russian manufacturers have to find their position in between.
Big growth rates are expected also for Brazil, but for the time being they are still behind expectations. I’m sure the market will increase in the next years and everyone is preparing for this.
DP: ZF’s Efficiency Package is mainly intended for the Ergopower transmission range. For which oth-er transmissions will it be offered and for which machine segments?
Mark Mohr: With our CVT trans-mission, we will cover the same power range as the Ergopower does today. At the higher product range we will have an additional size for wheel load-ers up to 35 tonnes.
DP: What about future develop-ments for the cPower CVT range?
Mark Mohr: There are a lot of op-tions. The CVT is interesting for all those machines working mainly in the low-speed area where the torque converter is open or for applications
where the engine speed is dominated by the working hydraulics and not by the driving. With the CVT you have a high degree of freedom for the driving strategy and that offers a lot of poten-tial for different applications. Several projects for different applications are in process.
DP: In your hybrid concept you of-fer for now an electric machine with maximum 120 kW output. Are there expectations or demands for more power output?”
Mark Mohr: In the excavator seg-ment we see a lot of hybrid projects, some already in serial machines. In special operation conditions, as for example material handling, a return of investment for a hybrid excavator is possible.
In other machines we rather see the utilization of different technologies such as CVT transmissions, which can offer a higher fuel consumption reduction at lower cost. We think man-ufacturers have to take these steps first, only then the machines will be ready for hybrid technology.
I’m sure that we will see hybrid solu-tions in construction machines in the future, but then we have to utilize all potentials of the technology in the ma-chine system. ZF is ready for hybrid, but it will take some more time. dpi
Industry news
Diesel Progress international 43 January-February 2013
For More inForMationwww.zf.com
ZF is also seeing a greater opportunity for continuously variable transmission technology. In the company’s cPower CVT, the percentage of hydrostatic pow-er versus direct drive is kept low during the typical working cycle for maximum efficiency. In wheel loader applications this transmissions has shown up to 30% reduced fuel consumption and up to 20% more efficiency, according to ZF.
DPI526.indd 2 1/11/13 4:02 PM
New Flow Directional ValVes anD
Fan DriVe Hics Comatrol’s DV15 directional control valves developed to drive more
compact, efficient designs of the new reversing fan drive HICs.
Comatrol, part of the Sauer-Danfoss Group and a manu-facturer of engineered hy-draulic cartridge valves and
hydraulic integrated circuits (HICs), has introduced a new line of high flow directional control valves. The intro-duction of the new DV15 valves has also allowed Comatrol to update its RFDE fan drive HICs.
According to Darren Magner, Co-matrol’s manager of marketing, the latest products are a continuation of the company’s recent focus on high flow directional controls and represent continued investments in fan drives for controlling the speed and reversing functions of hydraulic fan systems, typically used on diesel engine-powered equipment.
At bauma China 2012 in November, Comatrol also rolled out a localized update to its EasyValve software to now include the Chinese language. Thus EasyValve, a circuit design soft-
“An additional benefit of the piloted design is that customers are not lim-ited to piloting the DV15 using a sole-noid valve, as they can also pilot with other valves, including sequence, re-lief and manual valves.”
Comatrol also said the DV15-P5-24 is a solution that customers can use in place of several two-position, four-way CETOP D03 or D05 valves, reducing space. The five-way piloted directional control valves can be piloted using one of Comatrol’s 08 size solenoid valves, allowing use of new robust coils which were designed to withstand extreme ambient temperatures when mounted in an engine compartment.
With a total length of 101 mm, the DV15 comes in a smaller and lighter design, which Magner said is essen-tial for fan drive systems near engine compartments where space is limited. The valve’s rated pressure of 230 bar is a good match for these fan drive ap-plications, he said.
ware designed to allow hydraulic cir-cuit designers to communicate and document their ideas, now offers the flexibility of switching between English and Chinese. The addition of Manda-rin will also provide for further collabo-ration of circuit design in China, the company said.
The DV15 is a five-position piloted directional control valve with flow ca-pacity of 70 L/min at 7 bar pressure drop and capable of flows up to 80 L/min. The new five-port design is a two-position, four-way directional valve that is available in various schematics, and is shifted by applying a 2 bar pilot pressure to port number five.
“We designed the DV15 to help us create a more compact, efficient and cost-effective reversing fan drive solution,” said Enzo Soncini, product development leader. “It provides our customers with a new way to control the direction of flow on their vehicles with a very low pressure drop.
Diesel Progress international 44 January-February 2013
MOBILE HYDRAULICS
Comatrol has introduced the DV15, a five-position piloted directional control valve with flow capacity of 70 L/min at 7 bar pressure drop and capable of flows up to 80 L/min. This new five-port de-sign is a two-position, four-way directional valve that is available in various schematics.
DPI514.indd 1 1/11/13 4:11 PM
Comatrol previously launched a portfolio of six pre-engineered re-versing fan drive HICs, four of which were designed using CETOP D03 or D05 valves for the reversing func-tion. With the launch of the DV15-P5-24 valve, the portfolio has been revamped to replace these four HICs with updated designs.
“Our customers were seeking more efficient and compact designs than our existing 40 and 80 L/min HICs us-
ing CETOP valves,” said Rocco Marel-la, account manager. “They needed lower pressure drop through the HIC to improve the efficiency of the fan drive system and a much slimmer de-sign to fit around the tight space con-straints in the engine compartment. We worked closely with product devel-opment, leveraging Comatrol’s com-putational fluid dynamic capabilities, to design and optimize a solution that met these stringent requirements.”
MOBILE HYDRAULICS
The result of this development work includes a 79% reduction in pressure drop of the 40 L/min HIC, from 24 bar to 5 bar, while reducing the overall HIC size by 30%. The pressure drop for the 80 L/min HIC is equivalent to the previous design, but comes in a more compact build with an overall re-duction equaling 60%, he said.
The RFDE-40 and RFDE-80 come in both the PRV (open circuit gear system) and 000 (variable piston pump system) designs, support-ing the most common reversing and modulating fan drive solutions in the industry. For commonization of de-sign, the 40 and 80 L/min versions are the same size but are optimized for their respective maximum flow ca-pacities, Marella said. dpi
For More inForMationwww.comatrol.comwww.comatrol.cn
Diesel Progress international 45 January-February 2013
Johnson Matthey offers a brochure that details the company’s ca-pabilities to help stationary diesel and gas engine owners comply with the U.S. Envi-ronmental Protection Agency’s (EPA) RICE
NESHAP regulations, which became effec-tive in 2013. The brochure is titled Station-ary Emissions Control Modulex Catalytic Converters; The winning combination for
your stationary engines to achieve RICE NESHAP compliance in 2013.
Power Systems Research announced that its European office has moved to a new location at Avenue Lloyd George 6, Brussels, Belgium. The move supports the company’s international growth strategy as it continues to increase its market research capability and capac-ity. Power Systems Research has been in Brussels for more than 20 years. The Eu-ropean office provides market intelligence, consulting and market research support to global engine, equipment and components manufacturers, the company said.
Chinese crane manufacturer Zoom-lion has appointed Houston, Texas, U.S.A.-based Global Crane Sales as the exclusive distributor in Latin America of its full line of rough terrain, crawler, truck, all-terrain and tower cranes. Previously, Global Crane Sales was the exclusive international dis-tributor of the Zoomlion rough terrain
crane line and the North American dis-tributor of the Zoomlion crawler crane line. Zoomlion has partnered with Global Crane Sales since early 2010.
Correction: Due to an editing error, the displacement range for gear pumps manu-factured by Aber was listed incorrectly in the 2012 Mobile Hydraulic Pumps & Motors Specs-At-A-Glance chart that ap-peared in the November-December issue of Diesel Progress International. Aber’s gear pumps range in displacement from 12 to 150 cc/rev. Diesel Progress regrets the error.
PoweRlineS
Comatrol’s RFDE-40 and RFDE-80 fan drive HICs come in both the PRV (open circuit gear system) and 000 (the variable piston pump system shown here) designs, supporting the most com-mon reversing and modulat-ing fan drive solutions.
DPI514.indd 2 1/11/13 4:18 PM
Cat Upgrades C15, C18 Gen-SetS
Rated 365 to 600 kW, sets are suitable for prime or standby power; new enclosure options
Caterpillar Inc. announced it has made several enhance-ments to its C15 ACERT and C18 ACERT generator sets,
moves made to improve the overall performance and enclosure options, the Peoria, Illinois, U.S.A.-based man - ufacturer said.
Rated from 365 to 600 kW, these enhancements to the gen-sets are suitable for prime or standby power and are available in a range of con-figurations with optional equipment, Caterpillar said.
A number of improvements were made to the enclosures, available in either sound-attenuated or high-ambi-ent 49°C configurations. The new en-closed models feature rear-mounted, side-by-side power and control panels and a standard, integral fuel tank base with drip tray, allowing for eight hours of runtime at 100% prime rating, the company said.
Cat said the top tank plate is now sloped to contain any accidental oil, coolant or fuel spills. An optional inte-gral dual wall fuel tank base for total fluid containment is also available.
The new sound-attenuated models are constructed of noise-absorbent materials designed to further improve
The EMPC4.1 features auto/start/stop; engine cool down timer; emer-gency stop and engine cycle crank controls; as well as a number of digital indicators. These include generator ac voltage; rpm and battery voltage; generator ac current; generator fre-quency; engine oil pressure (psi, kPa or bar); engine oil temperature (C or F); engine coolant temperature (C or F); multiple language support; and en-gine start and crank attempt counter.
The EMPC4.2 controls offer addi-tional functionality, including a pro-grammable cycle timer control and the following digital indicators: power metering (kW, kVA, kVAr, pf); hour meters (kW-Hour, kVAr-Hour); and a real-time clock.
Cat said utilizing the EMCP remote monitoring software on a PC in con-junction with the EMPC4.2 allows for as many as eight generator sets to be controlled using virtual computer screen control panels. In addition, the open protocol communication en-sures remote monitoring compatibility with most building management or su-pervisory control systems. dpi
noise reduction, typically by 3 dB(A) at 1 and 7 m. An internal exhaust silencer system enhances generator set safety, aesthetics and silencer life, Cat said.
For added protection to the enclo-sure, the package has been designed with an all-round, overhanging base frame. The control panel viewing win-dow and access doors for the fuel fill and battery are lockable.
Finally, installation and service are improved, Cat said, by oversized ca-ble access, an oversized rear door for panel access and purpose-designed improved dragging and jacking points in the base and an integrated lifting frame (C15 only).
The open configuration models now also feature rear-mounted, side-by-side power and control panels, and come standard with an integral narrow fuel tank base with drip tray, allowing for a full, eight hour runtime at 100% prime. A narrow skid base is an avail-able option.
Further, the new C15 and C18 gen-erator sets are fitted with Cat’s latest EMCP4 control panels, designed for enhanced performance monitoring ca-pabilities. The EMCP4.1 and EMCP4.2 control panels are equipped with many operational and protection features.
Diesel Progress international 46 January-February 2013
power generation
For More inForMationwww.cat.com
Caterpillar has announced several enhancements to its C15 and C18 generator sets. Improvements to the enclosures are available in sound-attenuated or high-ambient configurations, as well as rear-mounted, side-by-side power and control pan-els and a standard, integral fuel tank base with drip tray.
DPI499.indd 1 1/11/13 4:24 PM
GeneratinG Greater Protection And control
Basler develops new digital voltage regulator for gen-set control and monitoring
Expanding its DECS digital volt-age regulator lineup, Basler Electric has added the DECS-250 regulator for control, mon-
itoring and protection of brushless ex-cited ac synchronous generators.
The microprocessor-based exci-tation control system is designed to provide metering and communication capabilities along with fully program-mable inputs and outputs. It incorpo-rates a PWM power stage and pro-vides high field forcing, Basler said, and can accommodate 32, 63 or 125 Vdc nominal voltages with a continu-ous output rating of 15 Amp.
New additions to the DECS-250 unit is an integrated power system stabiliz-er, automatic synchronizer, integrated programmable logic, enhanced com-munication capabilities and advanced data capturing capabilities.
The digital voltage regulator incor-porates self-tuning, which is designed to automatically measure the system’s responses and create proportional in-tegral derivative (PID) parameters to
to allow multiple units to communicate over Ethernet to share the reactive power output of all machines on the network. This allows load sharing at zero droop within the network, which according to Basler, eliminates the maintenance and drawbacks associat-ed with conventional hardwired reac-tive differential compensation circuits.
Basler said the DECS-250 has true RMS sensing for single- or three-phase voltage and current. It also in-corporates an integrated automatic synchronizer and is equipped with configurable generator protection for increased flexibility.
The DECS-250 utilizes Basler’s BestComsPlus PC software, which allows for quick setup, configura-tion, operation and control of the unit. The integrated PLC capabili-ties allow users to customize their control scheme to meet virtually any application, Basler said.
Basler offers the DECS-250 with multiple communication options as well as a power system stabilizer op-tion. Other options include an auto-matic synchronizer and two separate analog inputs for remote set point control or limiter scaling available for either 4 to 20 mA or ± Vdc inputs.
The DECS-250 is certified per CSA standard CAN/CSA-C22.2 and UL recognized per standard 508. It is also CE, EMC and LVD compliant and has DNV certification, Basler said. The control can operate in tem-peratures from -20° to 70°C and has been shock tested to 15 G and vibra-tion tested to 5 G from 18 to 2000 Hz. It is salt fog rated per MIL-STD 810E method 509.3, the company said. dpi
ensure optimal response. Basler said its design minimizes commissioning time and system setup, which can save both time and money.
The DECS-250 control is equipped with 16 programmable inputs and 12 programmable outputs. It has I/O expansion module compatibility and can communicate through a variety of interfaces including USB, ModBus RS-485 RTU, J1939 CANBus, Ether-net or Profibus.
For added capacity, Basler said its CEM-2020 or CEM-2020H modules could be added to the DECS-250 to provide 10 additional contact inputs. The AEM-2020 expansion module adds eight remote analog inputs, eight remote resistance temperature detec-tor (RTD) inputs, two remote thermo-couple inputs and four remote analog outputs. The AEM-2020 communi-cates with the DECS-250 through a CANBus interface.
The DECS-250 was developed with reactive load sharing via communica-tion interface. This feature is designed
Diesel Progress international 47 January-February 2013
Controls
For More inForMationwww.basler.com
Basler’s DECS-250 digital voltage regu-lator provides protection, control and monitoring for ac synchronous generators. New features include an in-tegrated power system stabilizer, auto-matic synchronizer, integrated program-mable logic, enhanced communication capabilities and advanced data captur-ing capabilities.
DPI498.indd 1 1/11/13 4:31 PM
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bauma 2013 ....................................................... 33
bC India 2013 ..................................................... 41
Bondioli & Pavesi S.p.A. ...................................... 9
China (Beijing) International Power Transmission &
Control Technology Exhibition 2013 (CIPTC) ....51
Comer Industries ................................................ 17
* Concentric Inc. ..................................................... 1
* Dana Off-Highway Systems ............................... 19
* Deutz AG ..............................................Third Cover
* Doosan Infracore Co. Ltd. ................................. 29
* Ellwood Crankshaft Group ................................. 17
FSX Equipment Inc. ........................................... 39
Haldor Topsøe A/S .............................................. 5
HJS Emission Technology GmbH & Co. KG ..... 21
* John Deere Power Systems ............Second Cover
* Kubota Corporation .............................................. 7
Oerlikon Graziano SpA ...................................... 13
Scania CV AB .................................................... 25
TEDOM a.s. - Engines Division ......................... 11
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Hochtemperaturdämmungen GmbH ............... 15
WETEX 2013 ..................................................... 37
ZF Friedrichshafen AG ...................... Fourth Cover
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Diesel Progress international 49 January-February 2013
dieseldotcomtecsis GmbH, which specializes
in measuring technology, has launched its new website at www.tecsis.de. The new website features a modern design that of-
fers customers an overview of the compa-ny’s four business units, which are Force, Pressure, Temperature, and Switch. It also has a product finder feature that guides visitors to the right product. The website is available in German and English, with a Chinese version coming soon.
Poclain Hydraulics has a new website at www.poclain-hydraulics.com. The website features digital images in high defini-tion as well as a search engine and a systems function that helps manufacturers find the most relevant Poclain Hydraulics product in
relation to their activity. Company news can also be found on the website, which is avail-able in English and French, with other lan-guages set for release in the coming months.
ausa, the Spanish manufacturer of heavy compact machinery for industrial, construction, agriculture, municipal, min-ing and lawn and garden applications, has
launched a new website. The website, www.ausa.com, is designed to be interactive, de-fining different departments with a new con-tact system that the company said assures answers in one business day on average and
“Glocal” — global with a local message. The homepage is divided into main menus, and can display the language of the user by de-tecting it via the user’s browser.
trojan Battery Co., a manufac-turer of deep-cycle batteries, has launched Trojan Tips, its video tutorial series created to provide information on battery topics such as deep-cycle battery technologies,
maintenance practices, charging proce-dures and battery safety. Trojan Tips can be viewed at www.trojanbattery.com. A new Trojan Tips video tutorial will premiere each month throughout the year. The first video reviews the various battery technologies available on the market, and what to con-sider when selecting a battery for a particu-lar application.
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Wabash Classified.indd 1 12/11/12 9:49 AM
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DPIJanFebMarketplace.indd 1 1/11/13 4:31 PM
Adding APU Power
Liebherr LR series crawler cranes use 11 kW APU to reduce main engine idling
Liebherr Nenzing Crane Co. has introduced an auxiliary power unit (APU) for its LR series crawler cranes. The APU is used to power the air conditioning in the cab without using the crane’s main engine.
Liebherr said crawler cranes spend most of their time idling, with the main engine running and the crane not working. To overcome the problem of keeping the main engine idling for the air conditioning system, Liebherr has introduced an 11 kW APU, which needs less fuel than the crane’s 270 or 450 kW main engine.
“Most of my customers tell me that their cranes are typi-cally idle for as much as 75% of the time that the engine is running,” said Scott Moreland, vice president of Liebherr Nenzing Crane. “On that basis, we would easily expect the APU to pay for itself and start rapidly ramping up the sav-ings within 12 to 15 months.”
Liebherr estimated the fuel savings of using the APU versus idling the main engine, could reach 16 L per hour. Conservatively, Liebherr said, a crane runs idle for 50% of
its operating time, the fuel saving could be approximately 16 000 L per year.
The APU is built by Austrian-based Aircontech and is powered by a Hatz 1B40 diesel engine rated 11 kW at 2250 r/min. The APU is integrated into the machinery housing and well secured from the risk of damage.
All B Series engines by Hatz are EPA certified, even for countries without emissions regulations. These engines fea-ture automatic speed and load regulation and are air cooled for an easier integration into existing systems. The engines are also lighter in weight thanks to an alloy cylinder head and alloy die cast cylinder crankcase.
Liebherr’s LR series is comprised of 14 crane models with lift capacities of 104 462 kg at 3.1 m to 3 million kg at 11.9 m. dpi
Diesel Progress international 50 january-february 2013
power generation
For More inForMationwww.liebherr.com
Liebherr is offering an 11 kW Aircontech auxiliary power unit (APU) on its LR series crawler cranes to allow the main engine to be switched off during idling. The APU is pow-ered by an air-cooled 1B40 Hatz diesel engine.
DPI471.indd 1 1/11/13 4:32 PM
CIPTC.indd 1 12/12/12 10:22 AM
Driveline Technology For TracTors
Oerlikon Graziano develops new front steering axle, carbon synchronizer for agricultural applications
By RoBeRta PRandi
Oerlikon Graziano has in-troduced a series of new components for agricultural equipment, led by a new
front steering oscillating axle designed to provide higher vehicle road speeds and increased payload capability. The axle targets larger high horsepower tractors rated up to 336 kW.
The front axle can be combined with a rear steering axle that incorporates a double reduction and spiral bevel gear-ing along with outboard disc brakes and a 100% hydraulic locking differential.
For the market of agricultural ve-hicles, the Italy-based manufacturer further offers a comprehensive range of driveline products, including a rigid mounted rear axle incorporating a pow-er take off (PTO) with hydraulic shift-ing. The PTO is available in two speed ranges — 540 to 1000 r/min and 750 to 1000 r/min. This axle is also equipped with outboard disc brakes and a 100% locking differential.
Within the product range of Oerlikon Graziano, tractor manufacturers can also find the Torque-Hub family of final drive units — indicated for industrial
Shift performance exceeds that of a single cone design, Oerlikon Graziano said, and is comparable to a standard double cone assembly of the same di-mensions, but with a lower cost. Other benefits include reduced demands on the control system, lower weight and quieter operation, the company said.
Oerlikon Graziano has also devel-oped a forward-reverse shift actua-tor for agricultural transmissions that incorporates a carbon-faced syn-chronizer. While carbon synchroniz-ers were originally developed to give high-performance sport cars faster gear times, Oerlikon Graziano said it is finding application for the technol-ogy in off-highway transmissions.
“During shuttling, gearboxes shift quickly between forward and reverse, making control and durability a key chal-lenge for transmission development,” said Andrea Serra, product manager synchro and powershift design at Oer-likon Graziano. “To handle the high rela-tive speeds involved and to remove the engagement problems with some ma-terials we encounter, we worked closely with our customers to develop special
vehicles and off-highway mobile equip-ment too. From the 7000 series of final drive units, through the C014 series and up to the CT45 Compact Track Drive series, this product family is capable of handling a maximum intermittent torque output from 7000 to 45 000 Nm, offering several types of motor mount options.
Oerlikon Graziano has also intro-duced a new synchronizer designed to combine the durability and perfor-mance of the company’s existing long life products with a new internal activa-tion system. “New machines target 20 to 30% better fuel efficiency than their predecessors,” said Andrea Serra, product manager Synchronizers and Powershift Design at Oerlikon Grazia-no. “Our new synchronizer technology offers a step-change improvement in fuel efficiency for the next generation of heavy duty transmissions.”
The new Servo-Synchronizer tech-nology has been designed especially for off-highway transmissions. It in-corporates a self-energizing inter-nal design that increases efficiency especially in applications presenting high drag torques, the company said.
Diesel Progress international 52 january-february 2013
POWERTRAIN Designed for tractors up to 336 kW, the new front steering oscillating axle by Oerlikon Graziano is designed to provide higher travel speeds and increased tractor payloads.
DPI515.indd 1 1/11/13 4:33 PM
materials and a bespoke shift activation technology for an agricultural vehicle. Our carbon synchronizer technology is also being applied to construction equipment for the first time.”
The carbon synchronizer technol-ogy uses a double cone layout with carbon-coated steel rings. The com-pany said the friction and wear char-acteristics of the carbon synchroniz-ers provide higher mechanical and thermal load capability, making gear shifts smoother and vehicles easier to control when shuttling. The technolo-gy also allows transmission designs to become more compact and durable.
Oerlikon Graziano said the dynamic friction characteristics of the carbon synchronizers provide a number of advantages compared to alternative materials. In addition, the cost of car-bon coating is comparable to other surface coatings.
A good application for the carbon synchronizer technology is agricultural tractors, where shuttling is a common operation involving repeated forward and reverse movements. Moving direct-ly from first to reverse creates a hard shift, which places key components as synchronizer and gears under stress.
“Our carbon synchronizers evolved out of our company’s work with su-percar manufacturers,” Serra said. “We are now working with off-high-way customers on projects to pro-duce carbon synchronizers for new applications, to make tractors and
construction equipment easier to op-erate and more durable.”
Oerlikon Graziano has more than a decade of experience in carbon syn-chronizer technology, originally devel-oped for high-performance sport cars. While the automotive sector has re-mained a key market for the company, it has shifted its focus to the off-highway industry. Agricultural equipment ac-counts for more than 70% of Oerlikon Graziano’s carbon synchronizer sales.
From an operational point of view, Oerlikon Graziano recently expanded its Indian plant to better serve its Asian customers. The operation, located in Greater Noida since 1999, is special-ized in the production of gears, shafts, synchronizer assemblies, crown wheel and pinion, axle and transaxle assem-blies. All these components are used not only in agricultural tractors, but also in construction equipment, commercial vehicles, utility vehicles and other off-road applications.
The location now covers an area of 29 821 m2 and features a new grinding shop, a redesigned packing area and a separate warehouse for incoming material. At the same time, the paint shop has been relocated and modern-ized and the heat treatment area has been revamped with a continuous car-burizing furnace. dpi
POWERTRAIN
Diesel Progress international 53
For More inForMationwww.oerlikon.com/graziano
The new carbon-faced synchronizers by Oerlikon Graziano are de-signed for use in agricultural and other off-highway equipment that incorporates shuttling with repeated forward and reverse movements. The coating material has the capability to withstand the stress created by hard shifts.
During the last 12 months, GSGnet.net has hosted:
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DPI515.indd 2 1/11/13 4:34 PM
TAKING THE TOUGH APPROACH
New Tough series engine and gen-set controls from DynaGen designed for longer
service life in severe-duty applications
BY MIKE BREZONICK
Product design has always been a kind of balancing act. Design-ers walk a tightrope between developing sophisticated, fool-
proof (and expensive) designs capable of extended service life versus configu-rations more specifically engineered to meet economic targets while still provid-ing an acceptable level of performance and longevity.
Yet in the case of engine and gener-ator set controls, DynaGen, the Cana-dian-based control system specialist, thought things had gone a little too far in the second direction.
“What we saw in the market over the last several years was a lot of re-ally great work in trying to streamline the cost of engine and generator con-trols,” said Paul Wareham, DynaGen president. “There have been a lot of advancements in terms of produc-ing really efficient electronic designs. There have been efficiencies in manu-facturing, getting quantities up to the levels where you could achieve econ-omies of scale — that’s all been good.
“But we saw some sacrifices being made in terms of the long-term dura-bility and robustness of the products.
tion functions while adding generator-metering functions.
The engine controller offers a range of display parameters, including oil pressure, engine temperature, fuel level, oil level meter, engine speed (rpm, via magnetic pickup or through J1939 data bus) and battery voltage. It also includes a real-time clock display with time and date, J1939 DCT codes with custom text and two customer-defined parameters.
Wareham said the Tough series de-velopment was “really a multifaceted effort” that focused on a number of dif-ferent areas, “which primarily included mechanical, electronics and software.”
“We wanted a trifecta of design that includes software reliability, mechani-cal integrity, and electronic design,” Wareham said. “The mechanical in-tegrity deals with things like vibra-tion and moisture intrusion. On the electronic side, we dealt with issues such as electrical noise and resiliency to voltage spikes and transients that often are the source of mysterious failures. When a control unit suddenly stops working after a period of time in the field, often times it’s chalked up to
Things had swung a little bit too far to-ward being narrowly focused on cost reduction and less so on the durability of the controls.
“Since the industry had designed out a lot of the cost, we thought what re-ally needed some attention was robust-ness, without raising the cost too much.”
The result of that attention is Dyna-Gen’s new Tough series digital engine and generator set controls. Developed over 18 months, the new products have gone into full production at the company’s manufacturing facility in Nova Scotia.
The Tough series engine controls are designed to provide complete control, protection and engine instru-mentation for both mechanically con-trolled diesels and electronic diesel engines from Cummins, John Deere, Volvo, Yanmar and Isuzu, as well as natural gas engines from PSI and others. They target a broad range of engine-powered equipment applica-tions such as pumps, compressors, light towers and generator sets. The Tough series digital gen-set control-ler — available in two models — offers the same engine control and protec-
Diesel Progress international 54 JanUarY-FeBrUarY 2013
CONTROLS
Canadian controls specialist DynaGen has released its Tough series controllers, de-signed to provide control, protection and engine and generator set instrumentation for mechanically and electronically controlled diesel and gaseous fueled engines.
DPI493.indd 1 1/11/13 4:36 PM
bad luck but the underlying reason is often unexpected voltage spikes.
“That really is sort of the three-pronged approach we took — soft-ware, mechanical and electrical — and looked at adding significant improve-ments in all three of those areas. We tested our existing designs to com-monly used standards in the industry to get a baseline and then we focused on not just passing the test but on far exceeding the limits.”
Yet there was also careful consider-ation of cost throughout, Wareham said. “It was designed to fit somewhere from small to midrange end of the range of applications,” he said. “You would even expect to see some versions of the controller that are going on residential standby units as it is not cost prohibitive for high quality residential units.”
Both the engine and generator set controls offer a range of auto-matic shutdowns and warnings along
with sensor trim features, mainte-nance counters, exerciser clocks, a 100-event log and pre-heat and other configurable timers.
Manual and remote start options are available, including momentary start and momentary stop inputs designed for float switch control in pumping ap-plications and multiple stop-start sta-tions, DynaGen said. Passcode pro-tected, the controllers accept common senders including VDO, Datcon and FW Murphy.
The Tough series units can be pro-grammed manually via pushbuttons on the front panel or with DynaGen’s PC configurator software that pro-vides customization of screen mes-sages, sender selections and control settings. The configurator uses a stan-dard USB cable with no special pro-gram are required, DynaGen said.
Both the engine and generator set controls also include DynaGen’s snap-on RelayPak option that is designed to eliminate the need to mount and wire external slave relays for fuel, crank and as many as two other loads. The Relay-Pak is socketed to accept four standard 40A cube relays, the company said.
The Tough series controls are housed within a conformally coated, 10.59 x
16.5 x 3.5 cm automotive-grade plastic enclosure that is gasketed to provide protection against water and contami-nation ingress. Operating temperature range of the controller is -40° to 70°C, with display screen viewing. DynaGen said the Tough series units meet or ex-ceed SAE J1455 standards for shock and vibration.
Along with the engineered-in ro-bustness and durability, DynaGen made a point to make sure that the Tough series controllers also looked the part. “Once we figured out how to make it tough, we wanted to make sure that there were visible signs of that,” Wareham said. “We wanted peo-ple to be able to see, when they look at it and touch it and interact with it, that it feels very solid and robust.
“The interesting thing about a gen-set controller is that very often, it becomes the ‘face’ of the machine. The machine itself can have some great character-istics and features, but what the owner sees and interacts with more is the con-troller. So it’s imperative that the control-ler is representative of the high quality of the machine that it’s on and we think a rugged looking physical design plays a key role in that.
“We wanted the packagers and their customers to see that this looks and feels like something that belongs in a rough environment. We didn’t want it to feel like a toy — it’s something that is really solid and has a commanding presence. We also focused on appear-ance so we could give our customers a more differentiated look, by bringing their machines a little more upscale and reinforce the notion that their product is in the category of a tough machine.”
As proof of the company’s confi-dence in the robustness of the design, Wareham pointed to the five-year standard warranty. “That is certainly at the very top end of anything that’s of-fered in the market.” dpi
CONTROLS
Diesel Progress international 55 JanUarY-FeBrUarY 2013
For More inForMationdynagen.ca
The new Tough series controllers from Dy-naGen include the company’s snap-on Re-layPak option that is designed to eliminate the need to mount and wire external slave relays for fuel, crank and as many as two other loads.
DPI493.indd 2 1/11/13 4:44 PM
Mahindra & Mahindra Ltd. (M&M) and Navistar International Corp. have announced that Mahindra in-tends to purchase Navistar Group’s stake in Mahindra Navistar Automo-tives Ltd. (MNAL) and Mahindra Navi-star Engines Pvt. Ltd. (MNEPL). Fol-lowing the purchase, both MNAL and MNEPL would become wholly owned subsidiaries of Mahindra.
The terms of the proposed transac-tion call for Mahindra to pay approxi-mately US$33 million for Navistar Group’s stake in both ventures. The agreement allows Navistar to con-tinue sourcing components from India while Mahindra would continue to pro-vide engineering services to Navistar. Navistar group would continue to sup-port M&M through a license agree-ment and extend necessary support to MNAL and MNEPL for the purpos-es of business continuity.
The sale, which is subject to the conclusion of definitive agreements, requires regulatory approval in In-dia and is expected to be completed in early 2013. Mahindra would then take complete ownership of opera-tions and continue to sell MNEPL and MNAL products.
AGCO has begun production of ag-ricultural equipment at its joint venture facility in Africa. The first Massey Fer-guson tractors are being produced in Constantine, Algeria, at Algerian Trac-tors Co., a joint venture between AGCO and L’Entreprise Publique Economique de Production de Tracteurs Agricoles and L’Entreprise Publique Economique de Commercialisation de Matériels
Agricoles. AGCO owns 49% of the op-eration. The tractors being built at Con-stantine are destined for sale into the domestic Algerian market.
Deutz AG said it has sold its pipe manufacturing operation at the Cologne-Deutz site in Germany to T.ERRE Deutschland GmbH, ef-fective April 1, 2013. The purchase price was not disclosed. Deutz and T.ERRE have signed a long-term sup-ply agreement for pipes and conduits. T.ERRE will manufacture pipes at the Cologne-Deutz site until the end of 2014 and at the same time will set up a new production facility with growth prospects in the immediate vicinity.
Hyundai Heavy Industries (HHI) announced that it would start machin-ery manufacturing in Brazil in March 2013. A new plant is under construc-tion in Itatiaia, in Rio de Janeiro State.
The investment will be US$180 million and the plant is part of the year-old BMC-Hyundai joint venture with Brasil Máquinas de Construção (BMC). The plant will primarily sup-ply excavators, wheel loaders and forklifts. Initial production is targeted at approximately 2400 machines and roughly 80% of the production will be sold in the domestic market.
ZF has received an order to deliver its six-speed EcoLife automatic trans-mission, front and rear axle systems, and steering technology, for 2043 new city buses for various Turkish transport authorities in the cities of Istanbul, Ankara, Izmir, Gaziantep, Konya, and Erzurum. The six-speed EcoLife automatic transmission is
used in new solo or articulated bus-es made by Karsan, Mercedes-Benz Türk, Temsa, and Solaris.
Mercedes-Benz do Brasil will pro-vide 2600 model OF 1519 R chassis for the Brazilian Ministry of Educa-tion. The chassis will be assembled as school buses together with the Brazilian body builder Caio within the framework of the national fund for training development.
Metso and ZAO Russian Copper Co. (RMK) have signed a contract to supply crushing, screening and grinding equip-ment — as well as on-site services for six years — to the first plant of the new Tominsky GOK copper concentrator in the Chelyabinskya region in southwest-ern Russia. The complete value of the order is approximately €150 million. Metso will supply a primary gyratory crusher, three cone crushers, one semi-autogenous grinding mill, three screens and three ball mills.
Volvo Construction Equipment (Volvo CE) announced it is extending its business relationship with attach-ment supplier Steelwrist AB. Along with its factory-fitted Tiltrotators that allows buckets or other attachments to be tilted and rotated simultaneous-ly, Steelwrist will now supply excava-tor quick couplers to Volvo CE.
The first Grove rough-terrain cranes assembled in Manitowoc’s newest fac-tory in Passo Fundo, Brazil, have been delivered to the first two customers: Servi-Sá Auto Crane Rental & Services, and Machinery and Engineering Lauer. The companies both received Grove RT765E-2 rough-terrain cranes. dpi
Mahindra & Mahindra Buys Out Navistar JVs … AGCO Begins African Production … Deutz Sells Pipe Operation … Hyundai Heavy Begins Production in Brazil … Turkish Order For ZF …
internationalbusinessreport
Diesel Progress international 56 January-february 2013
DPI519.indd 1 1/11/13 4:39 PM
Are you ready
Facts?
DEUTZ AG · Ottostr. 1 · 51149 Cologne · Germany · Phone +49 (0) 221 822-0 · Telefax +49 (0) 221 822-3525 · www.deutz.com · E-Mail: [email protected]
visit us at hall A4stand 321/416
Deutz_facts.indd 1 1/2/13 11:46 AM
This is only one reason for installing ZF driveline technology in your construction machines. Increased productivity, reduced tire wear and easier operation are further benefits leading to reduced operating costs. You can depend on ZF, the leader in driveline technology, for optimum solutions in all types of applications.
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