Diesel Progress January February 2013

GLOBAL PRODUCTS TECHNOLOGY INDUSTRY NEWS
January-February 2013
DIESEL PROGRESS
INTERNATI ONAL
Technology
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Doosans New Small Diesels Weichai Finalizes Linde Acquisition Hyundai SeasAll Show Distribution at:
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Worldview
Next Up: Africa?
By Ian Cameron, Ashbourne, England The bauma China construction equipment 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 forward 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 stunning opportunities for change and development 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, Ghanas economy should be solid in the medium term while Kenya is growing, thanks in part to its strong agricultural and fishing sectors, although its construction industry was beset by high borrowing costs. Thus it is unlikely Africa as a collective whole will see across-the-board economic growth, but singular countries could develop, eventually raising the fortunes of the entire continent. Other reports paint conflicting pictures of the potential for many countries, with literacy remaining a critical issue, although all agree infrastructure investment in roads, rails and ports is essential. If Africa does copy Asia in a transition combining economic prosperity with equality, we could have another economic miracle. dpi
A Market Greater Than Numbers

By Mike Brezonick, Waukesha, Wisconsin, U.S.A. Over the last few months, its 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 weve 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 number of exhibitors (1837), most exhibit space (300 000 m3) and the highest 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 history, taking up one entire hall. Anybody who thought Cats 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 countrys 12th Five Year Plan calls for continued infrastructure development. Much will be constructed with domestic machines, but there will be plenty left over for the imports, particularly since there is a growing emphasis on fuel economy and emissions reduction, technologies that play to the strengths of the international suppliers. Looking just at only the numbers, Chinas 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
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DIESEL PROGRESS
INTERNATI ONAL
38 52
Driveline Technology For Tractors
10
Meeting Bigger Emissions Challenges
New Single-Cylinder Kohler Diesel
Whats Inside
Technology
4 Thermal Management For Euro 6 20 Tackling The Threat Of Water 40 MAN Adds To Gas Engine Range 52 Driveline Technology For Tractors 54 Taking The Tough Approach
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 H Heavy Begins Production in Brazil Turkish Order For ZF
Technology Of Clean Air

10 Meeting Bigger Emissions Challenges 12 Keeping The Heat On
Official Publication Of
EUROMOT
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
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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: sbollwahn@dieselpub.com. 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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Technology
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.
New smart coolant pumps, EGR valves and coolers can help deal with increased heat loads in advanced commercial diesels
By Roberta Prandi
ete Kohler, president BorgWarner Global Commercial Market Development, knows what is ahead. With upcoming emissions standards, increasing engine 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 diligently on developing smarter thermal management systems. A good example of that development effort is BorgWarners new Heavy-Duty Controlled Coolant Pump (HDCCP) for heavy-duty engines. The new pump system integrates a conventional coolant pump with an electronic viscous drive and features high modulation capabilities including operation independent of engine speed. It is designed to provide full engagement in less than three seconds, with an equally fast disengagement, taking about three seconds at peak power, the company said.
Diesel Progress International
Management For Euro 6
Thermal
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 multiplecore EGR coolers with specially designed hybrid tubes to provide superior heat rejection with less soot and hydrocarbon build-up. BorgWarner has supplied similar multiple-core EGR coolers to Tognum for its MTU off-highway diesel engines. BorgWarner explained that the floating core and optimized coolant flow of these EGR coolers increase the durability even with extreme thermal loads which are typical for some of the applications for these engines, such as mining vehicles, 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, Germany. 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 expected 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 control of the impeller speed produces the desired coolant flow rate with average lower pump speed. BorgWarner Thermal Systems said it is also developing a Dual Mode Coolant Pump featuring electric and mechanical mode to exactly control the coolant flow. The electric mode provides the required flow rate even when the engine is off, while the mechanical
4
For More information

www.borgwarner.com
Industry News
With changes in off-highway driveline technologies beginning to come into the market, Weichai, and by extension its Shandong construction equipment manufacturing parent, now add systems from Linde designed to reduce CO2 and increase the efficiency of the drive system. This concept, first shown at Agritechnica for electronic overall vehicle management, uses Lindes LINC 2 ECU with the MPR 50 electronically controlled, mediumpressure hydraulic pump and flowoptimized valve blocks.
Acquisition Of Linde Hydraulics

By Mike Osenga
Weichai Finalizes
Deal adds hydraulics to Weichais engine-powertrain portfolio, along with stake in global lift trucks business
Linde Hydraulics, as well as a share of Lindes lift trucks business. KION is involved in forklifts, warehouse equipment, industrial trucks, hydraulic pumps and motors and tractors for construction, agricultural, commercial and manufacturing sectors. It markets its products under Linde, Still, Fenwick, OM, Baoli, and Voltas brands. KION also provides services, such as fleet management, logistics, financial, warehouse equipment systems, consultancy and IT solutions for truck and material flow management. To this point Weichai has been primarily a diesel engine and powertrain manufacturer with engines used in buses, construction equipment, marine and power generation applications. Its powertrain components in6
eichai Power Co., Ltd., KION Holding 1 GmbH, along with various subsidiaries of the two companies, have announced the successful completion of their previously announced 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 manufacturers, such as Sanys acquisition of Putzmeister and Weichais own acquisition of the French engine manufacturer Moteurs Baudouin S.A. in 2009. Weichai Power is part of Chinas Shandong Heavy Industry Group, and Germanys KION Group is a manufacturer of industrial trucks and hydraulics. 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 announced in late August of 2012, is for Weichai Power and KION to strengthen their industrial base in the European markets, create additional opportunities for expansion for their Asia-Pacific businesses and build a platform for future joint growth, according to the announcement of the agreement. The hydraulics business will now be operated and managed as an independent company called Linde Hydraulics. Lindes fluid power products will continue to be branded under the Linde Hydraulics trademark. The business plan for Linde Hydraulics includes relocating the existing hydraulics activities in Nilkheim, continued on page 8
january-february 2013
Industry News
Gordon Riske (left), CEO of the KION Group and Jiang Kui, general manager of the Shangdong Heavy Industry Group, and board member of Weichai Power Co. Ltd. at the signing of their strategic partnership.
Aschaffenburg, to a new hydraulics plant nearby and increasing capacity at other hydraulics production sites. Further, the existing strategic sales agreement between Linde Hydraulics 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 products including hydraulic pumps, motors and valves, as well as swing drives and compact drive units. On the electrical side the portfolio includes electric motors, power modules and integrated subsystems, electronic control units, sensors and machine interfaces. The financials of the deal has Weichai 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 business 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 inDiesel Progress International
crease its share in KION to 30% on a fully diluted basis, upon the completion of a potential future IPO. Further, Weichai 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 chairman of the supervisory board of KION. Weichai Power has invested a total of 738 million, including 467 million 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 hydraulics, said Tan Xuguang, chairman and CEO of Weichai Power. The new Aschaffenburg-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 applications for Linde Hydraulics technologies 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 growing Asian and Chinese markets. Moreover, the additional enhancement of our capital structure provides exciting opportunities with which we can build on our growth strategy. The long-term strategic partnership 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 Industry Group and director of Weichai 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 consist 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 nominated by Linde Material Handling. The respective employee representatives have yet to be nominated. Jorg Ulrich, speaker of the management 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
Among the product lines coming to Weichai in its acquisition of the Linde Hydraulics group are electronic control units, such as the LINC 2 line, designed to control a mobile hydraulic system.
8 january-february 2013
dateline
*Sept 24-March 22 Diesel Progress Online Show XI At www.dieselprogress.com and Diesel Progress Magazine Diesel Progress 20855 Watertown Road, Suite 220 Waukesha, Wisconsin 53186 U.S.A. Tel: +1 (262) 754-4100 Fax: +1 (262) 754-4175 E-mail: info@dieselpub.com *Feb 5-8
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Need more information on industry shows? Turn to www.dieselprogress.com
Fax: +49 89 949-11349 E-mail: info@bauma.de Web: www.bauma.de April 25-26 34th International Vienna Motor Symposium Congress Center Hofburg Vienna, Austria
VK Austrian Society of Automotive Engineers Elisabethstrasse 26/24 A - 1010 Vienna, Austria Tel: +43 1585 27 41-0 Fax: +43 1585 27 41-99 E-mail: info@oevk.at Web: www.oevk.at
*Indicates shows in which Diesel Progress International Edition will participate.
bC India
Bandra Kurla Complex Mumbai, India The Association of Equipment Manufacturers 6737 West Washington Street Suite 2400, Milwaukee Wisconsin 53214, U.S.A. Tel: +1 (414) 298-4176 Fax: +1 (414) 272-2672 E-mail: bcindia@aem.org Web: www.bcindia.com *Feb 17-19
M.E.E. Middle East Electricity 2013

Dubai International Convention & Exhibition Centre Dubai, United Arab Emirates IIR Middle East Office 301, Sultan Business Centre P.O. Box 28493 Dubai, U.A.E. Tel: +971 4 3365161 Fax: +971 4 3353526 E-mail: meelectricity@iirme.com Web: www.middleeastelectricity.com April 8-12 Hannover Messe Exhibition Grounds Hannover, Germany Deutsche Messe Messegelnde, 30521 Hannover Germany Tel: +49 511 89-0 Fax: +49 511 89-32626 E-mail: info@messe.de Web: www.hannovermesse.de *April 15-21
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bauma 2013
New Munich Trade Fair Centre Munich, Germany Messe Mnchen GmbH Messegelnde, 81823 Mnchen Germany Tel: +49 89 949-11348
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BondioliPavesi.indd 1
2/6/12 10:08 AM
TECHNOLOGY
of clean
Emissions Challenges
Meeting Bigger
One size definitely doesnt fit all when it comes to SCR system technology on larger engines
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.
By Raimund Mller
hen it comes to emissions control, much of the focus for diesel and gaseous-fuel engine 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, regulations 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 stationary generator set engines.
Dr.-Ing. Raimund Mller is general manager, Technical Sales of the heavy-duty truck and nonroad business at Emitec GmbH, Lohmar, Germany. Diesel Progress International
As in the case of smaller engines, selective catalytic reduction (SCR) is expected to be the prime technology used to help larger engines meet Tier 4 final emissions regulations. SCR has shown that emissions of nitrous oxides (NOx) can be very efficiently reduced in the presence 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 exhaust fluid) is injected in small, precise quantities calculated according to the momentary NOx mass flow of the engine and the required NOx reduction rate. The quantity of urea solution is typically done by a metering pump or metering valve. Urea dosing pumps and injectors are used when com10
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) injection valve mounted in the exhaust stream upstream of the SCR catalyst. Airless/liquid-only systems are preferred in applications where compressed air is not available on the vehicle, 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
TECHNOLOGYof clean
Urea demand for large diesel engines with SCR can exceed the capacity of pumps and injectors developed for smaller engine applications. One solution is to combine two or more pumps, such as Emitecs UDA2 urea pump, with specific control software.
installed hydrolysis catalyst (with the special Emitec MXstructure), 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, Emitecs solution is to combine two or more pumps with specific control software. For larger engines requiring multiple injectors, a highcapacity industrial pump has been modified to meet the requirements of large stationary and mobile engine applications. Combined with a special manifold, the reducing agent is distributed to the multiple individual injectors, providing a homogeneous 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 diameters 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 allocaDiesel Progress International
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 turbulenceinducing structures, such as Emitecs LS-structure. Several proven catalyst coating material variants are available on metal substrates. Most commonly used is the TiO2-Vtechnology 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

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7/2/12 4:08 PM
TECHNOLOGY
of clean
The Heat On
By Roberta Prandi
JS, the Menden, Germany-based specialist in exhaust gas aftertreatment technology, has developed a new system designed to assure that exhaust gas temperatures required to make aftertreatment systems work properly can be effectively reached and maintained. The company said its new Catalytic Bypass Burner (CB2) is especially useful in urban vehicles such as city buses, where cold ambient operating temperatures and stop-start duty cycles can prevent 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 bypass flow pipe by means of an exhaust flap. The exhaust
Keeping
New CB2 thermal system from HJS designed to keep aftertreatment at proper temperatures
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 oxidation catalyst (DOC) where part of the injected HC is already converted, bringing the bypass gas flow to a temperature greater than 600C. 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 turbocharger 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 engine 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 700C. The system also has a beneficial effect on eventual downstream SCR for which it also assures the necessary exhaust temperatures. As a complement to its exhaust gas aftertreatment systems, HJS also offers an Aftertreatment Control Unit (ACU) that acts as the brain for the complete system. The company said the ACU measures temperature, pressure and gas concentrations and uses the information to automatically 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 twostage thermal management system engineered to assist aftertreatment components to maintain proper operating temperatures.

www.hjs.com
12
INDUSTRY NEWS
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.
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
oosan 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 compact and midsized equipment such as loaders, tractors, portable power units, excavators and forklifts.
Mark Big Move For Doosan

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 Industrial 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 delivers a top rating of 55 kW at 2600 rpm, while the top of the line D34 is a 3.4
14
Small Engines
L diesel rated up to 74 kW at 2400 rpm. Both the D24 and D34 are inline, 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 lowend torque ratings are 113 154 Nm for the D18, 235 Nm for the D24 and 410 Nm for the D34, all at 1000 rpm.
marine propulsion marine propulsion
power generation power generation
automotive automotive
commercial vehicles commercial vehicles
INDUSTRY NEWS
from Prototype from stagePrototype through stage through to large-scale to large-scale Production Production
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 president Doosan Infracore Engine Business Group
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While all of the new engines incorporate diesel oxidation catalysts (DOCs), none requires the use of diesel particulate 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 eliminated 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 engines the 5.9 L DL06 and the 7.6 L DL08 invested heavily in its new compact engine facility alongside its existing plant in Incheon. The first engines rolled off the production line in early October 2012. This year, the company will also start building the D18 and D34, with the company estimating 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 developed 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
Diesel Progress International 15
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INDUSTRY NEWS
Doosans 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.
rail technology with injection pressures of 1800 bar and a compression ratio of 17:1. The wastegate turbocharger and external cooled exhaust gas recirculation (EGR) systems help to ensure best performance, even in the most challenging conditions in any application, the company said. All of the new models 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 standards, 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 lower 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 cylinder head cover module means that no external oil separator is needed. The wastegate turbocharger gives us a better fuel efficiency and performance and we can also achieve excellent low end torque which is a big requirement from the customer. We also introduced a reliable EGR system which has reduced NOx emissions and the EGR system is electronically 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 piston 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 emissions reduction is Doosans Ultra Low Particulate Matter Combustion (ULPC) technology. Simply, it is the optimized combination of the combustion bowl shape, the injector nozzle, cylinder head swirl and EGR mixing to minimize raw exhaust emissions, Lim said. The ULPC system is very clean
16
with no soot visible. In this ULPC system the low particulate matter emissions 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 emission regulations. This simple and easy aftertreatment system removes concerns about installation, maintenance and quality issues that might have arisen in a more complicated system. The compact sized, flexible aftertreatment system can also be either engine or chassis-mounted. Dry engine weight for the D18, D24 and D34 is 163, 204 and 265 kg, respectively. Regarding maintenance, recommended oil/filter change, fuel filter change and valve adjustment intervals are all 500 hours, the company said. Along with the new engines, Doosan 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
INDUSTRY NEWS
We participate in the global market growth by transforming our products and our organization We contribute to building a better world through our commitment to sustainable development while protecting en the environment
Doosan has invested significantly in its engine manufacturing plant at Incheon, South Korea, as part of the new compact engine development.
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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. Comer.indd 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 process. There is also a Vision Check system enabling robots to check the final assembly, which enhances product quality, he added. Overall at its two engine factories at Incheon, Doosan plans to have a capacity to produce 172 000 engines a year by 2015, including its existing range of larger compact engines and medium and large engines. The companys other engine building interests include a 5050 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 annually; and its Doosan Infracore America (DIA) Engine Division 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 Infracore 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 become one of the worlds top three machinery companies and a global top tier engine maker by 2020. continued on page 18
Diesel Progress International 17
12/20/12 10:18 AM
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INDUSTRY NEWS
Doosans 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, testing section and two paint areas for washing and final coating.
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 Chinas Xugong construction machinery group, provides 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 Doosans Construction Equipment Business Group and improving the medium sized engine for Tier 3 for the Chinese market. Lee said Doosans engine business has achieved sustained global sales growth of 7.8% between 2007 and 2011, but added that with some markets 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 portfolio and by developing new products, Lee said. Sales of engines for generator sets account for the biggest sales volume in our overall Engine Business Group. China is one of our biggest markets and with the downturn there, total sales have been sluggish even though other markets have been steadily growing in 2012. A modest economic recovery is forecast in 2013 but it still remains unclear how much it will be. The Korean economy has remained flat in 2012 but Korean domestic product market share is expected 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 demand 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 increased sales of natural gas engines.
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Due to the efforts of the U.S. government to boost recovery following 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 engine, Lee said our main targets are agricultural machinery and small construction 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 favorable position in this market, Lee said. We aim to gradually broaden markets starting with our domestic market and then proceeding to markets around the world. We are also targeting forklift truck manufacturers who do not produce their own engines. dpi

www.doosaninfracore.com/engines
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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.
Conductivity-based sensor from Gems Sensors designed to detect moisture in engine fuel and lube oil systems
The Threat Of Water
Tackling
compressor crankcases to determine if water is present in the lubricating oil, the company said. Founded in 1955, Gems manufactures liquid level, flow and pressure sensors, solid-state relays and barriers, liquid and pneumatic miniature solenoid valves and pre-assembled fluidic systems. With its headquarters 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 leading to engine failure have become increasingly common. However, there is a particular urgency to protect high20
By Ian Cameron
uel is subject to the relentless and unceasing hazard of contamination, and moisture is one of the most common dangers. Water in fuel that reaches the fuel system can affect the operational performance and life of engine components. Worse, it can lead to early and sometimes catastrophic failures. Controlling the ingress of moisture in fuel systems is therefore of vital importance. Gems Sensors and Controls has developed a conductivity-based sensor designed to detect the level of water in fuel and lubricating oil and prevent mechanical damage as a result 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 problematic in diesel engines than in petrol engines because the subsequent corrosion can cause serious damage to the injection pump and injectors. Diesel 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 engine 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 lowvoltage source, Dockendorff said. In a tank of liquid, simple conductive sensors can be positioned at high and low points in the tank to detect maximum 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, conductivity sensors such as those produced by Gems Sensors and Controls can be mounted in any position and withstand extreme temperatures. Their output can be used to actuate reJanuary-February 2013
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-temperature-rated electronics that generate an alternating voltage to a probe tip. The probe tip is electrically isolated from the housing via a fused glass seal, providing a hermetic, 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 offhighway vehicles, locomotive and generator sets, Dockendorff 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 presence of water in fuel, but customer feedback tells us that this is proving to be an ideal solution for fuel filters, compressor crank cases, lubricating oil tanks and diesel fuel storage tanks as it has high reliability and long term stability in oil. dpi
diesel hr
Chueire New President Volvo CE Latin America President
Afrnio Chueire has been named president of Volvo Construction Equipment Latin America. He succeeds Yoshio Kawakami, who held the position 12 years and is leaving the company to pursue other professional opportunities. Chueire, 53, has worked for Volvo CE since 2000, when he was named chief financial officer. Volvo CE Latin Americas headquarters is in Curitiba, Paran State, with a factory in Pederneiras, So Paulo State.
A. Chueire
New COO For JCB
JCB has announced that Arjun Mirdha has been appointed chief operating officer of JCB, Inc. overseeing Sales, Commercial Operations, Parts and Service, Manufacturing, 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 A. Mirdha 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 Europe

www.gemssensors.com
Peter Aarsen has been appointed vice president of Yanmar Europe 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 Marine International. continued on page 31
Technology to Meet Present and Future Emissions Limits
EXHAUST-GAS AFTERTREATMENT
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.
For 30 years, HJS has specialised in technical solutions for the reduction of pollution caused by diesel engines, and offers system-specific exhaust-gas aftertreatment technologies, which can be fitted as standard or retrofitted in passenger cars, commercial vehicles, busses and a wide range of non-road applications.
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INDUSTRY NEWS
A new LWA acoustic generator set powered by a Lister Petter Alpha diesel engine is one of several new or updated products Lister Petter is launching into the market this year as it aims to grow its business worldwide.
Sweeping Changes
For Lister Petter
Traditionally we have run Lister Petter as one business, said Bryan Draper, Lister Petters 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 companys Alpha engine has provided 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 business, 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 wont 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 applica22
New products, global expansions and investments in machining and distribution target continued growth
tions. We expect to relaunch the gas version of the Alpha this year and certainly will have EPA compliance by the start of 2013. Part of the engines 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 enable us to put more power into the engine at the fixed speed nodes, Draper said. The net result has been to take the direct injection Alpha up one power 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 watercooled and the air-cooled engines are
BY IAN CAMERON
ngine, generator set and pump manufacturer Lister Petter has unveiled sweeping changes across its business worldwide, which include new products, a significant expansion in North America and heavy investments in both its distribution network and machining capabilities. Since its acquisition by private investors eight years ago, the company based in Dursley, Gloucestershire, England, has embarked on a swift program of acquisitions, closures, disposals and expansions all amid tempestuous economic circumstances. Lister Petter said its order intake last year rose to approximately 59 million worldwide. Orders climbed another 6% during the first half of this year, the company said. While that level is below the companys ambitious 20% growth projections, it represents a healthy return when considering the volatility of the markets.
INDUSTRY NEWS
now capable of 2000 hours service intervals, which is a market differentiator. 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 ratings for 60 Hz. Coupled to these will be the Lister Petter Energy Centre, a stand-alone hybrid unit designed to offer 30 combinations 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 Petter 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 increase from 32 to 112 kW, noncompliant by 2016 and a common rail, EPAcompliant 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 Midlands 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 major investment in CNC equipment at its machining plant in Sheerness, Kent. It is in the United States where some of the most interesting developments have taken place. Lister Petter said it has upgraded its factory in Olathe, Kan., to not only remanufacture 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 inDiesel Progress International
The other thing we have done quietly 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
stalled capacity from a single shift of 10,000 a year. There are currently 40 people employed 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 havent aggressively attacked 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, especially when we put the gas product back into the market there. Looking at the broad scope of its business throughout the global market, Draper said the territories that were hit the hardest during the last recession are proving to be more resilient in this one. We are doing well in Latin America the Mercosur countries of Argentina, Brazil, Paraguay and Uruguay, Draper said. North America is steady
23
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 business 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 Africa. We have been more aggressive in some parts and increased our business there. On the back of Africa we are going to attack pirating in South America. The other thing we have done quietly 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. 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 service the local markets and provide both commercial and technical support to master distributors in neighboring territories, significantly reducing 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 engines. A Lister Petter engine landed in China is still a considerably better economic proposition than some Chinese engines produced by other Western manufacturers. dpi

www.listerpettergroup.com
brazilnotebook
A report from the Brazilian association Anfavea puts the countrys 2012 sales of farm equipment at 69 374 units, an increase over 2011.
Brazil Ag Machine Sales Up 6.2%

By Mauro Belo Schneider
ales of agricultural machinery rose 6.2% in 2012 over the previous year, according to information from Brazils National Association of Motor Vehicle Manufacturers (Anfavea). Anfavea said domestic sales of equipment both locally manufactured and imported 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 represents a decrease of 10.6% compared to 2011. In December, exports reached R$400 million (US$198 million). The number of farm machines exported in 2012 from Brazil reached 16 896 units, a drop of 7.8% compared to 2011.
Soprano Hidrulica Expands Factory

Marking its 35th anniversary, Soprano Hidrulica, 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 continued on page 26
Mauro Belo Schneider is a Diesel Progress correspondent based in Porto Alegre, Brazil. His e-mail is belomauro@gmail.com. Diesel Progress International
An investment by Soprano Hidrulica in its hydraulic component factory is expected to double the companys cylinder output.
24 JANUARY-FEBRUARY 2013
Plug in and relax. Its the all-new Scania Gensets.

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Middle East Electricity 1719 February 2013, Dubai International Convention & Exhibition Centre. Stand: S3B40
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brazilnotebook
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 capability, improve production flow and achieve a level of excellence in product quality and processes. DH 2013 places Soprano Hidrulica 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 m, expanding its factory complex to 12 000 m. 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. Soprano 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 countrys agricultural industry. Data supplied by the Organization for Economic Cooperation and Development (OECD) shows Brazil is expected to be the biggest exporter of chicken, pig and cattle products, as well as of orange juice, soy, coffee, corn, banana, cocoa and sugar, through 2020. Our agriculture industry has been growing since 1995 at an average index of 10.5% a year, Miotti said. We are feeding the world and will be more and more. India and Chinas emergence will keep boosting our agriculture. It means more combines, tractors, sprayers and as a consequence, hydraulic cylinders. The company said it expects its 2012 fiscal year sales to be approximately R$33 million (US$16.5 million), down 15% to 20% compared to 2011. Sopranos main export markets are ArDiesel Progress International
gentina, Uruguay, Chile and Peru. The company also has a plant in Mexico.
Agrale, Marcopolo Invest In Argentina

Agrale S/A, the Brazilian manufacturer of trucks, bus chassis, military vehicles, tractors and diesel engines, announced an investment of R$25 million (US$12.5 million) at its Argentinean plant in the city of Mercedes. The company said it plans to manufacture tractors there.
already reached 3300 units, in addition 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, Metalpar Argentina, Marcopolo acquired 51% of the shares of Metalsur Carrocerias. Carlos Zignani, investor relations director, said that the purchase is intended to enhance Marcopolos presence in Argentina and enlarge its range of models.
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 manufacturer of long-distance buses in Rosario, for R$18 million (US$9 million). Agrale said it aims to start production 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 secondstage goal of 70% local content. The manufacture of bus chassis in Argentina will be increased in 2013 with the production of chassis for articulated 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. Agrales plant in Argentina began operations in 2008 with the production of bus and light truck chassis. It has
26
Agrale S/A has announced an investment of US$12.5 million at its Argentinean plant, where it plans to manufacture tractors.
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 annual 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, So Paulo State.
JANUARY-FEBRUARY 2013
brazilnotebook
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.
Toyota plans to put its first lift truck factory in Brazil in the city of Artur Nogueira.
Hyundai To Start Production in Brazil

Hyundai Heavy Industries (HHI) announced it would start manufacturing 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 partnership with Brasil Mquinas de Construo (BMC). The joint venture BMCHyundai 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 domestic market, said the company. This will be the second HHI plant outside of Korea, with the other facility in China.
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 mother-factory aims to give agility in the process of manufacturings implementation without the need of great profile changes, specification and quality in our flagship, which has wonderful reputation in the Brazilian market, said Hiroyuki Ogata, president, Toyota Material Handling Mercosur. We are trying to gather the best characteristics of the Takahama, in Japan, and the Columbus plants. The Brazilian factory will occupy a site of 93 000 m, with 31 000 m under roof. The investment was of R$101 million (US$50 million). Production is expected to start in October 2013 in the plant the company said would have 120 employees. Production of 5000 units is expected 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 Brazilian market, Ogata said. The machines expected to be manufactured in Brazil are the Toyota 8 series internal combustion lift trucks, powered by Toyota 4Y-ECS fourDiesel Progress International
cylinder, OHV gasoline engines, with lift capacities from 1.63 to 2.72 tonnes. These models are of greatest demand in the market nowadays, Ogata said. In a first step, we wont manufacture electric machines in Brazil, although the markets demand will be monitored and we will study the availability of producing them locally. Other models sold in the country 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 capacities higher than 3.18 tonnes as well as electric lift trucks. With the construction of its first Brazilian plant, Toyota will have 11 lift truck manufacturing plants worldwide. The
Scania Launches Car Hauler In Brazil

Scania has introduced the first 6x2/4 truck in Brazil, targeting the continued on page 28
Scanias P 360 6x2/4 truck is targeted toward the car hauler market.
27 JANUARY-FEBRUARY 2013
brazilnotebook
vehicle transportation market with the model P 360. Scania has the philosophy of constant production evolution, services and technologies, said Victor Carvalho, Scanias sales manager in Brazil. We are launching a range of trucks that elevates the profitability of the operation. We follow our tradition of listening to the market requirements and with this unique configuration, 6x2/4, Scania offers a new efficiency baseline to customers in road transport. The company said the 6x2/4 enhances the load capacity and manages longer trailers, besides moving in a smaller turning radius and with fewer wheels on the ground (two fewer compared to the traditional 6x2), avoiding unnecessary wear and tear. The turning radius makes handling easier with deliveries in big cities, it said. In many services, the traction of the 4x2 doesnt satisfy the customers demands and the 6x2 is more than whats needed, said Celso Mendona, 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 as a leader in the segment of road construction equipment in Latin America. Initially, the plant will create 40 jobs, said the company.
Ammann Announces New Factory

Rio Grande do Sul States government 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 Gravata city, Brazil. The factory is to be located on a 5000 m 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 Development and Investment Promotion Secretary Mauro Knijnik. The company was founded in 1869 and is a leading supplier of construction machines with expertise 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 established in Brazil since 2010, with a subsidiary in Gravata and dealers in Porto Alegre, Belo Horizonte, Recife and Sorocaba. Gilvan Medeiros Pereira, who was chosen to be CEO for Ammann Latin America, said starting from our Brazilian unit, the goal is to position
Deere Launches Sugarcane Simulator

John Deere has launched a simulator for training operators in Brazil on the companys 3520 sugarcane harvester. The simulator, which replicates the machines 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 Carlos Newton Graminha, Deeres account manager. The equipment was developed in partnership with a leading company in simulator technology. The demand for such training is growing in the South American market, especially since after 2014 the burning of sugarcane for the harvest will not be allowed. It is said that mechanization minimizes the environmental impacts. Being portable, the simulator can train several groups, even during the sugarcane off-season, said Cristiano Trevizam, from Deeres sugarcane marketing department. A new harvester involves at least four employees. dpi
John Deere has introduced a simulator to train operators of its new sugarcane harvester.
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global trends
Mobile Cranes In India See Ups And Downs

By David Phillips
ast year, mobile cranes were among the leading products in terms of volume in the construction equipment market in India. In the first half of 2012, backhoe loaders, crawler excavators and mobile cranes accounted for approximately 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 weathers 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 nearly 17% in 2009. However, demand recovered 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 dominated by the locally manufactured pickand-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
David Phillips is managing director of OffHighway Research, a London-based management consultancy that specializes in the research and analysis of international construction equipment markets. Phone: (44) 020 7404 1128; E-mail: mail@offhighway.co.uk Diesel Progress International
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 major sectors of the economy. Sales declined by 20% during the first half of 2012 and trends indicated a 16% decline for mobile cranes to 9500 units in 2012. However, the outlook for these machines remains optimistic in view of ongoing industrial and infrastructure development, and the high level of construction activity future projects are likely to generate. Current trends indicate a steady growth in demand, with sales likely to touch 13 000 units by 2016. While local manufacturers are significant players in many of the crane segments, some familiar global equip-
The Mobile Crane Market In India By Type, 2007-2011 Units

Crane Type Truck-Mounted All Terrain Rough Terrain Crawler Industrial Total Pick-And-Carry Segment Share Of Pick-And-Carry (%) 2007 121 3 126 220 24 494 7621 94 2008 101 12 115 295 24 547 7323 93 2009 134 6 91 192 34 457 6048 93 2010 108 13 120 284 11 536 8755 94 2011 101 16 117 463 5 702 10 604 94
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globaltrends
ment names are also competing effectively. JCB strengthened 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 designed 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 important for plant hire (rental), whose operators often have stay for months on remote sites. This launch was part of JCBs 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 industrial 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 components 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 maximum 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 company 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 JCBs 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
diesel hr
Lima New Parker Latin American Group President
Parker Hannifin Corp. appointed Candido Lima, 47, to vice president 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 Groups continuous improvement manager with the additional responsibility of establishing operations for Parkers 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.
The Electrical Generating Systems Association (EGSA) has named Robert (Bob) Breese as the associations 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 Generacs factory and field service training programs. R. Breese He also served as an EGSA Advanced and Basic school instructor for the past three years. Breeses responsibilities will include directing the associations 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.
New Education Director For EGSA
Tognum Board Gets New Member
Jrg Schwitalla, 51, has been named to the Tognum AG executive board, responsible for Personnel and Integrity. Tognum said it has created the new position to meet future requirements such as the planned integration of Bergen Engines AS and the groups growth targets and to bring the Personnel, Legal Affairs and Compliance divisions closer together and underline the growing importance of ethics in corporate management. 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.
31 January-February 2013
Indianotebook
Escorts Limited has ambitious goals for its products, including the recently launched Powertrac DS Plus tractor series.
Escorts Seeks Greater Share of Tractor Market

By T.C. Malhotra
ndian 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 Machinery, 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 tractors last year. Reports suggest the deT.C. Malhotra is a technical journalist based in Dehli, India. His e-mail is tc_malhotra@ rediffmail.com
mand in India is for 525 000 tractors per annum, with market size estimated 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 emerging commerce-minded segment, Indian 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 Escortsbuilt engines and are designed to provide 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.
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Force Motors Aims For Growth

Commercial vehicle manufacturer Force Motors expects to increase vehicle sales by 25% in the 2012-13 fiscal year. Naresh Kumar Rattan, the companys president and chief operating officer, said that Force is forecasting sales of 40 000 vehicles in the current fiscal compared to 32 000 units sold in the previous year. Force Motors also announced the launch of the Traveller 26, a light commercial 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 manufacturer of three-wheelers, multi-utility and cross-country vehicles, light commercial vehicles, tractors, buses and now heavy commercial vehicles.
Mahindra and Mahindra Reports Gains

Mahindra and Mahindra Limited
indianotebook
(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 season, witnessed a 12% drop in sales during 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%.
Volvo Trucks has launched the new five-axle FM480 dump truck for the Indian mining industry.
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 period last year. Net Profit after tax for the quarter was Rs9.018 billion (US$167 million) compared to Rs7.374 billion
Study: Tractor Volumes Likely To Rise

The domestic tractor industry is likely to grow from 500 000 units to about 860 000 units by 2015, according to the continued on page 34
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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 applications, 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 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.
Daimler Starts Light Truck Production In Oragadam

Daimler India Commercial Vehicles, the Indian subsidiary of the truck manufacturer Daimler AG, has started production of its 9-tonne rigid, 12-tonne rigid & 12-tonne construction BharatBenz light-duty truck (LDT) range at its plant in Oragadam 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 manufactured at the Oragadam manufacturing plant, which has a capacity of 36 000 units.
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 (MNREGA) 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 general of ASSOCHAM. Increasing application of tractors for nonfarm operations like infrastructure and construction projects, transportation and increasing farm labor costs due are key growth drivers of the tractor industry, he said. An increased domestic demand in the replacement market is another significant 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 horsepower market, with 31 to 40 hp tractors accounting for about 42% of inDiesel Progress International
dustry volumes. But the ASSOCHAM study points toward a shift in the trend with a higher growth in the upper 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 players and few regional players. The industry 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 Tractors 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 India, said Philippe Divry, managing director 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
34
Cummins Increases Gen-Set, Engine Prices

The power generation business of Cummins India Limited has increased the price of its diesel generator sets and generator set engines in the range of 7.5 kVA and 3000 kVA by up to 3%. The price increase became effective Jan. 1, 2013. Cummins powered generator sets, transfer switches and paralleling systems are used for continuous, prime and standby power in a variety of commercial and industrial applications. Cummins said it would continue to deliver the highest quality and value to its customers while remaining competitive in the market. dpi
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
In its home market, most of its engines go into commercial fishing vessels, as the recreational market has only recently started to gain momentum in Korea. In Europe, most Hyundai SeasAll engines are destined for pleasure boats, one interesting exception being water taxis in Venice, where the companys local distributor, Socoges, has gained a significant slice of the business. The burgeoning marine business stems from the ambitions of Seungkab Jeong, Hyundai SeasAlls president and chief executive officer. A keen boater, Jeong was working as a senior development engineer in Hyundais 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 companys cars could be successfully adapted for marine use, Jeong put together a business plan,
35
Four years after launch of its first engine, Hyundai SeasAll growing marine diesel range, distribution network
and, along with several colleagues, convinced the corporations senior executives 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 engine 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 competitors because our brand is not so strong yet and the customers dont know our engines so well. continued on page 36
By Ian Cameron
One of the worlds youngest marine engine companies, a spin-off from a giant global carmaker, is gearing up for further growth. Based in Gyeonggi-do, South Korea, Hyundai SeasAll is backed by the countrys Hyundai-Kia Motor Co. And while the first production marine engines only came off the line in December 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 parent 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 recent appointments. Hyundai SeasAll has mainly supplied the global pleasure-boat sector.
Industry News
strongly on expanding its international sales footprint. Like most engine suppliers the company was hit by global economic 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 market 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 representative. In the past seven months, the company has appointed distributors in western Canada, Colombia, Ecuador, Egypt, Singapore and Thailand and expects further representation to be finalized soon in Russia, which the company said has great potential. The company is also active in China, 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 expanding 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 engines 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 anticipating that the market will start to improve 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 economic cyclicality than the pleasure engine market. dpi
Seungkab Jeong, Hyundai SeasAll president and chief executive officer.
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 Series provides 280 kW at 1800 r/min at full load. It incorporates a Denso electronic 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 onboard comfort, Hyundai SeasAll said. Also featuring Hyundai electric variable geometry turbochargers the HSeries 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 previously limited to using petrol engines. The 1.6 L, in-line four-cylinder, fourstroke engine has an output of 93 kW at 4000 r/min full load. Aimed principally at the pleasure boating and lightduty commercial markets, the engine has a Hyundai variable geometry turbocharger with a Bosch common rail direct fuel injection system and bore
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 incorporating a Bosch piezo-controlled, common-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 double the fatigue strength of iron and aluminium, the company said. The S250S, S250P and S250J engines 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 offering 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 engines are rated 125 kW at 3800 r/min full load, while the D150S and D150P engines produce 112 kW at 3200 r/min. All five engines weigh in at 261 kg. Along with boosting its product offering, Hyundai SeasAll is also focusing
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TRIZAC
HOLDING
MIDDLE EAST
industry news
New Single-Cylinder
KD15 replaces Lombardinis single-cylinder 15LD diesel; KDI diesels go into production
Kohler Diesel
The KD15-440 is the first version in Kohlers new KD15 range of aircooled, single-cylinder diesel engines. The new engines are a revamp of the existing Lombardini 15LD diesels.
By Roberta Prandi
here was a lot to celebrate at Lombardinis 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 companys newborn, the KD15-440 is the first unit to be presented within a range that will be ultimately composed of four singlecylinder engines the KD15-350, KD15-350S, KD15-440 and KD15440S 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-
ers are scheduled for release at the end of the year. The KD15 family KD Kohler Diesel will replace the current 15LD (Lombardini Diesel) engine family while offering a series of enhancements, mainly in the area of air filtration 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 design update from the existing singlecylinder series, said the new engines incorporate a new air filter system composed of a high-efficiency cyclonic separator with prefilter and an accumulated-dust drain valve in the primary filter.
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According to Massimiliano Bonanni, Lombardinis director of engineering, a bigger cartridge and the high filtration capacity of the filters paper element assure the best protection for the engine, while maintenance is much improved thanks to higher intervals (up to three times greater than the current version) and an easy system 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 safety, Bonanni said. The two filters working 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 disassembling 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 inauguration of the new assembly line for the KDI engines, which mark the Reggio Emilia plant as the center of excellence for diesel engines within the Kohler Group. Lombardinis 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 investments, the company said. The KDI assembly line is subdivided into two major parts, Paini said. The
industry news
The new highly automated line at the Lombardini plant in Reggio Emilia, Italy, has begun production of Kohlers new KDI diesel range. The 1.9 and 2.5 L versions are already in production. The 3.4 L model will follow in 2014.
first, called Short Block, assembles those elements which are common to all engine models, such as crankcase, bedplate, oil pan, camshaft, crankshaft, 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 versions. A third subline runs parallel to the Long Block and is dedicated to the assembly of the cylinder head, essentially 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 compose the cylinder head line. This is a highly automated assembly concept, based on the theory of objectification, Paini said. Objectification is an approach aiming at creating an industrial design finding a best practice for every operation. This leads the operator to execute the operation correctly. The assembly line applies standard 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 potential bottleneck. We will adopt a mixed testing process, with short acceptance tests on hot running engines for all those units featuring mechaniDiesel Progress International
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-
tion machines, are some latest generation machining centers for the finishing of the crankcases. Two of these machines cover a production output of 26 000 units/year of the three- or fourcylinder crankcase at the same time, while five centers will handle up to 65 000 units per year. Cylinder honing is also an operation 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 customers request. dpi
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FXS.indd 1
1/4/13 10:40 AM
POWER GENERATION
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.
To Gas Engine Range

AN Truck & Bus has developed a new gas-powered engine for power generation 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 applications using agricultural biogas, in wastedisposal 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 displacement 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
MAN Adds
based on a newly developed engine block with monoblock four-valve cylinder head. For many years, the base engine has been installed as the diesel 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 newly 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 engine coolant pump, thus increasing the systems overall efficiency. The combination of four-valve technology and a new combustion chamber geometry increases the specific power output, optimizes economy and reduces emissions, said Reiner Rssner, vice president and head of sales at MAN Engines in Nuremberg, Germany.
40
220 kW output power for new six-cylinder gas engine by MAN Truck & Bus based on diesel truck engine
In accordance with MANs minimum requirements for gas quality, it is possible to use natural gases at a compression ratio of 12.5:1 as well as special gases at 14:1. The E2676 LE202 engine was designed especially for decentralized, continuous power supply and optimised for operation with natural and special gas, MAN said. MAN Truck & Bus said it would deliver the natural gas or biogas variant from the fourth quarter of 2013. The new engine completes the MAN range of gas-powered engines for operation in CHP plants, with outputs ranging from 37 kW to 550 kW at 1500 rpm for 50 Hz applications powered by natural gas and from 68 kW to 550 kW for biogas versions. Five series with a total of 19 gas engines are available. dpi

www.man-engines.com
productbriefs
Diagnostic Display
FW Murphy introduced the PowerView model PV25, a diagnostic display designed for Tier 4/Euro Stage 3b/4 and below engines. The PV25, which displays engine parameters and diagnostic trouble codes, is part of the companys existing PowerView display portfolio. The display provides equipment operators with a way to see how the engine is performing 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 devices 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 parameter number (SPN), failure mode indicator (FMI) and occurrence count (OC). www.fwmurphy.com
Fuel Filters
Racor, a division of Parker Hannifin Corp., has released the DFBO14 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 certification. A prefilter, water separator/particle filter, or water absorptive filter can also be used, according to the company. www.parker.com/racorproducts
Industry News
Powertrain specialist ZF, seeing 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.
The Off-Road
How the creation of the Off-Highway Systems business unit continues the evolution of global powertrain specialist ZF
By Roberta Prandi
Editors Note: In business, it is an accepted fact that nothing stands still. Whether it is a companys 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 Friedrichshafen 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 development has resulted in the creation of the Off-Highway Systems business unit within the Industrial Technology Division, which bundles the companys off-highway operations into a single entity. Diesel Progress International spoke
Ahead
easily find the right contacts independent from the requested technologies, be it axles or transmissions. DP: Dr. Mohr, you are now responsible for construction machinery. What are your main tasks and goals in this new structure? Mark Mohr: As a global-acting supplier for drivetrain components, the main challenge for the future will be managing the spread between hightech drivetrains for the Western markets 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 considerable potentials at limited efforts. After optimization of the individual components, additional potentials can only be achieved by a system approach. This system approach will play a major role in our future strategies. In combination with our axle and transmission expertise, we see fuel saving of 20 to 30% for our products. Our ZF Efficiency Package is the recent technology to address this system approach. Based on our long-term experience in
with Dr. Hermann Beck, head of OffHighway Systems, and Dr. Mark Mohr, head of ZFs Construction Machinery Systems segment, about the new organizational developments and future product plans. DP: ZF reorganized its structure in the off-highway business segment whats behind that? Hermann Beck: In order to improve our One face to the customer strategy and to benefit from internal synergies between our cross-functional departments, we decided to create a new business unit, Off-Highway Systems. Under its roof you find three strategic market segments construction machinery, 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
42
Industry News
the agricultural sector we already made the next step in this evolution, CVT technology for construction machinery. Hybrid modules for all relevant applications will be a final step as soon as markets, customers and environmental/political scenarios request that technology. DP: With bauma in Munich not far ahead, what will your message be at the worlds 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 transmission technology. Bauma Munich for us is the perfect platform to present these Innovations of Great Value, as our bauma slogan says. DP: What are your current market and product strategies for off-highway? Hermann Beck: Design to market is one key element in ZFs global strategy. 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 technological steps exactly to the according market requirements; from basic power-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 China 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.
ZF is also seeing a greater opportunity for continuously variable transmission technology. In the companys cPower CVT, the percentage of hydrostatic power 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.
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 capability 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 dominated by Western companies for the high-end machines and Chinese companies for the lower level of technology. 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. Im sure the market will increase in the next years and everyone is preparing for this. DP: ZFs Efficiency Package is mainly intended for the Ergopower transmission range. For which other transmissions will it be offered and for which machine segments? Mark Mohr: With our CVT transmission, 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 loaders up to 35 tonnes. DP: What about future developments for the cPower CVT range? Mark Mohr: There are a lot of options. The CVT is interesting for all those machines working mainly in the low-speed area where the torque converter is open or for applications
43
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 potential for different applications. Several projects for different applications are in process. DP: In your hybrid concept you offer for now an electric machine with maximum 120 kW output. Are there expectations or demands for more power output? Mark Mohr: In the excavator segment 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 manufacturers have to take these steps first, only then the machines will be ready for hybrid technology. Im sure that we will see hybrid solutions in construction machines in the future, but then we have to utilize all potentials of the technology in the machine system. ZF is ready for hybrid, but it will take some more time. dpi

www.zf.com
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 design is a two-position, four-way directional valve that is available in various schematics.
Comatrols DV15 directional control valves developed to drive more compact, efficient designs of the new reversing fan drive HICs.
Directional Valves And Fan Drive HICs

ware designed to allow hydraulic circuit designers to communicate and document their ideas, now offers the flexibility of switching between English and Chinese. The addition of Mandarin will also provide for further collaboration of circuit design in China, the company said. The DV15 is 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. The new five-port design is a twoposition, 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.
44
New Flow
omatrol, part of the SauerDanfoss Group and a manufacturer of engineered hydraulic cartridge valves and hydraulic integrated circuits (HICs), has introduced a new line of high flow directional control valves. The introduction of the new DV15 valves has also allowed Comatrol to update its RFDE fan drive HICs. According to Darren Magner, Comatrols manager of marketing, the latest products are a continuation of the companys 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 softDiesel Progress International
An additional benefit of the piloted design is that customers are not limited to piloting the DV15 using a solenoid valve, as they can also pilot with other valves, including sequence, relief 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 Comatrols 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 essential for fan drive systems near engine compartments where space is limited. The valves rated pressure of 230 bar is a good match for these fan drive applications, he said.
MOBILE HYDRAULICS
Comatrols 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 common reversing and modulating fan drive solutions.
Comatrol previously launched a portfolio of six pre-engineered reversing fan drive HICs, four of which were designed using CETOP D03 or D05 valves for the reversing function. With the launch of the DV15P5-24 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 Marella, account manager. They needed lower pressure drop through the HIC to improve the efficiency of the fan drive system and a much slimmer design to fit around the tight space constraints in the engine compartment. We worked closely with product development, leveraging Comatrols computational fluid dynamic capabilities, to design and optimize a solution that met these stringent requirements.
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 reduction 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, supporting the most common reversing and modulating fan drive solutions in the industry. For commonization of design, the 40 and 80 L/min versions are the same size but are optimized for their respective maximum flow capacities, Marella said. dpi

www.comatrol.com www.comatrol.cn
powerlines
Johnson Matthey offers a brochure that details the companys capabilities to help stationary diesel and gas engine owners comply with the U.S. Environmental Protection Agencys (EPA) RICE
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 companys international growth strategy as it continues to increase its market research capability and capacity. Power Systems Research has been in Brussels for more than 20 years. The European office provides market intelligence, consulting and market research support to global engine, equipment and components manufacturers, the company said. Chinese crane manufacturer Zoomlion 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 distributor of the Zoomlion rough terrain
45
crane line and the North American distributor 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 manufactured by Aber was listed incorrectly in the 2012 Mobile Hydraulic Pumps & Motors Specs-At-A-Glance chart that appeared in the November-December issue of Diesel Progress International. Abers gear pumps range in displacement from 12 to 150 cc/rev. Diesel Progress regrets the error.
NESHAP regulations, which became effective in 2013. The brochure is titled Stationary Emissions Control Modulex Catalytic Converters; The winning combination for
power generation
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 panels and a standard, integral fuel tank base with drip tray.
Rated 365 to 600 kW, sets are suitable for prime or standby power; new enclosure options
C15, C18 Gen-Sets

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 enclosure, the package has been designed with an all-round, overhanging base frame. The control panel viewing window and access doors for the fuel fill and battery are lockable. Finally, installation and service are improved, Cat said, by oversized cable 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-byside 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 available option. Further, the new C15 and C18 generator sets are fitted with Cats latest EMCP4 control panels, designed for enhanced performance monitoring capabilities. The EMCP4.1 and EMCP4.2 control panels are equipped with many operational and protection features.
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Cat Upgrades
The EMPC4.1 features auto/start/ stop; engine cool down timer; emergency 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 frequency; engine oil pressure (psi, kPa or bar); engine oil temperature (C or F); engine coolant temperature (C or F); multiple language support; and engine start and crank attempt counter. The EMPC4.2 controls offer additional functionality, including a programmable 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 conjunction 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 ensures remote monitoring compatibility with most building management or supervisory control systems. dpi
aterpillar Inc. announced it has made several enhancements 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 manufacturer 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 configurations with optional equipment, Caterpillar said. A number of improvements were made to the enclosures, available in either sound-attenuated or high-ambient 49C configurations. The new enclosed 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 integral 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

www.cat.com
Controls
Generating Greater
Protection And Control
Basler develops new digital voltage regulator for gen-set control and monitoring
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 associated with conventional hardwired reactive differential compensation circuits. Basler said the DECS-250 has true RMS sensing for single- or threephase voltage and current. It also incorporates an integrated automatic synchronizer and is equipped with configurable generator protection for increased flexibility. The DECS-250 utilizes Baslers BestComsPlus PC software, which allows for quick setup, configuration, operation and control of the unit. The integrated PLC capabilities 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 option. Other options include an automatic 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 temperatures from -20 to 70C and has been shock tested to 15 G and vibration 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
Baslers DECS-250 digital voltage regulator provides protection, control and monitoring for ac synchronous generators. New features include an integrated power system stabilizer, automatic synchronizer, integrated programmable logic, enhanced communication capabilities and advanced data capturing capabilities.
xpanding its DECS digital voltage regulator lineup, Basler Electric has added the DECS250 regulator for control, monitoring and protection of brushless excited ac synchronous generators. The microprocessor-based excitation control system is designed to provide metering and communication capabilities along with fully programmable inputs and outputs. It incorporates a PWM power stage and provides high field forcing, Basler said, and can accommodate 32, 63 or 125 Vdc nominal voltages with a continuous output rating of 15 Amp. New additions to the DECS-250 unit is an integrated power system stabilizer, automatic synchronizer, integrated programmable logic, enhanced communication capabilities and advanced data capturing capabilities. The digital voltage regulator incorporates self-tuning, which is designed to automatically measure the systems responses and create proportional integral derivative (PID) parameters to
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, Ethernet 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 detector (RTD) inputs, two remote thermocouple inputs and four remote analog outputs. The AEM-2020 communicates with the DECS-250 through a CANBus interface. The DECS-250 was developed with reactive load sharing via communication interface. This feature is designed
47

www.basler.com
adindex
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
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*Further information on this companys products can be found in the 2012 Edition of the Diesel & Gas Turbine Publications Global Sourcing Guide and at www.GSGnet.net.
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Tecsis GmbH, which specializes in measuring technology, has launched its new website at www.tecsis.de. The new website features a modern design that ofrelation to their activity. Company news can also be found on the website, which is available in English and French, with other languages set for release in the coming months.
Glocal global with a local message. The homepage is divided into main menus, and can display the language of the user by detecting it via the users browser.
Trojan Battery Co., a manufacturer 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,
fers customers an overview of the companys 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.
Ausa, the Spanish manufacturer of heavy compact machinery for industrial, construction, agriculture, municipal, mining and lawn and garden applications, has
Poclain Hydraulics has a new website at www.poclain-hydraulics.com. The website features digital images in high definition as well as a search engine and a systems function that helps manufacturers find the most relevant Poclain Hydraulics product in
launched a new website. The website, www. ausa.com, is designed to be interactive, defining different departments with a new contact system that the company said assures answers in one business day on average and
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maintenance practices, charging procedures 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 consider when selecting a battery for a particular application.
power generation
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 powered by an air-cooled 1B40 Hatz diesel engine.
Adding APU
Liebherr LR series crawler cranes use 11 kW APU to reduce main engine idling
Power
iebherr 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 cranes 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 cranes 270 or 450 kW main engine. Most of my customers tell me that their cranes are typically 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 savings 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 feature 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. Liebherrs 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

www.liebherr.com
50
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.
POWERTRAIN
Technology For Tractors

By Roberta Prandi
Driveline
Shift performance exceeds that of a single cone design, Oerlikon Graziano said, and is comparable to a standard double cone assembly of the same dimensions, 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 developed a forward-reverse shift actuator for agricultural transmissions that incorporates a carbon-faced synchronizer. While carbon synchronizers were originally developed to give high-performance sport cars faster gear times, Oerlikon Graziano said it is finding application for the technology in off-highway transmissions. During shuttling, gearboxes shift quickly between forward and reverse, making control and durability a key challenge for transmission development, said Andrea Serra, product manager synchro and powershift design at Oerlikon Graziano. To handle the high relative speeds involved and to remove the engagement problems with some materials we encounter, we worked closely with our customers to develop special
Oerlikon Graziano develops new front steering axle, carbon synchronizer for agricultural applications
erlikon Graziano has introduced 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 gearing along with outboard disc brakes and a 100% hydraulic locking differential. For the market of agricultural vehicles, the Italy-based manufacturer further offers a comprehensive range of driveline products, including a rigid mounted rear axle incorporating a power take off (PTO) with hydraulic shifting. 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
vehicles and off-highway mobile equipment 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 introduced a new synchronizer designed to combine the durability and performance of the companys existing long life products with a new internal activation system. New machines target 20 to 30% better fuel efficiency than their predecessors, said Andrea Serra, product manager Synchronizers and Powershift Design at Oerlikon Graziano. Our new synchronizer technology offers a step-change improvement in fuel efficiency for the next generation of heavy duty transmissions. The new Servo-Synchronizer technology has been designed especially for off-highway transmissions. It incorporates a self-energizing internal design that increases efficiency especially in applications presenting high drag torques, the company said.
52
POWERTRAIN
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The new carbon-faced synchronizers by Oerlikon Graziano are designed 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:

More than 250,000 individual page views More than 76,000 unique visitors from 190+ countries More than 200,000 ad impressions An average time-on-site of almost 9 minutes
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 technology uses a double cone layout with carbon-coated steel rings. The company said the friction and wear characteristics of the carbon synchronizers provide higher mechanical and thermal load capability, making gear shifts smoother and vehicles easier to control when shuttling. The technology 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 carbon 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 directly 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 companys work with supercar manufacturers, Serra said. We are now working with off-highway customers on projects to produce carbon synchronizers for new applications, to make tractors and
construction equipment easier to operate and more durable. Oerlikon Graziano has more than a decade of experience in carbon synchronizer technology, originally developed for high-performance sport cars. While the automotive sector has remained a key market for the company, it has shifted its focus to the off-highway industry. Agricultural equipment accounts for more than 70% of Oerlikon Grazianos 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 specialized in the production of gears, shafts, synchronizer assemblies, crown wheel and pinion, axle and transaxle assemblies. All these components are used not only in agricultural tractors, but also in construction equipment, commercial vehicles, utility vehicles and other offroad 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 modernized and the heat treatment area has been revamped with a continuous carburizing furnace. dpi
Searches on Google, Yahoo, Bing, etc., directed users to GSGnet.net more than 69,500 times, demonstrating high search engine optimization.
Combined with the Global Sourcing Guide, the companion print version now in its 77th year of annual publication, Diesel & Gas Turbine Publications GSGnet.net and Global Sourcing Guide provide the most comprehensive information on engines, power transmissions, hydraulics, emissions systems and the many other product technologies used in engine-driven machinery and equipment.

www.oerlikon.com/graziano
If you buy engines and components, you need to look here! If you sell engines and components, you need to be here! See for yourself at GSGnet.net or call 800-558-4322 or 262-754-4100 to order your print edition!
53
CONTROLS
TOUGH APPROACH
BY MIKE BREZONICK
TAKING THE
New Tough series engine and gen-set controls from DynaGen designed for longer service life in severe-duty applications
Canadian controls specialist DynaGen has released its Tough series controllers, designed to provide control, protection and engine and generator set instrumentation for mechanically and electronically controlled diesel and gaseous fueled engines.
roduct design has always been a kind of balancing act. Designers walk a tightrope between developing sophisticated, foolproof (and expensive) designs capable of extended service life versus configurations more specifically engineered to meet economic targets while still providing an acceptable level of performance and longevity. Yet in the case of engine and generator set controls, DynaGen, the Canadian-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 really great work in trying to streamline the cost of engine and generator controls, said Paul Wareham, DynaGen president. There have been a lot of advancements in terms of producing really efficient electronic designs. There have been efficiencies in manufacturing, getting quantities up to the levels where you could achieve economies of scale thats all been good. But we saw some sacrifices being made in terms of the long-term durability and robustness of the products.
Things had swung a little bit too far toward 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 really needed some attention was robustness, without raising the cost too much. The result of that attention is DynaGens new Tough series digital engine and generator set controls. Developed over 18 months, the new products have gone into full production at the companys manufacturing facility in Nova Scotia. The Tough series engine controls are designed to provide complete control, protection and engine instrumentation for both mechanically controlled 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 applications such as pumps, compressors, light towers and generator sets. The Tough series digital gen-set controller available in two models offers the same engine control and protec54
tion functions while adding generatormetering 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 customerdefined parameters. Wareham said the Tough series development was really a multifaceted effort that focused on a number of different areas, which primarily included mechanical, electronics and software. We wanted a trifecta of design that includes software reliability, mechanical integrity, and electronic design, Wareham said. The mechanical integrity deals with things like vibration 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 its chalked up to
CONTROLS
bad luck but the underlying reason is often unexpected voltage spikes. That really is sort of the threepronged approach we took software, mechanical and electrical and looked at adding significant improvements in all three of those areas. We tested our existing designs to commonly 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 consideration 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 automatic shutdowns and warnings along with sensor trim features, maintenance 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 applications and multiple stop-start stations, DynaGen said. Passcode protected, the controllers accept common senders including VDO, Datcon and FW Murphy. The Tough series units can be programmed manually via pushbuttons on the front panel or with DynaGens PC configurator software that provides customization of screen messages, sender selections and control settings. The configurator uses a standard USB cable with no special program are required, DynaGen said. Both the engine and generator set controls also include DynaGens snapon 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 RelayPak 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 contamination ingress. Operating temperature range of the controller is -40 to 70C, with display screen viewing. DynaGen said the Tough series units meet or exceed SAE J1455 standards for shock and vibration. Along with the engineered-in robustness 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 people 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 characteristics and features, but what the owner sees and interacts with more is the controller. So its imperative that the controller is representative of the high quality of the machine that its 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 didnt want it to feel like a toy its something that is really solid and has a commanding presence. We also focused on appearance 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 companys confidence in the robustness of the design, Wareham pointed to the five-year standard warranty. That is certainly at the very top end of anything thats offered in the market. dpi
The new Tough series controllers from DynaGen include the companys 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.

dynagen.ca
55
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
Mahindra & Mahindra Ltd. (M&M) and Navistar International Corp. have announced that Mahindra intends to purchase Navistar Groups stake in Mahindra Navistar Automotives Ltd. (MNAL) and Mahindra Navistar Engines Pvt. Ltd. (MNEPL). Following the purchase, both MNAL and MNEPL would become wholly owned subsidiaries of Mahindra. The terms of the proposed transaction call for Mahindra to pay approximately US$33 million for Navistar Groups stake in both ventures. The agreement allows Navistar to continue sourcing components from India while Mahindra would continue to provide engineering services to Navistar. Navistar group would continue to support M&M through a license agreement and extend necessary support to MNAL and MNEPL for the purposes of business continuity. The sale, which is subject to the conclusion of definitive agreements, requires regulatory approval in India and is expected to be completed in early 2013. Mahindra would then take complete ownership of operations and continue to sell MNEPL and MNAL products. AGCO has begun production of agricultural equipment at its joint venture facility in Africa. The first Massey Ferguson tractors are being produced in Constantine, Algeria, at Algerian Tractors Co., a joint venture between AGCO and LEntreprise Publique Economique de Production de Tracteurs Agricoles and LEntreprise Publique Economique de Commercialisation de Matriels
Agricoles. AGCO owns 49% of the operation. The tractors being built at Constantine 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, effective April 1, 2013. The purchase price was not disclosed. Deutz and T.ERRE have signed a long-term supply 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 machinery manufacturing in Brazil in March 2013. A new plant is under construction 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 Mquinas de Construo (BMC). The plant will primarily supply 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 transmission, 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
56
used in new solo or articulated buses made by Karsan, Mercedes-Benz Trk, Temsa, and Solaris. Mercedes-Benz do Brasil will provide 2600 model OF 1519 R chassis for the Brazilian Ministry of Education. 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 equipment 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 southwestern Russia. The complete value of the order is approximately 150 million. Metso will supply a primary gyratory crusher, three cone crushers, one semiautogenous grinding mill, three screens and three ball mills. Volvo Construction Equipment (Volvo CE) announced it is extending its business relationship with attachment supplier Steelwrist AB. Along with its factory-fitted Tiltrotators that allows buckets or other attachments to be tilted and rotated simultaneously, Steelwrist will now supply excavator quick couplers to Volvo CE. The first Grove rough-terrain cranes assembled in Manitowocs newest factory in Passo Fundo, Brazil, have been delivered to the first two customers: Servi-S Auto Crane Rental & Services, and Machinery and Engineering Lauer. The companies both received Grove RT765E-2 rough-terrain cranes. dpi
January-february 2013
Are you ready

visit us at hall A4 stand 321/416
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: info@deutz.com
ZF technology the intelligent choice. Because we offer future trends like the Continuously Variable Transmission already today.
Innovations of Great Value.

Visit us at the bC India in Mumbai, 5-8 Feb 2013, Indoor H2-C18/H2-D17
www.zf.com
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.
Driveline and Chassis Technology

Diesel Progress January February 2013

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