Pages 4

THE MAGAZINE FOR INDUSTRIAL VEHICLE TECHNOLOGY, DESIGN & ENGINEERING
iVT Industrial Vehicle Technology International
Engines & Emissions

Mobile cranes – one
lump or two?
NOVEMBER 2015
Everything you need

to know about Stage V
NOVEMBER 2015
China in the spotlight

Best of the region’s
industrial vehicle design
VOL 23 No. 4
Market report: China’s lack

of high-tech components
Case studies
BYD lithium-iron phosphate
lift-trucks
www.iVTinternational.com
XCMG’s western-styled
wheeled loader cabs
LiuGong
856H Groundbreaking advances
Published by UKIP Media & Events Ltd
in wheeled loaders – from

a Chinese OEM?!
EFFICIENCIES you may not see,
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DOSG45152 IVT_Intl_June2014_MaterialHandlingAd_215x275_X1a.indd 1 5/1/14 4:04 PM

CONTENTS
p20
COVER STORY p32

BOYS ‘N THE HOOD
By concentrating on one key area,
the guys at LiuGong are pushing
wheeled loader design – and the
OEM’s entire way of operating –
into brand new territory
p26
REGULARS CASE STUDIES & SPECIAL FEATURES

6 NEWS 14 THE HEART OF THE MATTER 44 DESIGN DISTRICT
Despite its high volumes, China’s off- We take a look at some of the best industrial
9 CONSTRUCTION FOCUS highway sector is heavily reliant on imports design coming out of China
BY JIM MANFREDI of key, core components. How long will this
48 ONE LUMP OR TWO?
11 AGRICULTURE FOCUS situation be the norm?
Is performing an ‘engine-ectomy’ the latest
BY JIM MANFREDI 20 THE GIFT OF THE CAB trend in mobile crane operations? Liebherr,
12 MATERIAL HANDLING Everyone’s always going on about the Grove and Terex Cranes certainly think so
FOCUS importance of ergonomics – but Chinese
56 THE FIFTH AMENDMENT
BY MICHAEL LEU OEMs have often only paid lip service to
Our handy guide to the latest iteration of
the subject. But with its new wheeled
72 BULLETIN BOARD loader cab, XCMG has something worth
emissions compliance will help avoid any
awkward silences arising when the topic of
76 THE INSIDER talking about
EU Stage V comes up
‘Made in China’ is no longer a 26 DESIGN FOR LiFe
derogatory expression – but does BYD – the world’s largest manufacturer
that mean it’s good enough for
of rechargeable batteries – has created an
your machinery?
entire range of lift-trucks around its lithium
iron phosphate (LiFe) technology
“We’ve got at least four ideas

in the Skunk Works that will
rewrite the rules and really
scare some people!” p32
THE MAGAZINE FOR INDUSTRIAL VEHICLE TECHNOLOGY, DESIGN & ENGINEERING
SUBSCRIPTION / CHANGE OF ADDRESS Deputy Production Editor Nick Shepherd The views expressed in the Worldnet Shipping USA Inc, Average net circulation for the period
iVT Industrial Vehicle Technology International
Engines & Emissions
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Mobile cranes – one
lump or two?
INQUIRIES TO: Proofreaders Christine Velarde, Lynn Wright, articles and technical papers
NOVEMBER 2015
Everything you needed

to know about Stage V
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not endorsed by the publishers. paid at Jamaica, NY 11431.
NOVEMBER 2015
China in the spotlight

Best of the region’s
industrial vehicle design
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VOL 23 No. 4
Market report: China’s lack
Circulation Adam Frost adam.frost@ukipme.com Art Director Craig Marshall

of high-tech components
Case studies
BYD lithium-iron phosphate
lift-trucks during production, the publisher changes to iVT International c/o
Design Louise Adams, Andy Bass, Anna Davie,

XCMG’s western-styled
wheeled loader cabs
does not accept any liability for Air Business Ltd, c/o Worldnet UKIP Media & Events Ltd,
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Groundbreaking advances
richard.carr@ukipme.com
Published by UKIP Media & Events Ltd
in wheeled loaders – from

a Chinese OEM? 627 is published quarterly, Subscription records are held Tel: +44 1306 743744
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iVTInternational.com November 2015 1

CONTENTS
PRODUCTS & SERVICES

62 CONQUEST OF THE AIR 66 TABLE FOR TWO 70 TOUGH AT THE TOP
Engines from Cummins are helping The latest Stage II/Tier 2 variants of Taking the new HydraForce G3
Kalmar Motor and other GSE suppliers Hatz’s 4-cylinder H-series platform are generation of drop-in valves to the next
meet the strict air-quality requirements ideal for OEMs selling into the lesser- level was a difficult task – but ultimately
of airports worldwide regulated markets it was well worth the effort
65 MAN AND MACHINE 68 CRANE OF THOUGHT
MAN Engines is shifting focus toward Have you ever wondered just how
easier customization in the search for intelligent modern mobile cranes would
perfect harmony be without the latest sensors, such as
those from Siko?
p65 p66 p68 p70

FOREWORD
In terms of green credentials, cars and bicycles could hardly be The thing is, most consumers have long been aware that the fuel
further apart, but when discussing ‘Dieselgate’ with an industry economy figures touted for new cars aren’t realistic – and not just
contact the day after the news broke, I couldn’t help but think about because everyday driving is far less forgiving than a test cell or rolling
professional cycling’s historical problems with doping. As we discussed road. It’s well-known that the proffered figures rely extensively on the
the smoke and mirrors (if you’ll pardon the phrase) that enabled VW to use of masking tape to improve the aerodynamics, overinflated ‘special’
pass stringent emissions tests, the subsequent finger-pointing and blame- tires, or the removal of parasitic but crucial real-world components, to
shifting, and our incredulity about how these people must have believed deliver figures up to 50% more favorable than ordinary drivers will ever
they could get away with it without ever being found out, the similarity experience – so should we really be surprised that NOx output has been
to the Lance Armstrong affair became inextricably lodged in my mind. equally smudged to achieve the desired result?
Once the Texan’s confession was out in the open, the whole house of In a sense, however, the Armstrong Lie has ultimately been good for
cards quickly came tumbling down, with the collaboration of his entire cycling, with changes to top management at the UCI heralding a new,
team being exposed for all to see – and sure enough, VW’s sister cleaner dawn – one which so impressed Sebastian Coe, as the incoming
companies Audi and Škoda soon became the next big names to be president of the IAAF (International Association of Athletics
implicated. There also appears to have been some element of the Federations), that he vowed to follow the association’s lead to seek out
authorities showing some staggering hypocrisy about both scandals after dopers wherever they be. Likewise, on September 25, California’s ARB
the story was out in the open. It’s now clear that some at the UCI, wrote to all manufacturers of IC-powered vehicles to remind them that
cycling’s governing body, turned a blind eye to early instances of the use the use of defeat devices is prohibited, and that it would be beginning
of the sport’s own ‘defeat device’, EPO – before condemning Armstrong “enhanced testing procedures for modern light-duty diesel vehicles to
et al’s cheating when there was no alternative course of action. Similarly, determine compliance with emission levels to which they were
the UK, French and German governments have been particularly vocal originally certified”. The B-sample, in other words…
in demanding an inquiry into VW’s test-rigging – yet reportedly had So, the logical question is, will the off-highway engine industry have
been actively lobbying to retain loopholes in the old testing methods anything to fear from a tenacious Travis Tygart-style investigation/witch
that would increase CO2 levels by 14% above those claimed. hunt (delete as appropriate) in the wake of what happened in the
The end result? Everyone in professional cycling – no matter how automotive sector? While I still can’t hear the term ‘Volkswagen fiasco’
scrupulously clean they may be – automatically falls under suspicion without entering a Homer Simpson-style reverie concerning attractive
should they produce anything other than the most workaday Swedish au pairs driving compact, brightly colored German-built city
performance. Armstrong single-handedly halted the huge progress that runabouts, the implications of such a scandal hitting the off-highway
cycling had made in tackling doping since the 1998 Festina affair – the sector don’t bear thinking about. When the industry has made such
same year, coincidentally, that several heavy-duty engine OEMs were major strides in reducing pollutants in such a short time, it has an awful
caught out by the EPA after similar use of defeat devices to enhance lot to be proud of – and the implementation of yet another stage in
on-road fuel-efficiency figures. Everyone is damned by association – and Europe should be another challenge that it can, for the most part, easily
if the short-sighted calls for all diesel cars to be banned from London are overcome. You can find out a lot more about Stage V on page 56. In the
anything to go by, the compression ignition-skeptics are eagerly grasping meantime, I have a reverie to get back to…
this golden opportunity to grind their axes. Richard Carr, editor, iVT International
• bauma 2016 preview • Powertrain – focus on multi-axle equipment • OEM interview – Paco
Coming up in the March issue of iVT
Pérez Salinas, Ausa • And much, much more…
2 iVTInternational.com November 2015

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Outstanding
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Due to magazine deadlines, our visit to Agritechnica was all too brief this year – but here are just a few
of the new machines, prototypes, concepts and other novelties that caught our eye on the Preview Days
We visited Peecon’s stand to find out about its silver-medal-winning Gull

Wing double-tire system, but it was the Biga Pacman Gen2 that really
caught our eye. It’s not brand new, but adapting a Linde 396 forklift into
a self-propelled and self-loading feed mixer is definitely innovative!

WHAT’S NEW
HANOVER, GERMANY – McCormick was

finally able to reveal its first-ever foray into
the +300hp tractor range, revealing its long-
awaited X8 VT series on the first evening of
the show (left). Three models are offered –
the 660, 670 and 680 – delivering 264, 286
and 310hp respectively, from ‘BetaPower
Fuel Efficiency’ (i.e. FPT NEF), 6.7-liter,
6-cylinder Tier 4F engines.
The range also features ZF’s four-stage
continuously variable transmission and what
the OEM claims is a class-leading cab that
sports automotive levels of design.
And speaking of superb looks, Zetor’s new
design concept collaboration (right) with the
Pininfarina design studio really caught the eye
at the stand next door. Some, if not all, of this
new styling will gradually be adopted across
all models in the OEM’s range, right down to
its forthcoming series of 50hp Zetor-powered
3-cylinder models, as well as a 200hp line-up.
The show even witnessed the return of a
famous name. Almost 20 years after Arbos
called time on 96 years of production, it was
presented as the new brand of China’s Foton
Lovol group, which has created three series of
tractors in the 100-260hp bracket (the range-
topping 7260 is pictured center right) and the
C5200 combine harvester. Work on these
began at a new R&D center in Bologna, Italy,
with the design work carried out by Envision
Incorporated. Whether the cab interior, which
wouldn’t look out of place in a Bentley, is a
good idea, remains to be seen however…
There was yet more Chinese presence –
while it’s still surprising to see Zoomlion
equipment in green (not pictured), this OEM
more noted for its construction equipment
made its second visit to the show to display
its latest agricultural tractors and an 81hp
hydrostatic-drive combine harvester.
Deutz-Fahr showed its 5120C prototype
tractor that has been adapted for running on
natural gas (bottom right). Working with the
University of Rostock, it has modified an
industrial diesel engine (an 86kW TCD 3.6) –
rather than a petrol engine – replacing the
diesel injectors with spark plugs, integrating
a natural gas proportioning system, and
adapting pistons and the turbocharger. It
burns 100% natural gas, 236 liters of which
is held in seven tanks, enabling almost half
the operating range – and almost the same
power – of a comparable diesel tractor, but
emitting 10-14% less CO2 and almost no
methane, and effectively meeting Stage V –
without needing an SCR system or DPF.
But it wasn’t just tractors that caught the
eye – Manitou (far left) showed off its MLT
960 6-metric ton CVT telehandler fitted with
Eco Booster hydraulic hybridization. Using
Dana’s Spicer PowerBoost technology, this
prototype recovers the energy generated
from braking, storing it in accumulators,
and supplementing it with energy from the
engine when that isn’t fully under load, and
returning it when more power is demanded
– reducing fuel consumption by up to 15%.

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©2015 Cummins Ltd., Yarm Road, Darlington, DL1 4PW, UK
IVTOffHighwayReview_WheeledLoader_215x275.indd 1 26/10/2015 10:52

WHAT’S NEW
CONSTRUCTION FOCUS
JIM MANFREDI, MACHINERY OUTLOOK
ALL CHANGE UP TOP US$500,000. Cat is planning

Terex has made some key on hiring an additional 31
leadership changes. John employees.
Garrison has become CEO
and president, and a member EXTRA VERIFICATION
of its Board of Directors, Manitowoc is to build a PVC
succeeding Ron DeFeo, who (Product Verification Center)
will continue as executive on a 9ha site close to its
chairman until the end of Wilhelmshaven factory in
DEFINING GENERATION X
this year, and as a consultant Germany, where it builds
until the end of 2016. Grove all-terrain cranes. It
Garrison joins Terex from has also announced a major
HIROSHIMA, JAPAN – In adding helps reduce the amount of Serviceability has received Textron, where he served as updating and modernization
the SK260LC-10/SK260NLC-10 DEF consumption, while NOx a few key updates too – most president and CEO of its Bell of the factory, which will
to its Stage IV excavator range levels are reduced by about notable is the revised layout Helicopter Segment. Prior optimize production and
for Europe, Kobelco is offering 88%. A new global motif now of the upper deck that aids to that, he was president of increase manufacturing
some major improvements features in the color scheme easy access to the engine Textron’s Industrial Segment capacity by up to 40%.
over the Gen 9 machine. to denote global awareness. compartment. Not only does and E-Z-GO. He has also Manitowoc opened its
Producing 124kW, the Hino Greater efficiency results this give the machine a clearer held senior leadership first PVC at its factory in
J05E-TJ’s fuel consumption is from the Arm Interflow System profile, it also enhances the positions at Case. Shady Grove, PA, USA, in
down by 9 and 10% in S-mode (AIS), which uses a hydraulic view to the right-hand side. Other moves include Ken 2012, to help it produce
(normal work) and Eco-mode regenerative system to enable Other improvements include Lousberg, currently president stronger and more reliable
respectively, while there is a the weight of the lowering an easily replaceable canister- of Terex China, taking on the cranes. Components can
5% productivity improvement boom to force hydraulic fluid type hydraulic oil return filter, role of president of Terex be more rigorously tested
in H-mode. The new Kobelco- to the dipper arm, reducing a fuel filter with more filtration Cranes plus responsibility to simulate a complete
developed engine-cooling fan the volume of fluid being area and a reinforced air for Latin America, following working lifetime and the
design is one of the main required from the pump. The cleaner element. On-screen the departure of Tim Ford. results used to modify or
contributors to this more boom and arm also feature and audible warnings for the George Ellis will take on a adapt designs. This can also
efficient operation. several revised structural hydraulic oil temperature or new role as SVP, operations speed up the product design
Adding a DPF and DOC to sections, reinforcement clogged oil filters help ensure planning, and president, Terex process, reducing downtime
the SCR aftertreatment system points and pin bosses. greater work continuity. Construction and will assume for customers, and enabling
global responsibility for the the OEM to directly compare
Terex Business System. Scott components from individual
Hensel has taken on the new suppliers. Its second PVC will
DOING IT BY HALVES
position of VP and MD, Terex increase capacity further,
Utilities & Services, reporting ensuring even greater
to Lousberg. Kieran Hegarty, component quality.
SAINT-DIZIER, FRANCE – created, providing the SV100 greatly improving its stability. president, Terex Materials Both the PVC and the
Yanmar has launched the 2PB with what Yanmar claims The additional weight of the Processing, will assume facility renovation are likely
SV100 2PB, its first excavator is class-leading visibility. configuration has in fact been responsibility for the Terex to be completed before the
to incorporate an articulated, Further improving comfort, limited to 845kg, including the Fuchs business that will end of 2016.
two-piece boom for greatly as well as maneuverability additional counterweight, become part of the Terex
enhanced performance in of the boom, a proportional which has improved lifting Materials Processing US EXPORTS DOWN
terms of lifting, moving and control switch installed in the capacity by up to 45%. The segment. Exports of US-made
placing loads. left joystick governs the operating weight is 10,360kg. construction equipment
By reversely mounting the articulation. The OEM also claims an ONE GOOD DEED… declined 17% for the first
only boom articulation cylinder, The use of a single, top- approximate 50% reduction Minnesota’s Department of half of 2015 compared with
and combining it with high mounted articulation cylinder in TCO, largely facilitated by Employment and Economic the same period during
hydraulic pressure, Yanmar also enables the excavator’s a similar reduction in the Development (DEED) will 2014, producing a total of
has enabled a high breakout dead weight to be halved, number of greasing points. provide incentive funds to US$7.4bn, with all world
force of 68.5kN. Additionally Caterpillar’s Paving Products regions cutting back.
this orientation enables the division to expand its factory From January-June
operator to raise the boom in Brooklyn Park. Cat is set 2015, Canada dropped 12%,
faster, and lower it more to invest US$3m. The Job to $3.1bn; South America
slowly, which is optimal for Creation Fund will provide by 23% to $990m; and Asia
precise load positioning. US$307,300 once Cat Paving decreased 11%, to $923m.
The top-mount configuration meets its investing and hiring At $878m, Europe was down
also guarantees much greater requirements. To meet DEED by 14%; Central America fell
protection of the cylinder rod, funding criteria, companies by 21%; Australia/Oceania
considerably reducing the must create at least 10 full- declined 10%; and Africa
risk of damage. It also enables time jobs and invest at least decreased 44% to $385m.
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WHAT’S NEW
AGRICULTURAL FOCUS
JIM MANFREDI, MACHINERY OUTLOOK
DEERE DIARY #1 DEERE DIARY #2

Deere & Company has John Deere has opened its
N signed definitive agreements expanded Montenegro city
to buy The Climate Corp’s plant in Rio Grande do Sul
Precision Planting equipment state, Brazil. The US$40m
business. “As a result of these investment will enable the
milestone agreements, national production of 8R
farmers will experience the tractors, allowing customers
fastest, most frequent and to use the Finame financing
highest resolution third- program.
party connectivity between
John Deere’s equipment DEERE DIARY #3
and the Climate FieldView John Deere has announced
HAND-ME-DOWN IDEAS
platform,” said Mike Stern, an alliance with Soucy Track
Climate president and COO. to distribute products through
Climate will retain the Deere’s dealer channel. The
SUOLAHTI, FINLAND – Having able to select outputs of 115, system, and up to 6.5m2 of digital agriculture portfolio agreement allows dealers to
reached its fourth generation, 160 or 200 l/min (73 or 90 l/min glass for excellent visibility in that has been integrated into provide a track configuration
Valtra’s 105-165hp N Series on the HiTech option). The all directions, the cab is also the platform. “[This will] on all 1770NT and 1775NT
now boasts many of the same hydraulics on the Direct and similar to that of the T Series. enable farmers to combine planter models equipped
features as found on its big Versu transmission models Available with one or two doors, John Deere equipment with with hydraulic drive or
brother, the 6-cylinder are controlled electronically, other options include a window Climate FieldView,” added electric drive.
T Series, which reached its and mechanically on the in the roof for a better view of Stern. “This allows farmers
fourth generation last year. HiTech and Active options. a raised front loader, or the to collect and directly share DEERE DIARY #4
In doing so, it offered the An innovation in the industry, SkyView forest cab, enhancing data to the Climate cloud, Deere’s Agriculture & Turf
possibility to operate the the Automatic Slip Regulator visibility to the rear and above enables data visualization division’s Q3 net sales fell
powershift like a stepless (ASR) limits engine power if via a large polycarbonate in the cab, and supports 24%. Its worldwide sales are
transmission; an option the sensors and tire speed window with wiper. development of customized forecast to decrease by 25%
carried over to the largest exceed a set level, ensuring Even more compact than data science-driven insights.” for FY2015, with declines
three N Series models with the best pulling ratio and fuel before, the new series has a Customers will have the most pronounced in higher-
the Direct transmission. Like efficiency are maintained, and turning radius of 4.5m, from a option to share their current hp models. Conditions are
the Active and Versu options, avoiding damage to the ground. 2,665mm wheelbase. Ground and historical agronomic more positive in the US
this features load-sensing Featuring noise levels below clearance of 55cm makes it data between the John livestock sector, supporting
hydraulics, with customers 70dB, a TwinTrac reverse drive suitable for forest work. Deere Operations Center improvement in the sales of
and the Climate FieldView smaller sizes of equipment.
platform and seamlessly Industry sales of ag
execute prescriptions with equipment in North America
John Deere equipment. are therefore forecast to be
Three months earlier, down about 25% for 2015,
AGCO had entered into an although sales of turf and
agreement with Precision utility equipment are likely
Planting to introduce factory to be flat to 5% up.
integration of that technology In the EU28, 2015 sales
to its White Planters line. It are forecast to be down 10%,
appears that this acquisition due to lower crop prices and
will not force a rethink. farm incomes, and pressure
HALL OF FLAME
This was Deere’s second on the dairy sector. In South
acquisition in a week, having America, sales of tractors
earlier acquired Monosem, a and combines are projected
MEMMINGEN, GERMANY – powered steering drive axle available in the X-tended AST- European market leader in to be down 20-25%, mainly
The first joint Goldhofer and for seamless acceleration up 2X version fitted with a GPU precision planters, which also as a result of economic
Schopf design engineering to 32km/h, while providing and offering an additional 60 owns two facilities in the USA. uncertainty in Brazil and
product, the AST-2P Phoenix maximum traction even under or 73hp. An optional extended- Deere has no plans to higher interest rates on
high-speed aircraft tow tractor light loads. With a new TÜV- range diesel tank enables all interfere with Monosem’s government-sponsored
enjoyed double-figure advance certified brake system and models to work a full shift independence – president, financing. With most of the
orders when it was introduced improved diff lock, safe and without the need for refueling. Agricultural Solutions and decline in India and China,
at Inter Airport in October. reliable operation in all A new fully air-conditioned chief information officer Asian sales are projected to
Based on a new compact, weathers can be ensured. cab with optional lift/lowering John May said the business be down moderately, and will
modular design concept, it Cummins QSL9 Stage III or function provides excellent all- will retain its own brand and drop significantly in the CIS
has the flexibility to handle Stage IV-compliant engines are round visibility, while vibration- trademark, and leverage its due to economic pressures
80% of operational aircraft. A used, featuring a stop/start free cab suspension enhances own operational strengths. and tight credit conditions.
key feature is its hydrostatically system. The Phoenix is also comfort during long shifts. Subscribe online at www.machineryoutlook.com

WHAT’S NEW
HANDLING FOCUS PICK A NUMBER

ANCENIS, FRANCE – In
MICHAEL LEU, FORKLIFTACTION.COM
supplementing its MI range
BRAND NEW BAOLI while there was also a rise with six medium-tonnage and
Kion North America has in repair and maintenance eight heavy-tonnage models,
launched the Baoli brand at revenues, which increased Manitou’s industrial forklifts
its first dealer meeting under 18% to €9.7bn. now provide a solution from
its new name, Linde Material Net production value rose 1.5-10 metric tons.
Handling North America. by 3% to €49.1bn, although All models are built on a
Kion Baoli Forklift will focus exports were down 4.8% to tough monobloc chassis and
on the economy segment, €21.8bn – although they feature strengthened 6m
supplying budget forklifts grew by 12% with the main masts and axles. The medium-
built in China. Kion NA is trade partner, the USA. The sized models are all equipped
distributing and supporting trade balance remains with drum brakes, while oil-
the range to complement its largely positive at €17bn. bathed disc brakes ensure
Linde range of products. Imports practically the longevity and improved
The dealer meeting stagnated (up 2% to €5bn) efficiency of the heavy trucks.
outlined the brand’s long- but maintained their share Okamura transmissions
term strategy, showcased in domestic demand (15.5%). optimize the efficiency of the
the most new products at Cummins or PSI engines, honeycomb roof pattern to latter enabling efficient
any one time in its history, GREENE GROWTH which deliver 55-82kW. enhance upward visibility. changes in travel direction,
and unveiled new sales and Raymond Corporation has Intended to reduce the Optimized hose passages – lighting and signaling.
marketing tools. Dealers unveiled a 4,400m2 addition possibility, and the extent of, especially through the mast’s Power steering facilitates
got their first look at the to its Greene facility. The breakdowns, there is a limited upright channels – create a more precise maneuvering,
Class V Baoli D+ Series creation of the Raymond number of electronic parts, better view to the front. especially with heavy loads.
Model KBG25. Additional Operations Center has with the main components, With a wide, anti-slip step, Simple instrumentation and a
Baoli models are currently added 3,000m2, while the relays and fuses contained well-positioned handles for a cleverly positioned display on
being developed specifically reconfiguration of 5,500m2 in sealed, but easy to access, quick grip, and a large, open the dashboard facilitate the
for the North American on the manufacturing floor casings to protect them from platform, access to the cab is flow of useful information,
market and will be released and optimization of the first- dust and damp. safe and easy. High levels of while the shape and position
over the next few years. floor support operations Mounted on a silent block adjustability are provided by of the hydraulic controls have
have improved efficiency that absorbs vibrations, the the seat and steering wheel, been designed for effortless
WELL DEVELOPED and production capacity. An overhead guard features a with intuitive controls on the and natural handling.
Taiwan’s Tailift has launched additional 1,400m2 has been
its first product since Toyota added for new 18m test bay
paid US$83m for 55% of its capabilities, office space,
spun-off forklift operations.
Toyota said the acquisition
was aimed at increasing its
and team and break rooms.
It also implemented
several upgrades to its
TERMINAL WELLNESS
market share in developing manufacturing technology, STARGARD SZCZECINSKI, T2 launched on the US market
economies, which accounted such as advanced automatic POLAND – Kalmar has brought last year, but with a totally
for almost 40% of the global welding and laser-cutting its T2 terminal tractor to the different cab, it can be tailored
market in 2014. technology, the upgrading European market, aimed at to individual requirements due
The new Z series consists of warehouse management operations in busy distribution to its modular construction
of 10 new models, with load software, and integrating the terminals as well as heavier and manufacturing flexibility,
capacities from 1.5-10 tons. corporate logistics plan with (LoLo) port operations. which helps reduces costs by
The models are available in JIT delivery of equipment Based on the chassis of avoiding over-specification.
diesel, gasoline or LPG and materials. the highly acclaimed Ottawa Combining the electronic
versions and include an engine RPM management of insulation. The clear-view
enlarged cabin, a clear-view SEVEN WONDERS the 129-160kW Cummins or cab provides the driver with
mast and pedal-type parking Doosan Industrial Vehicle Volvo Penta Tier 4F options an uninterrupted view of the
brakes. Vibration and noise UK has launched its with the efficient Allison working environment.
are greatly reduced and a 7-Series range of 1.5- powertrain results in up “Improving cycle times for
range of safety functions 2.0 tonne electric to 10% reductions in fuel trailer movements is of vital
and devices are included. forklifts, described as consumption – or over importance when calculating
a ‘leap forward for the €4,000p/a on average. cost of ownership,” said Chris
MATERIAL GAINS market’. Improvements The two points of Booth, VP, Terminal Tractors.
After two years of decline, the include a newly designed access into the cab and flat “The new T2 provides
value of European materials steer axle, which reduces rear access platform speed optimum visibility and ease of
handling production rose by the forklift’s turning radius up the hooking-up process use. This ensures that cycle
5.5% to €58.8bn, according by 160mm to just 1,795mm for improved productivity times, machine damage and,
to the latest statistics from – more than 100mm better and reduced operating costs. ultimately, the cost of every
FEM. This was boosted by than the equivalent models It comes with ROPS/FOPS trailer movement are reduced,
vigorous domestic demand, from most competitors, certification as standard, allowing more movements
which rose 11% to €32.2bn, Doosan claims. as well as high-density per shift and greater
Global materials handling online: www.forkliftaction.com noise-reducing cabin throughput.”

GEORG STIELER, STM-STIELER
THE
HEART OF
THE MATTER
DESPITE ITS HIGH VOLUMES, THE OFF-HIGHWAY
MACHINERY SECTOR IN CHINA AND OTHER BRIC
COUNTRIES IS EITHER CENTERED AROUND BASIC
MODELS OR RELIES ON IMPORTS OF CORE
COMPONENTS. IS THIS TREND SET TO
LAST – OR CAN THE EMERGING ABOVE: Dana Rexroth’s continuously
MARKETS START OVER? variable HVT transmission is unlikely to
be challenged by anything being built in
China for some time to come
TOP: High-power engines are something

Chinese manufacturers aren’t producing
to the desired quality – yet

CHINA MARKET REPORT
The off-highway machinery dynamic market for agricultural

industries – and agricultural equipment among the four BRIC
equipment in particular – in the BRIC countries – but many observations
regions are as diverse as those four can be equally applied to other
countries themselves. What they do emerging markets too.
have in common, however, is a lack
of domestic component suppliers for Established supply system
certain crucial components, such as China’s large agricultural machinery
high-power engines, continuously industry boasts a well-established
variable transmissions, sophisticated supply system and over 60 years of
hydraulic systems and electronic history. Most of its manufacturers
controls. of tractors, harvesting machines or
This article deals with the reasons implements have a relatively high
for this phenomenon, as well as the manufacturing depth (>80%), and
different approaches toward strategy, all major domestic OEMs produce
operations and technology that axles and simple transmissions.
established western and domestic YTO and Shandong Shantuo
component manufacturers exhibit. Tractor make some engines in-house,
It concludes with a critical appraisal although parts for their heavy units
of the different ways that component are imported. Most agricultural OEMs
suppliers from emerging countries in the country tend to purchase
may close the gap on their foreign components such as drivelines,
counterparts. The focus will be on axles, steering units and electrics
China, as it is the largest and most from domestic suppliers.

MARKET REPORT
RIGHT: PMP’s drives for

construction equipment
enjoy strong sales in China
OPPOSITE PAGE:
Poclain Hydraulics’ High
Performance drive system
– a highly energy-efficient
drive technology of the
type not produced in China
A LITTLE HELP HERE…

There are several components that the majority of Chinese
suppliers cannot produce by themselves, such as:
• Heavy, high-power engines – the major obstacles here include Structured approach Rexroth or Hydac spend more than
engine vibrations, noise and emissions; Aside from these different starting 5% of their annual revenue on R&D
• Continuously variable transmissions – an essential part of modern, conditions, what are the western each year.
user-friendly and energy-efficient tractors; component manufacturers doing On the other hand, Chinese
• Hydraulics – Chinese suppliers are still weak in terms of offering differently with regard to strategy, companies still frequently follow a
highly reliable and durable load-sensing solutions for compact and
operations and technology? primarily sales-driven approach, i.e.
efficient drives;
• Electronic controls.
Foreign companies usually follow to increase market share through low
All these components are a crucial factor in the performance a more structured approach than their prices, which can result in R&D
and efficiency of the whole machine. This aspect is underlined by Chinese counterparts; they analyze spend of less than 3%.
the fact that hydraulics and drive components are responsible for their environment very carefully and Finally, there is the subject of
40% of the cost of a tractor made in Germany, but in China this set clear goals for the development internationality. Western suppliers
is even more (up to over 60%). Interestingly, the most promising of new products and technologies as have learned how to handle various
developments on this front are not coming from independent they enter new markets. They set the markets and cultures and how to earn
domestic component suppliers, but from the large tractor according measurements to reach money there. They not only follow
manufacturers themselves. these goals and control the progress their existing OEM clients around
Among the many differences between early-industrialized
by milestones. Once decided, these the world, but also help new clients
countries and China are the completely different geographical
sales markets for agricultural equipment. Why should there be a
plans are executed, with adaptations in emerging markets to raise their
multitude of sophisticated component suppliers when there is no only made when really necessary – products to new levels.
demand for those technologies? Low-income households cannot although this can sometimes also So in terms of operations, what
afford expensive agricultural equipment. be a disadvantage. are western suppliers doing better on
Western companies consider a daily basis? Firstly, they are usually
HYDRAULICS AND DRIVE innovation as a means to success; organized according to key accounts:
COMPONENTS ARE end customers pay a premium for

innovations that can help them to
this means establishing global long-
term relationships with particularly
RESPONSIBLE FOR 40% OF increase their productivity and to important clients. But key account
THE COST OF A TRACTOR cut fuel costs. Inventions can create a
competitive advantage and generate
management means not only selling
clients high volumes – it’s helping
MADE IN GERMANY, BUT IN profits for suppliers – as a matter of to improve their products, processes
CHINA THIS CAN BE OVER 60% fact, this results in higher spending and profits too – a comprehensive
for R&D. Companies such as Bosch and individualized approach.

MARKET REPORT
Internal training and education is Differing approach • Electrohydraulic hitch controls

crucial too: at the beginning of their Probably the most fundamental (HUSCO, Bosch Rexroth and Parker
working life, skilled western workers difference between German suppliers are already offering the first solutions
are typically educated in a dual and their Chinese counterparts is their for the <80hp power range);
education system, which combines approach toward technology. Western • Continuously variable transmissions;
apprenticeships in a company and component suppliers will provide • Energy-efficient drive hydraulics
vocational education at a vocational customized system solutions instead with load-sensing;
school or a university of applied of just selling parts – they help their • Software and hardware for electro-
sciences. Further training during OEM clients to realize safer, more hydraulic and electronic control.
their career helps them keep up with comfortable and more energy- Another important aspect that
technological change and to develop efficient solutions. Reduced noise western suppliers are working on is
leadership skills. and vibrations enable operators to the design of lightweight, compact
In addition, better calculation work longer and therefore increase solutions. This is a crucial aspect, as
skills often serve to help suppliers productivity. This aspect, along with reduced soil compaction results in
to control their costs, and helps reductions in fuel consumption, higher yields using less fertilizer.
them avoid entering into ruinous increase the profit of the farmer.
price wars, which we see in China One consequence of this strong Doing it for themselves?
so often these days. focus on system solutions is the Many of STM-Stieler’s clients have
Finally, a much higher degree of high degree of electrohydraulic fruitful cooperations with Chinese
automation not only helps to ensure solutions. Despite their high price- OEMs, whether these are project-
far more precise and higher-quality sensitivity, Chinese customers will no based or key-accounts. If such OEMs
production, but additionally reduces doubt soon increasingly appreciate display the courage to let foreign
exposure to rising labor costs. the appeal of technologies such as: suppliers develop complete systems,
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MARKET REPORT
EARLY-INDUSTRIALIZED COUNTRIES CHINA
Private farms, farmers are businessmen: Small and scattered farms (over 90%)
USA: 96.4% are family farms. usually below 2ha:
END CUSTOMERS
Average farm size: 176ha. However, state-owned farms, contractors and
EU: Family farms the dominating model. large-scale family farms (50-460ha) are gaining
Average farm size 14.7ha (Germany 16.7ha). in importance.
Set of rational decision criteria: 90% of sales are made through purchasing
BUYING CRITERIA
Machines must be high-performance and reliable, subsidies. The machines to be subsidized
and offer good profitability and returns. are selected by government agencies.
Private corporations with an increasingly global Primarily state-owned.
OEMs
presence, high competition. OEMs request Private OEMs suffer from a lack of funds
innovations from their suppliers to differentiate and a limited product portfolio.
their products.
Strict regulations on emissions and work Comparably low regulations concerning
REGULATORY FRAMEWORK
safety constantly force OEMs and suppliers to environmental friendliness. Low protection of
innovate. Powerful IPRs reward investments in R&D. IPRs contributes to low investments in R&D.
Strong ecosystem: R&D collaborations with Education system: does not encourage
world-leading universities, efficient value chains, creativity, dreams of overnight riches make many
OTHER FACTORS
skilled workforce. However, products have a tendency employees follow short-term goals (e.g. high
to be over-engineered and expensive. Markets are fluctuation, low incentives to build up professional
very mature. skills, copies instead of innovation).
TABLE 1: An overview of the different

environments for suppliers of agricultural a classic Chinese company culture.
components in early-industrialized But leaving your comfort zone and
countries and China
going new ways is the precondition
for change and future success.
they can lift their products to new
levels of usability and efficiency. Getting in on the act
But besides implementing some The Chinese will not remain unable
of the strategic and organizational to produce high value-added parts
patterns described above, which by themselves forever. The question
possibilities exist for domestic is, how long it will take them to get
suppliers to reach the next level? there? One promising company,
Takeovers of western companies Jiangsu Hengli, started out as a
is one option. Examples from the hydraulic cylinder manufacturer,
field of agricultural components and – after having conquered large
include Weichai’s huge stake in parts of this market – is now trying
Linde Hydraulics or YTO’s purchase to establish itself as a supplier of
of a former McCormick factory in more complex hydraulic systems.
France, with the intention of ABOVE: Load-sensing Chinese supplier companies, such as Shandong CCHC has also received
producing CVTs. hydraulics, such as low product quality, low automation good customer reviews for its
those produced by Bosch
This is a feasible option for Rexroth, are a staple levels, high manufacturing depths hydraulic valves recently.
companies looking for liquidity or product of western and underdeveloped calculation can The goal of acquiring the abilities
– this refers in particular to family- component suppliers make them unattractive partners. to produce core components with the
owned suppliers – without a suitable Hence, foreign companies have highest value-added is part of the
successor. In fact, the number of learned how to make money on Chinese government’s Made in China
inquiries reaching STM-Stieler from their own in China. The trend is 2025 strategy. However, some of the
Chinese business owners who are that foreign companies would rather obstacles on the way to this goal are
interested in acquiring western hire experienced Chinese managers rooted deeply in the Chinese culture
component manufacturers has with a successful track record of and it is uncertain when this might
increased significantly during the building up factories and powerful change. Some observers expect that
past two years. sales organizations than to join up aspects hindering China’s progress,
Cooperation between foreign and with a weak partner. mentioned in Table 1 (above) – such
Chinese suppliers is another route – An alternative, which has been as its stifling approach to education
though this option has become less very successfully applied at Chinese and short-term thinking – might
and less attractive. The legal system, companies from other industries, is become even worse during the
with the low transparency of capital to hire former Chinese employees of current economic downturn. iVT
structure and ownership, discourages western competitors and give them Georg Stieler is MD of STM Shanghai, a
many foreign entrepreneurs from freedom and responsibility. However, German management consulting firm that
entering joint ventures. The strategic this costs money and these people are specialises in the mechanical engineering
and operational weaknesses of many not always easy to integrate within industry: please visit www.stm-stieler.de

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JOERI DE VRIESERE
THE GIFT OF T
CHINA CASE STUDY
WE’VE LONG TALKED ABOUT THE IMPORTANCE OF AN ERGONOMIC

WORKSPACE, BUT FOR MOST CHINESE OEMS IT HAS OFTEN BEEN LITTLE
MORE THAN LIP SERVICE. UNTIL, THAT IS, XCMG WANTED TO WOW ITS
DOMESTIC AND INTERNATIONAL CUSTOMERS WITH A NEW-GENERATION
WHEELED LOADER OPERATING COMPARTMENT
THE CAB
CASE STUDY
XCMG has a solid reputation

on the Asian market, which is
reflected in the statistics: it’s now the
fifth largest construction equipment
company in the world. It is ranked
119th in the list of China’s Top 500
companies, 44th in the list of China’s
Top 100 manufacturing enterprises
and second in the list of China’s Top
100 machinery manufacturers.
The OEM sells most of its
machines to the domestic market,
which is reflected in its portfolio.
Although it enjoys better export
figures than most of its competitors,
the desire to increase sales in both
the international and home markets
meant some features needed to be ABOVE: Detail of the front of the new cab. We quickly sat down for noise-level reduction inside the
improved, or even implemented for console showing 12V plug, together and defined the new scope cab, the ROPS/FOPS frame, obtaining
integrated VDO display
the first time. But most of all, XCMG and louver directed to the of the project. It must be said, the a pressurised cab, and visibility. This
wanted to show – and wow – the operator engineers under the supervision of meant the OEM needed to build the
domestic market with an all-new ABOVE RIGHT: Overview of the XCMG Wheeled Loader Research new cab in a completely different
international-class cab. the final injection-molded Department’s engineering manager, manner than it had before, keeping
It was decided that one of the interior parts. The two- Zhenpo Lu, were open and eager to in mind the much stricter tolerances
tone color scheme creates
first products to receive a new cab a lighter feel contribute, so the cooperation got and upgraded material specs that
would be its 8- to 12-ton wheeled off to a smooth and open-minded would be required. XCMG invested
loaders: the LW800 – LW1200 series. BELOW: Visualization of the direction from the outset. heavily in the procedures, tools and
cab on the existing LW800
When the plans emerged, XCMG series wheeled loader One of the first key features to skills needed to obtain that goal.
found in us (Adams International) the consider was the international ruling
perfect partner for the development standards – most importantly, those Style choice
One of the first milestones to be
defined was the styling. We presented
various designs, of which the example
shown here was chosen relatively
smoothly. A consensus was obtained
quickly – that the styling reflects the
dynamism XCMG wants to show the
world, and its eagerness to show that
this is no mere evolution of a previous
cab, but a leap into the future.
Soon after the styling was chosen,
the engineering phase was launched.
This is where the tricky part came in:
how to achieve the ROPS/FOPS frame.
Because the ROPS was a key element
in this development, we quickly
presented and tested some proposals
on how the frame should be built.
Eventually, the FEA calculations
showed that using a steel tube frame
(including reinforced B- and C-pillars)
was the way to go. We combined this
with external plastic covers, much
thinner than the frame, to result in
a slim-looking cab, but one strong
enough to withstand the quite

CASE STUDY
severe forces and energy criteria styling. The tinted windows also
needed to pass the ROPS/FOPS test. partially hide the ROPS frame, again
To improve the visibility, it was adding to the desired styling. We also
necessary to avoid using a very large introduced the method of fitting the
A-pillar – the reinforced B- and C- glass using PU glue, which achieved
pillars helped to achieve this. For the airtightness of the cab so that it
extra visibility, glass was added in could be pressurized.
the lower front section of the cab. To test the ROPS capability, it was
The front window is a single-piece, necessary to build tooling to weld the
curved window – again to increase frame. Again, the OEM invested in
the visibility. To counter the dead this tooling, which although not new
angles and maximize the view to to XCMG, had not been used in its
some specific regions, the latest- cab builds before. The welders also
generation mirrors were added. displayed their best skills to deliver
The result is a spacious cab, one a perfect weld job. The ROPS could
that is fully compliant with the ROPS/ now be tested, in addition to the
FOPS regulations, while still providing visibility. Prior to the physical tests,
excellent visibility to the operator. calculations and simulations had
already provided a theoretical goal.
Mock-up stage XCMG and our team employed FEA
After more than a little effort, the calculation to compare results and
second milestone was achieved: a predict the actual test results as TOP: A-surface approval the advantage of being extremely
slim-looking cab, but one compliant accurately as possible. renders were produced accurate, and have an engineered
for discussions with the
with all international standards. This The interior needed to reflect the XCMG engineers and B-surface, making them suitable for
meant we could start to build mock- same values as the exterior, while also marketing teams many extra features. XCMG already
ups and prototypes. The frame and being slim looking, ergonomic and ABOVE: FEA was carried had some useful experience using
press parts were built using various noise reducing. The fit and finish were out to accurately assess injection-molded parts and a good
prototype technologies. This gave a key part of the total look and feel. the actual results of the supplier network, so the choice of
ROPS test
us a clear view of how the cab felt During the exterior prototype build, technique was not too ‘exotic’.
in reality, how the visibility worked we began styling and engineering A pressurized cab requires a
out, and a way to test the ergonomic the interior. Several different stylings rather voluminous HVAC unit,
base lines. were presented, and once again, the usually installed behind the driver
As for the exterior, physical consensus on the interior styling was seat, while the hydraulic system for
models were built for test purposes, quickly reached. operating the bucket also needed to
with plastic prototype parts being It was then necessary to select the be kept out of sight. Much attention
produced to show the final results. production techniques before going was given to the correct positioning
A tinted glass was chosen for the into the detailed engineering of the of these components, so that they
windows, so as to better highlight parts. Ultimately, the choice fell on could be nicely incorporated into
the continuous line in the exterior injection-molded parts; these have the styling.

CASE STUDY
Order of importance
As for ergonomics, all the operating
controls were centralized according
to importance. The A-post and side
console have been transformed into
a control area for functions related
to the operations of the machine on is able to work on an internal or a
the exterior. fresh air circuit, and features three
The ergonomic seat is equipped separate output circuits. Therefore,
with a console, incorporating all the operator can easily de-mist the
the hydraulic and electric controls front and rear windows, enhancing
related to bucket operation. The visibility, but also regulating the
head-liner incorporates the radio internal climate to near perfection.
and HVAC control, while offering As the operator’s chair is in use
the possibility for extra features. for many hours during the day, a
Finally, the steering column – good ergonomic seat was sourced.
which is adjustable in virtually all The SIP (seat index point) was
directions – and the pedals were chosen in such a way that operators
placed so as to enable the operator in the 5th to 95th percentile can adjust
to sit more comfortably, with a good it within their full ergonomic scale.
overview of the interior controls as The pedals, steering column,
well as good exterior visibility. controls and VDO display position
The use of CAD tools and software all contribute to enabling the perfect
for fine-tuning the ergonomics came ergonomic position for Asian and
in extremely handy. In the past it was TOP: All functions have The split-up of the front-lower western operators alike.
necessary to build mock-ups to test been located in the center part was done in such a way that
and on the right of the cab,
the ergonomics, but nowadays, the enabling the operator to they all fit together like Meccano to The wow factor
use of computer simulations and have a clear overview and form one big part, while actually The final result was revealed at the
a nice, ergonomic reach
computer representation techniques consisting of five visible and four Bauma China exhibition in Shanghai
can reduce both lead time and ABOVE: Exterior view of the invisible parts (the air ducts that in late 2014. The cab was very well
expense dramatically. ROPS frame, showing the were included to direct fresh air to received, the general feedback being
plastic parts used to make
The key styling feature in the the cab look slim, plus a the operator). The main reason for that XCMG had not just taken the
interior is undoubtedly the digital clear view of the removable this was to avoid expensive tooling next step, but jumped way into the
VDO display. Whereas the rest of hydraulics service panel (i.e. multiple slides in the tools) and 21st century with this cab. Both Asian
the interior parts have a textured avoid the need for excessively large and western operators and dealers
and rather dark surface finish, the tooling; both would have resulted in felt that this cab is what they need.
center console features a glossy a serious increase of that budget. XCMG spared neither effort nor
white cover. This surface has been To obtain the noise reduction cost in its desire to build this cab to a
repeated on the top console in the inside the cab, the quick wins were higher standard than its closest main
headliner, creating a feeling of unity. implemented first – noise reduction competitors, an aim in which it has
The contrasting surface finish and at the source, closing all openings in apparently fully succeeded. The
color thereby provide the cab with a the cab and good seals, etc – but the XCMG project leaders, the engineers,
recognizable styling feature that can materials were also key in this. The the production and test facility, all
be repeated in other cabs, creating a headliner and floor mat were made raised their game to produce this
family look across XCMG’s wheeled from noise-canceling materials to result, as they were sometimes faced
loader cabs. help reduce the noise level inside with new technologies or challenges
The use of injection-molded parts the cab. In fact, the need to provide – but when your end customer gives
also proved to be a great help in the a pressurized cab and improve noise you the ‘thumbs-up’, you know it
production of the center console. reduction are mutually beneficial, as was all worth it! iVT
The display needs to be oriented in a they both benefit from good sealing.
certain way for ergonomic reasons, Special attention also went into Joeri de Vriesere is co-owner of Adams
but at the same time needs to be the operator comfort in regard to International and has been developing cabs
protected from incoming sunlight. heating and cooling. The HVAC unit for major OEMs worldwide for over 15 years

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DESIGN
PHIL POPE, iVT INTERNATIONAL
FOR LIFE
IT CLAIMS TO BE THE WORLD’S LARGEST MANUFACTURER
OF RECHARGEABLE BATTERIES – AND NOW CHINA’S BYD
IS LOOKING TO EXPAND INTO NEW MARKETS WITH AN
EXTENSIVE RANGE OF LIFT-TRUCKS BUILT AROUND
ITS LITHIUM-IRON (LIFE) PHOSPHATE TECHNOLOGY
TOP RIGHT: BYD

guarantees that after
10,000 hours or eight
years, whichever is
sooner, the LiFe battery
will retain more than
65% of nominal capacity
MAIN IMAGE: BYD’s

alternatively powered
material handling range
is still growing

CHINA CASE STUDY
TOP LEFT: In
Launched last year, the BYD a planned 50-model range that

material handling range offers also encompasses reach trucks and
a choice of four conventional three- tow trucks, as well as high-tonnage
and four-wheel masted lift-trucks, a counterbalance machines.
stacker and a 2.0 metric ton capacity BYD’s marketing manager, Xian
walk/ride-on pallet truck. Produced Ou Leow, acknowledges that this
at the battery manufacturer’s new is an ambitious target, but cites the
1,000,000m2 purpose-built lift-truck factory’s capacity of 50,000 units
facility in Shaoguan, China, these per annum as the motivation for
units represent the initial phase of the planned expansion.

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CASE STUDY
The trucks sit squarely in the incorporating finger-tip controls for

popular 1.5-4.0t bracket, with the the principal functions of the mast. THE HIGH LIFE
smallest and newest unit at 1.6t Much has been made of the use
BYD’s mast offering is also pretty impressive for such a small range. The
capacity and the range currently of BYD’s own-brand lithium-iron
company offers no fewer than three basic configurations, with a carriage
topping out at 3.5t. All the larger (LiFe) battery range to provide the side-shift on the three-wheeler. Basic units are fitted with a standard two-
trucks have a conventional four- power for these units, which we’ll stage mast, giving the operator 150mm of free lift, which is fine for most
wheel layout, while the 1.6t and come to later. This may in itself be everyday handling operations.
1.8t units lose a wheel to provide a notable innovation, but in real Flexibility and stacking height can be added by going for one of the
these smaller units with a more terms the trucks themselves, while full free lift options, the two-stage giving a stacking height of 4m and the
maneuverable layout, giving a not advanced per se, do have some three-stage pushing that up to 6m. As with all trucks, though, the load
distinct advantage in narrow or very nice features that could create will restrict the lift height, so about one-third of the lift capacity will be
restricted aisle situations. value perception when customers lost at 6m. The masts are all conventionally constructed of rolled steel
Somewhat unusually though, the are making purchasing decisions. channel, rollers nesting within the section to provide rigidity. On the
full free lift options, the twin cylinders nest each side of the mast, giving
third wheel of this three-wheel variant Although it has to be said that the
a smoother lift and improving the driver’s forward vision for safer
is a double wheel, maintaining the general design is quite conventional, positioning when the load is at height.
straight line stability of the unit, yet it is well thought out and BYD has The multistage options provide a lower overall height when the truck
enhancing the truck’s maneuverability introduced some features that add is in operation, which is invaluable if it is to be used in operations where
in the aisles. The range is available in a touch of pizazz to the layout. the overhead height could be restricted, for example container stuffing.
either ‘standard’ or ‘comfort’ spec, For example, the truck has what Standard fork length is 1,070mm, while a load guard extending above
and although the base vehicle is the company defines as ‘automatic the fork carriage helps to stabilize loads during lifting and ensure that
identical in both versions, the more speed reduction’ which is triggered unsteady stacks stay in place when the load is tilted.
advanced features help to mark out by the steering angle. Should the Overhead protection for the driver is provided in the form of a sturdy
the comfort package. For example, truck be traveling too fast when the robot-welded ROPS/FOPS frame welded securely to the rear chassis and
front-axle support frame. The frame roof is actually formed by an open
this includes a Grammer MSG 65 driver attempts to turn a corner, the
vertical grid, wrapping forward down to the driver’s eye level, allowing
full-suspension operator’s seat with controller will automatically cut the for almost unrestricted vision of potential overhead hazards and the
an integrated multifunction armrest speed of the drive motor, hopefully mast, even when the carriage is at height.
ABOVE: The 1.6t truck

offers a turning radius
of 1,570mm
MAIN IMAGE: Side

charging offers a more
convenient and user-
friendly system, while
minimizing the risk
of accidents. There is
no longer a need for a
separate charger room,
meaning warehouses
can free up the large
amount of space they
currently have to set
aside for this purpose

CASE STUDY
reducing the likelihood

of a tipping accident.
A major improvement
to the existing hydraulic
circuit relief valve setup
is due shortly – should
the operator attempt to
RIGHT: A full-steel cab overload the lift system,
with heater is optional
on all models the lift motor will be
automatically shut off,
BELOW: The 1.4t stacker
is one of the most recent restricting any abuse to
products in BYD’s ever- a 10% overload. As this
expanding range system acts on the lift
BOTTOM: BYD’s motor rather than the
universal chargers can hydraulic circuit of the
charge each of its 80V lift cylinders, it also
forklifts – taking just 19
minutes to reach 50% prevents the popular
charge in the case of drivers’ trick of lifting
the ECB16C
an excessive load by
using the tilt cylinder
to pull the load clear
of the ground.
The electronics also provide what
BYD terms the Braking Assist System,
maintaining the truck at a standstill
after the mechanical park brake has
been released, even on a gradient. A
clear indication of the truck’s status
is relayed to the driver via the
multifunction TFT screen, which
offers an insight to the condition of
the battery as well as the accumulated
and individual shift working hours.
The screen also shows the vehicle’s
speed, speed mode setting, and even To the fleet owner, the biggest
the time of day – all housed in a advantages are cost and flexibility.
clear, easily read binnacle. Xian Ou Leow quotes a potential
saving of €4,000 (US$4,500) per
Work/LiFe balance annum based on a vehicle working a
The use of a lithium-iron phosphate two-shift day. Where does this come
battery in these vehicles will clearly from? Well, the lithium-based battery
offer some quantifiable advantage has a much longer useful life versus
over the more common lead-acid lead acid – BYD claims that most
cells. Smaller advanced batteries have owners (assuming a 10-year vehicle
been used by model makers in cars life) will never have to replace the
and aircraft for some years, so it was battery. As they age, lithium batteries
inevitable that these would eventually do not lose capacity at anywhere
develop to accommodate industrial near the same rate as the lead acid
and automotive applications. variety, and are approximately 90%
efficient versus around 65-70% for
BYD lithium iron phosphate technology – fast-charging times and equivalence table lead acid, while the total projected
BATTERY BATTERY CHARGING TIME number of charging cycles to failure
is much higher. The actual effective
AH V Nominal kWh BYD 90A charger BYD 180A charger
life storage capacity of lead acid is
230 80 18.46 2.5hr 1.2hr therefore said to be less than a third
BATTERY EQUIVALENCE TABLE of an equivalent LiFe cell.
Nominal kWh Available kWh In practical usage terms, there is
no hydrogen gas emission during
LiFe technology 230 80 18.46 16.6 (90%)
charging, no risk of explosion, and
Lead-acid technology 450 48 21.6 17.3 (80%) no energy loss due to warming. And

CASE STUDY
ALL WALKS OF LIFE

BYD’s pallet truck is a conventional 2t ergonomic design for the controls, in the machine changing direction,
lift-capacity design, using a tricycle- giving ease-of-use regardless of hand thereby alleviating the possibility of
layout pallet truck, with drive to the size, with an emergency stop effected the operator being crushed against a
steered front wheel coming from a lift by putting the handle at the vertical wall, for instance.
cylinder acting on the twin undriven or horizontal position. Electric power The company has also fitted the
rollers set into the forks. Motive power steering enhances maneuvering in pallet truck with what can only be
is via a single drive motor/hub in the tight situations. In addition, there is assessed as an ad hoc ride-on facility
main body of the machine, powered also a clever reversing feature built comprising a fold-down footplate and
by an integral 24V input, as opposed into the end of the handle, which folding hip guards to either side. When
to the 80V system seen on the automatically reverses the machine these are unfolded, the truck can reach
counterbalance units. when a pad on the end of the unit is 12km/h, but when just one element is
BYD contends that the steering/ depressed. Contact with the operator unfolded, the speed is reduced. It also
control handle incorporates an in a ‘pinning’ situation would result features cornering speed reduction.
that most controllers built into

trucks with systems designed for lead
acid will not handle the voltages of
the LiFe battery packs, which run 80V.
Dave Lamb of Sevcon UK elaborates:
“Our (Sevcon) Gen4 controllers can
be connected to systems with either
lead-acid batteries or one of the
various forms of lithium battery.
“The main thing to check is that
the minimum and maximum voltage
range for the chosen battery is within
the allowed range of the chosen Gen4
controller; most 48V controllers will
operate down to 20V and up to 69V.”
as the electrolyte is not evaporated charger, which may be inconvenient ABOVE/LEFT: The Another drawback for the would-
by the process, there is no need to for those running a large mixed fleet. ergonomically designed be converter is that LiFe batteries are
steering tiller of the 2.0t
add distilled water during charging, In general lithium-based batteries pallet truck ensures size-for-size lighter than lead acid –
or to either site chargers in vented are less forgiving if inadvertently over- optimum control of the not ideal if you need to stick to an
areas or provide additional extraction. discharged, but BYD’s BMS ensures electric power steering existing counterweight configuration.
TOP: Efficient top-
Far from exhibiting the memory 5% of the battery capacity cannot charging is employed for
Going back to the BYD lift-truck
effect typical of lead acid cells, by be used under any circumstance. Also, the pallet truck, using range, these come to the market as
which recharging an only partially at 10% SoC, lifting is interrupted to BYD’s own advanced a practical and well-thought-out
charging unit. This
discharged cell results in a partial ensure the forklift can be driven to is equipped with a offering. The rest of the technology,
total charge, LiFe batteries actually the charging point. computer that interacts while perhaps not groundbreaking,
thrive on partial charging, so the Another point – which BYD isn’t with the BMS to ensure is innovative and familiar, being
optimal charging speed
trucks can be ‘topped up’ whenever emphasizing – is that size for size, clearly based on similar designs.
they are not working – during breaks, they are more expensive. However, The company is first and foremost
etc – which means more productive Javier Contijoch, forklift director at a battery manufacturer, so it could be
operation between major charges. BYD Europe, told us, “The benefits assumed that, in addition to carving a
The ability to cope with deep of LiFe technology will be provided new niche for BYD, this warehouse
discharge also effectively means that at what is effectively no extra cost to truck range may have been released
the damaging voltage drop-off seen the users. The combination of fast to demonstrate to the material
in lead acid cells is not present. Add charging in breaks and lunch hours handling sector just how versatile its
to this the fast charge rate (typically is sufficient for the majority of users battery products are. As technology
two hours for a full charge) and things to work three shifts with one battery.” advances and environmental issues
are looking pretty good for the LiFe press, the industry will surely have
battery. In fact taking things on face Partners for LiFe? to move away from lead acid as a
value, the whole package does. There Any OEMs looking to integrate BYD’s storage medium. With this range,
are caveats – for example, the BYD commercially available batteries into BYD may well have shown others
trucks will need their own dedicated their own product should be aware the route to follow… iVT

CHINA
’N THE HOOD
BOYS

OEM INTERVIEW/CASE STUDY
RICHARD CARR, iVT INTERNATIONAL
FAR RIGHT: The core of

LiuGong’s 856H design
team guard their
handiwork at bauma
China 2014 (left to right:
Jamie Holmes, Gary
Major, Rich Killgren and
Ed Wagner)
CHINESE EQUIPMENT DOESN’T HAVE THE BEST

OF REPUTATIONS, BUT LIUGONG’S FORWARD-
THINKING TEAM OF WESTERN DESIGNERS AND
INNOVATORS APPEARS TO BE TAKING WHEELED
LOADER DESIGN – AND THE OEM’S ENTIRE
OUTLOOK – INTO A WHOLE NEW AREA
If I were to ask you to think of Beatenbough, VP of R&D, formerly of

a type of Chinese construction CNH, and his hiring strategy that has
equipment, and then correctly guess secured the creative talents of, among
that you picked the wheeled loader, others, Ed Wagner, director of new
D
only the most gullible showbiz agents technology and director of test, from
would be beating a path to my door CNH, Gary Major, director of ID,
to sign up my off-highway-themed from JCB, and Jason Izzard, now
mind-reading act. It’s a machine that’s director of quality at Dressta – and
not just ubiquitous in operation over emphasizing industrial design as the
there, it’s the must-have product in cornerstone of its new approach.
any OEM’s portfolio. Much of that
Chinese product is often of the cheap, Vive la differentiation
though not always cheerful, variety, Gary discussed his ‘mission statement’
so providing some key differentiation in our September 2011 issue (p14),
is always going to be key to success – and the subsequent implementation
and for it to take on the global market of an in-house ID department has
leaders is definitely an ambitious plan. now borne fruit with LiuGong’s first
Nonetheless, that’s what LiuGong ID-authored product, the 856H.
has in mind, and its development of “It’s the first of many next-
the 856H – seen in prototype at bauma generation projects that will inject
China 2014 – is a good example of the range with the new genetic code
how the company as a whole has and start the product differentiation
been evolving from a purely domestic phase I alluded to,” he says when I
OEM, into one producing machines catch up with the team at LiuGong’s
for the global market that it believes Stoke, UK, design studio.
are as good as anything those in the But is it actually possible to create
West have to offer. Much of this has differentiation in such a tried-and-
to do with the masterplan of David tested product as a wheeled loader?

LEFT: An early view of

the hood assembly and its
integration with the rest of
the machine
INSET: There’s now

additional volume and
a larger chamfer on the
rear bumper, but Ed’s still
working on a way to make
the hood overlap it
“Yes, absolutely!” confirms Ed. “By ‘clever’, I mean we’re always No problem
“The key to finding opportunities is looking for the simplest, cleanest So what were those problems they
when you look across the spectrum possible solution that has the exact saw, exactly? By way of illustration,
of what’s been built. Everybody’s same functionality, or sometimes Gary picks up a scale model from the
doing articulating frames, the Z-bar more, than our more complicated previous generation. “Everybody’s
and rigid axles, so if there are any previous solutions. Count the hinges, doing that rear hood differently,” he
opportunities there, they’re going to latches and little doors, etc, on your says. “We’ve tried to dial out some
take a lot more digging to figure out. typical Chinese wheeled loader, or of the bad habits – sometimes you
“But where I see variation, I know measure the meters of shut line, and could even see a door within a door!
we can do something better. Hoods, you’ll find it’s actually an extremely On our old machine, these side panels
cooling systems, the other associated complicated design. stayed in place when the hood was
bits of the superstructure; they’re all “You’d see the same thing on a raised meaning some poor guy had
over the map. That tells me there’s a Cat, for example. So we were looking to wrestle himself in behind the tire
lot of suboptimal – even bad – design at minimizing all those things, while to release the fixings and take them
out there, so those are the places we achieving all the functionality that out of the way. So, firstly, we wanted
focused on to raise our bar – either we needed.” to move away from the old way of
“WHERE I SEE VARIATION, I KNOW

level with the leaders in the industry, hinging it, to optimize access to the
or sometimes better.” cooling pack – we’ve created a really
So how does the 856H differ from WE CAN DO SOMETHING BETTER… big hood structure compared with
its Chinese contemporaries? “First
of all, the core of the design was
HOODS AND COOLING SYSTEMS some, and just hinging it differently
[Jason’s bright idea was for it to pivot
done by a very small group of very ETC ARE ALL OVER THE MAP. up from behind the cab] is a perfect
experienced team members, who THAT TELLS ME THERE’S A LOT example of designing for the user.”
come from completely different
perspectives,” Ed continues. “First OF SUBOPTIMAL – EVEN BAD – Next he points to a strange hole:
“It’s no wonder there was an inherent
we had to understand each other’s DESIGN OUT THERE, SO THOSE disinclination to lift up the hood for
perspectives to get a handle on the ARE THE PLACES WE FOCUSED filling the radiator – that’s why there
problems that we saw with not only
our own machine, but everyone else’s, ON TO RAISE OUR BAR” was this hole in the top of it!”
“Over time, dust gets inside and
and come up with clever solutions. Ed Wagner, director of new technology & director of test becomes like concrete,” adds Ed. “You

end up with latches and hinges that

just don’t work anymore, as well as
ON THE WEB
asymmetrical shut line gaps all over Exclusive sketchbook charting the 856H design process:
the machine – it just looks worn out. www.iVTinternational.com
“But not all shut lines are created
equal – a button-up shirt has one, but
it’s an overlapping one. If one edge is
moving around, you don’t notice it.
So where the hood meets the frame,
we overlap it. We’ve minimized the
number of areas where the shut lines
actually come together edge to edge
and we have far less than anybody
else, Chinese or otherwise. I haven’t
figured out a way to overlap the
bumper yet, but by minding the
gaps and ensuring the background
is dark, it hides any variation there.”
“In some ways, that has been
beneficial to us,” clarifies Gary. “Our
new DNA incorporates the core values
of Stance, Proportion, Symbolism and
Detail and introduces our new dark
gray and yellow color-way philosophy
to communicate a stronger message
of intent. Our older ‘yellow-centric’
color schemes had a whiff of weakness
and vulnerability about them, just
like in nature: it’s like comparing a
duckling with a hornet! Also, by “Gradually, we’ll gain more of
introducing more of the dark color, an understanding of user-experience
and reducing the gloss level, that design, where we are really learning
will help hide any defects, visible from talking to these guys.”
fixings and surface anomalies. “Our engineers are not used to
“Things like that have helped in getting negative feedback and seeing
terms of making the machine easier it as a positive,” Gary interjects. “But
to assemble, but it also looks higher we do, as we’ve learned something.
quality, as well as a lot harder edged, There’s no such thing as failure in
than our old products. And the DNA our books, but in Chinese culture,
you’re seeing there is now dropping it’s different.”
onto just about everything we do.” “When they tell us something’s
As good as this all sounds, I can’t bad, there’s nothing wrong with
help asking whether such attention taking it on the chin and saying,
to detail has an unfortunate effect on Do you really like it? TOP: Work on a new ‘Thanks for telling us, we’ll dial it
bucket shape for the
cost – not something that is easily The H-series has been designed with H-series adds 5-8% in out of the next one’,” Ed agrees.
surmounted when the bulk of your enhanced visibility, improved user terms of productivity. “Traditionally, any sort of failure
sales are to the Chinese market. interface, easier serviceability, better- Pictured is the top of has been seen as a bad thing, but
the range 890H
“Actually, by simplifying things so quality componentry and enhanced it’s worth its weight in gold!
much, we’ve driven quite a bit of durability all high on the customer INSET: The hood hinge “But what was certainly a major
cost out of it,” Ed affirms. “The old wishlist – because a growing part of line immediately behind change for LiuGong, and probably
the cab opens up access
model had 17 hinges and 12 latches. the design brief is now based on the to the service points to a unique among Chinese OEMs, is
Now it has two of each – and it only ‘voice of the customer’, reveals Ed. previously unimaginable that we did rigorous full reliability
level
has two latches so that if one of them “We tend to hand a machine over growth testing of the 856H before it
gets damaged, you can still use it. And to the customer for a few hundred went into production. I think we had
the new overlap joint makes life a lot hours, rather than just call him in more than 50 machines, running
easier when it comes to manufacture for a few days. Chinese OEMs seem more than 50,000 hours in various
and assembly, too. to get their prototypes into the hands configurations and with different
“I think that’s at the core of our of the customers far sooner than we engines. That way, we discovered
design philosophy, it has to tick all the ever did in the USA. There’s some hundreds of tiny, detailed problems
boxes: aside from the aesthetics, does good and bad with that – but mostly ourselves, rather than pushing a
it have better serviceability, reduced good – and definitely in more of a machine out too early and letting
cost and higher reliability?” hands-on way than I’m used to. the customer find them.

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“So the refinement of it was the different divisions, spread out all
definitely greatly improved – and across China, to commonize on parts.
warranty issues are quite low for “I remember counting six different
such a new product.” light clusters, all on the same series of
Other new approaches to the machine,” chimes in a clearly shocked
development process include the Rich Killgren (A luxurious background,
founding of a North American p41), who’s been quietly beavering
engineering team, focusing on away behind his monitor up until
structures and mobile hydraulics, this point. “They are astronomically
while back in the PRC there is a expensive to produce – and it’s more
push to create cross-functional trouble to use six of them when we
teams rather than the previous could have had one!”
individual, small groups who had “We’ve made the 856H cab work
very little communication with the across a big chunk of the series – the
engineers working on other models. 877, 886, 890, and we’re going to go
“We appointed a guy to head up up from there,” claims Gary. “We’ve
a group that just looked after hoods,” managed to design it to work well
Gary elaborates. “They were able to with everything else that’s around
come up with the best solution for experience. Whenever I’m in China, ABOVE: There’s no it, without looking ridiculous.”
how we mold it, how we create the we’ll try to have some kind of social debating Ed’s assessment Taking that idea to its logical
of the looks of LiuGong’s
substructure to hinge it. They learn event with these guys – it’s not just a single-drum rollers (see extension, then – could this new
a little bit more each time, and then bit of a blokes’ night out, it’s actually box below) but production cab even be used on entirely different
is still some way off at the
that knowledge transfer goes in to the serving a really good purpose, because moment
machines in the LiuGong portfolio?
next type of machine they work on. by the time those guys are online and “We are looking at that, but there’s
“We are looking at the long game effective, you’ll see a huge surge in obviously different functionality from
– one of Ed’s brilliant ideas was to terms of what we’re doing.” a loader to a grader, not to mention
start building up a relationship with the transportation side of it,” Rich
the really good, open-minded young Common denominator responds. “But maybe we could
engineers we have coming up through In a similar manner, there’s now a standardize the cab a lot more than
the ranks while they’re still gaining big push to reduce costs by getting they have done. My philosophy is,
THE DIFFERENCE A SKUNKWORKS MAKES IS PATENTLY OBVIOUS

develop ideas that come from a
conversation in a bar or whatever –
regular brainstorming sessions will be
encouraged and become the norm in
product development meetings.
“Ed’s a real ideas man, so we’ll be
able to help take them to the next step.
And we’re always looking at technologies
from vastly different business sectors to
maintain the evolution of the operator
environment – the user experience And what about the next generation
associated with our products is going of LiuGong products? Is it true that some
to become an exciting one…” potentially game-changing technologies
So what is Ed working on now then, are in the pipeline?
if that’s not a rude question? “We’re “There are some things I’m just
busy with product definition on the bursting to tell you, but I can’t, until
Designed for iVT’s November 2012 Design Challenge, the next generation of excavators and I’m we get the patents nailed down,” Ed
Tautona LHD may be a sign of things to come from LiuGong extremely excited about some new teases. “All I can say is that we’ve got at
bulldozers we have in the works. least four ideas in the skunkworks that
Gary Major, in particular, is very excited last piece in the jigsaw and, along with “There’s also a grader that carries will rewrite the rules and are going to
about the future at LiuGong, following a new industrial design procedure as a over a lot of what we learned on the H- really scare some people!” Gary adds.
the completion of its new R&D facility mandatory part of the product design series; some compact track loaders for “The 856H is great, but nowhere near
that will lead to an expanded industrial process, ID will have full authority on North America; and a family of new what it could be – it’s one of those that
design footprint. Both the UK- and China- the A-surfaces,” he beams. “And I’m forklifts, electric and diesel. Our tandem we’ve had to let go, like a sacrificial
based design teams are set to grow, with delighted we now have a small but fully roller should be up and running fairly goat, because it’s the testbed for all of
rotation of team members between these functional skunkworks orchestrated soon, but while our single-drum roller our ideas,” he admits.
sites to begin shortly and enable cross- by the synergy between ID and our prototypes look really nice, they are still “We had to make compromises on
pollination of ideas to naturally occur. expanding New Technologies group not meeting the requirements of the some of our big ideas to hit time targets
“Having permanent ID capability headed by Ed. It also has dedicated LiuGong Design Process, so they still on launch. This is the first step, and it
between the two sites will become the ‘thinkubator’ areas, where we can need some work.” really is a ‘watch this space’ thing.”

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LEFT: Even the moody Again, however, that is somewhat

lighting can’t disguise the
impressive features of the
complicated by those multimarket
rear hood design considerations. “Can our dealer in
the UK handle carrying curved
glass?” asks Ed. “Of course he can –
but what about Nigeria, Cambodia…
that’s a very different question.
“Uptime is king, and all these
other things don’t matter a bit if the
machine’s parked up. In that sense,
it’s far more challenging than the
engineering work I did in the USA.”
Window on the world

Nevertheless, the cab – which, for
the first time, was designed using
real-time ergonomic analysis – is not
the uncomfortable Spartan offering
produced by many Chinese OEMs.
Although software-driven systems
had been used previously, the H-series
cab was shaped following extensive
testing on ergonomic bucks using 5th
to 95th percentile subjects, who were
encouraged to be as critical as they
if you can make a cab serve a larger
range of vehicles, you can make it “THE BIGGEST PROBLEMS ARE were praiseworthy. Ultimately this
had a huge influence on the location
nicer, rather than save money. It’s WHEN SOMEONE SAYS ‘IT’S FOR of primary, secondary and tertiary
the approach we took in the car
THE DOMESTIC MARKET’. LIUGONG controls, giving the interior a much
IS A GLOBAL OEM NOW – WE’RE

industry – if we made something more feel contemporary feel.
cheaper where it wasn’t visible, we “In terms of visibility, reach
would bargain for an extra bit of NOT DESIGNING ANYTHING JUST envelopes and general user interface,
chrome trim on the side. More
attractive design will sell more
FOR THE DOMESTIC MARKET!” it’s chalk and cheese compared with
what we had before,” says Gary.
machines, which boosts the Gary Major, director of industrial design
company profile!”
However, this commonization the hood around it – then swapping
becomes more tricky as LiuGong is in the lower-tier engines is relatively HE’S FROM A LUXURIOUS BACKGROUND
supplying its machines to emerging easy. But of course, there are all the One relatively recent addition to the same as working with 0.3mm
and established markets alike. different mounting points that need Gary’s design team is ex-Bentley tolerances at Bentley, but I will try to
Competitors such as Cat and Volvo to be worked in – there are no two designer Rich Killgren, disproving push it toward that. Can we make
have the advantage of their value ways around that, unless someone the common belief that off-highway that gap tighter? Can we make that
Chinese offerings and premium comes up with an engine platform designers are all just frustrated radius a bit tighter?
wannabe sports car designers. So “On the other hand, because of
western brands enabling them to that will run all the way from Tier 2
what attracted him to jump ship? the scale of our products, it actually
cover all the bases, while LiuGong to Tier 4F.”
“I like to think I’ve come in at a serves us better to make some things
is working from a single platform. “It’s given us an aesthetic challenge totally different angle,” he begins. deliberately big. Like on our new
“A Chinese wheeled loader is as well, because we’ve had to deal with “Expertise is quite nicely spread grader – it wouldn’t look right if it
designed for a much wider range of all the different positions for the pre- around the team – that’s why we had little airy-fairy split lines. They
markets than a Volvo or Cat,” agrees cleaners and exhaust routing,” adds are a really good team, because look better if they’re chunky and
Ed. “We have targeted very under- Gary. “We have to disguise all manner we’re from completely different rugged, like a Yorkie bar. So I’m
developed markets for this machine, of different options with different disciplines. At one extreme, you’ve finding it all very interesting…”
but are also taking it into Europe and variants of that shaker hood.” got Jason saying ‘Machine design
the USA – that’s a lot of range for it And just think of all the different is all about functionality,’ then
there’s Ed, a genius at innovation,
to handle. So while the structures are radiator-fill port locations you’d have
while Gary and I come in from the
pretty much the same, we’re using to incorporate, I quip.
‘Its got to sell, let’s make it look
different engines, drivelines and “Yes, we’re trying to make the cool’ approach. We still believe
hydraulics systems. hood more commonized across all that the people who buy these
“Incorporating different engines markets,” Ed says, “although the spec things still think, ‘If it looks right,
isn’t nearly as hard as going from, level of the cab is different, like the it probably is right.’
say, Tier 2 to Tier 4F. You have to start seat and the controls. The visibility “But with our totally different
off with your largest space claim, to is set by the glass and the sheet metal, backgrounds, Gary and I can cover
handle the heat rejection, and design so that will all be common.” both bases. It’s obviously not quite

“We tried to design as much as we ABOVE: This earlier over the world, we can’t really push daily checks can now be done from
could with an inside-out approach, iteration of the cab design something like bespoke glass.” one side, at ground level.”
doesn’t highlight the grab
starting from the operator himself, rail that now extends all Manual cleaning of all that glass That user-friendliness has been
because on the older machines, it the way around the roof is now easier following the creation evident in conversations with many
wasn’t a great environment to be in. TOP RIGHT: A 360° grab of a walkaround area for the entire operators, even those in the UK. “So
The ergonomics were poor, and the rail in association with cab. “We came up with this idea to far, the feedback we’re getting from
visibility wasn’t great. With this one, a walkaround area all ensure accessibility around the whole them is really good,” Gary claims.
around the cab enhances
we’ve tried wasping in as much of the operator safety thing, with a grab rail around the “One of the guys said it was like
hood as we can, to optimize the rear roof you can hold on to,” says Ed. going back 15 years – but in a good
visibility – and it’s only going to get ABOVE RIGHT: For the first “On a lot of our competitors’ way! Meaning the simplicity of it,
time, real-time ergonomic
better as we get cleverer with the analysis was used for a machines, they’ll put a sticker on that nothing’s going to go wrong.
Tier 4 packaging.” LiuGong cab layout, putting top of the hydraulic tank that says “We achieved all that by actively
the operator at the center
A key factor in this improvement of things ‘No Step’. So how are you supposed designing around the limitations we
was the switch to a four-post design to clean the rear window? Everyone knew we were going to have. That
from the initial six-post arrangement steps there – so make it a real step, said, I’d love to go back to some of
– another simpler approach that has make it safe for them to do their job. the early H-series stuff I worked on
a beneficial effect for the operator. Don’t just add a sticker there saying and have another look at retractable
“We made sure everything was in ‘Don’t Step Here’ when you know steps, a fully integrated heavy-duty
the right place, making sure we had that everyone will!” FOPS guard, etc, that were sidelined
visibility to the four corners of the because of complexity, cost or the
machine,” Gary continues. “But the Service with a smile fear factor.
only curvature in the glass is on the “Serviceability was a major focus,” “It can be difficult getting some of
center section of the windshield – he continues. “We used SAE J817, the guys out of the domestic market
although just that one part alone which allows you to quantify the mindset when some of them haven’t
makes a huge difference. score for all your daily checks and even set foot outside of China. Some
“We were always wary about your regularly scheduled service. of the biggest problems we have are
going to extremes with curved glass, That was a huge part of our decision when someone objects ‘It’s for the
because flat glass is better in terms for coming up with the hood the way domestic market.’ But LiuGong is a
of absolute clarity, and it’s certainly we did, which really optimized that global OEM now – so we’re not
easier to replace. As Ed said, until score. Even at CNH, we never really designing anything just for the
our dealer networks are mature all quite did it on this scale. So all our domestic market any more!” iVT

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D E SI GN
WITH THE DESIGN CHALLENGE FEATURE NOW
MAKING ONLY OCCASIONAL APPEARANCES
IN THESE PAGES, WE TURN OUR ATTENTION
TO SOME OF THE BEST INDUSTRIAL VEHICLE
CONCEPTS COMING OUT OF CHINA
Fang He, Hunan, China
Human habitations are all-too frequently ruthlessly devastated

and swallowed up by natural disasters and wars. After such an
event, it is crucial to let those people affected by it regain
confidence, come out of its shadow, and build new homes. Great
progress has already been made with disaster-relief machinery,
but considering the huge expense, in terms of both funds and
time, the problem of post-disaster reconstruction has not yet
been properly solved.
Designed by me, along with – in no particular order – Jian Shi,
Xiaoyi Li and Jingjie Ban, Genesis is a system for post-disaster The print head is the core of Contour
rapid reconstruction, with the ability to recycle construction Crafting techniques, printing layer by
waste materials and rebuild habitations quickly. By employing layer, according to preset programs
the most advanced Contour Crafting technology, Genesis clears
up and collects construction waste from devastated areas and
turns it into 3D print materials, achieving the desired aim of fully
reusing resources, speeding up reconstruction, and reducing the
need for landfill.
hefangapply@gmail.com • www.fanghebaron.com
The mechanical arm can grasp bar-shaped

auxiliary building materials, using them to
construct a roof, for example

CHINA
N DISTRI CT
Can be raised during work
mode to provide a better
observation perspective
Can be assembled after

basic construction machines
are all set
Exterior cameras monitor
the road condition; an interior
camera monitors construction
status Provides access to observe
the mixture of material
inside
Provides illumination during driving

or for construction status
caption
Produce and store 3D
print material
Quick adaptation
to the construction
environment
+ +
MAIN MATERIALS AUXILIARY MATERIALS 1 AUXILIARY MATERIALS 2
1: Genesis stretches out working arms Recycled building Magnesium-based Calcium phosphate
materials powder materials glue channel channel
channel
2: Genesis raises working arms
3: It extends working railways = 3D PRINT MATERIAL

DESIGN DISTRICT
Wesley Tong, Hong Kong, China
The AT Forklift (all terrain) was a student concept for future forklifts
that addressed the need for transporting large and/or heavy cargo
over rugged terrain. The design itself may seem familiar because it
was inspired by iconic movie concepts, including Star Wars,
RoboCop and The Matrix.
After analyzing and selecting the most suitable walking
mechanism, it was then integrated with the gyroscopic-
controlled neck that connects the cockpit or ‘head’ with the
hydraulic forklift. This way, when the forklift is moving over uneven
surfaces, powered electrically and hydraulically, both head and
cargo can maintain their center of gravity, preventing it from
wobbling and shifting out of place. To relieve some of the stress from
the neck and provide extra balance to the overall unit, when the fork
extends to lift the pallet, a counterweight at the rear extends in the
opposite direction.
Other details such as headlights and rear lights, and cameras for
covering blind spots under the belly, were also added. Overall, the
AT Forklift may be a far-fetched idea, but it was definitely a fun and
instructive project to study and work on.
wesleytong322@gmail.com • www.coroflot.com/wesleytong
iVT
ON THE WEB Septembe
r
For extra content, visit: 2014 p38
www.iVTinternational.com/design_ BICES
district.php DESIGN
COMP

DESIGN DISTRICT
RIGHT: The rear

counterweight extends
to balance the load on
the forks
LEFT: The AT forklift
is designed for efficient
one-person operation.
The operator is strapped in
behind a large panoramic
viewing canopy, with the
view beneath and other
blind spots being shown
on multiple mini displays

JON LAWSON, iVT INTERNATIONAL
MOBILE CRANES HAVE LONG RELIED ON THE POWER FROM TWO

ENGINES TO PERFORM AT THEIR HIGHEST EFFICIENCY. SO WHY
ARE SOME OEMs NOW SWITCHING TO USING JUST ONE – AND HOW
IS IT SWEETENING THE DEAL FOR THEIR CUSTOMERS?

ENGINES & EMISSIONS
The desire to reduce maritime models (see Drop the dead

operator costs, increase donkey engine, p54) – it seems that
performance and productivity, the latest trend in the sector is now
and adhere to the increasingly to design out the smaller, ‘lifting’
stringent emissions regulations is engine and instead make far more
leading several manufacturers of efficient use of a larger unit that has,
cranes to carry out some radical up until now, been largely reserved
surgery on their machines. for traveling to the job site.
While the use of two engines has So what are the reasons for this
traditionally delivered the sweet spot trend, how widespread is it – and is
for mobile cranes – not to mention it set to continue?
MAIN IMAGE: Terex AC 1000

all-terrain cranes drop in
Mercedes-Benz’s popular
OM 502 LA engine. Only the
reduced fuel consumption
and a few other operational
benefits provide a clue to
the slimming-down process
– performance remains
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ENGINES & EMISSIONS
Crane surgery Final-specified cranes, accompanied

Well, for starters, Manitowoc is now with the ongoing discussions about
performing an engine-ectomy across Euromot 5 in 2018/2019, all of the same tasks such as ABOVE: Grove’s GMK5250L
features the Mercedes-
its entire Grove line-up, ranging from sensor kit that’s required and the telescoping, slewing, hoisting and Benz OM471 LA engine
the 40-ton capacity 2035E, a twin- AdBlue, that’s a lot of technology – boom elevation – and has measured – combined with the
axle model, up to the seven-axle, it’s like having a mobile chemical lower overall fuel consumption on innovative VIAB clutch
and Mercedes G280
450t capacity GMK7450. factory on board. There’s the real the larger engine running on lower transmission for
Andreas Cremer, global product incentive to eliminate one engine!” RPM. The single-engine configuration optimum performance
director for All-Terrain Cranes and comes out a clear winner.
BELOW: Simplified
Truck-Mounted Cranes confirms, “We Liquid diet “This is an operational matter,” layout of Grove’s
are just in the process of changing Further incentives lie in improving he explains. “We work closely with single-engine concept
the whole range to a single-engine the fuel consumption. By studying our customers, who tell us most of
design. Traditionally, everything up how customers use its machines, this the time they are not operating, but
to 80t was single engined, with two knowledge has enabled the OEM to in idle mode waiting to do the lift.
for everything above. The first big work with engine supplier Mercedes- The engine is just running to keep the
single-engined crane we introduced Benz to optimize the RPM-range, air-con on and the displays going.”
was the 400t GMK6400 at bauma in and therefore enhance economy. To accommodate this practice, a
2010, with deliveries starting in 2012. Cremer has compared a typical fuel-save mode is offered, such as on
That was joined by three more models working cycle of a single-engine setup, the 5250L, where auxiliaries such as
this year, all being shipped right now. operating at around 1,200rpm, with a the hydraulic pumps wind down,
All of our range will be single-engined dual-engine setup, where the smaller allowing the engine RPM to reduce.
by the time we move to Tier 4 Final.” superstructure unit operates between Also optional is a tiny generator
Cremer sees many advantages 1,800-2,000rpm when performing the engine, purely to supply the electrics
in the single-engine design. Firstly,
bearing in mind the 12t per axle rule,
weight: “As a design philosophy we
are trying to get as much crane as
possible on each axle, so if you can
save, for example, 500kg, this equates
to better performance for the same-
sized package. Good examples are
the GMK6400; and the GMK5250L,
which offers the best load charts in
its class with a 70m boom.”
Another huge advantage of
removing an engine concerns the
exhaust emissions – it’s much easier
to design, fit and maintain one set
of aftertreatment than two. Cremer
continues, “Considering the Tier 4

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ENGINES & EMISSIONS
“THE GOAL OF THE SINGLE-ENGINED

DESIGN WAS TO HAVE NO INCREASE
IN FUEL CONSUMPTION, AND WE
ACHIEVED THIS IN PART BY USING
MECHANICAL DRIVESHAFTS
Wolfgang Beringer, crane marketing division, Liebherr
and air-con. “This is not just for fuel

economy,” emphasizes Cremer. “This
little pony engine transfers some of
the operating hours away from the
main unit, further extending
maintenance intervals.”
And that’s not all. “For those
customers with access to electricity
at the site, we offer a plug-in option
for the air-conditioning and display
systems. We are trying to electrify
our cranes, and I predict more
hybrid systems in the future.”
From an installation perspective,
there were potential areas for trouble,
such as leaking swivels, but these
were dealt with at the design stage.
For example, on the GMK6400 a by the LTM 1160-5.2 – Liebherr’s term maintenance gains. “Another TOP & ABOVE: Liebherr’s
simply engineered unit with two latest single-engined mobile crane is factor in having just one mechanical LTM 1300-6.2. A mechanical
shaft ensures a particularly
upward and two downward ports is the 250t LTM 1250-5.1, featuring a driveshaft,” he continues, “is that it high efficiency level while
used to take hydraulic pressure to 400kW in-house engine. can be disconnected automatically low engine speeds provide
sufficient power for crane
the upper level, avoiding all the Wolfgang Beringer, from the when the engine is idling and then work. The lower weight can
complications of the smaller models. OEM’s crane marketing division, says, reconnected by the intelligent be compensated for with
The hydraulic pumps, driven by a “It is difficult to draw performance controller in a matter of seconds load-bearing components
to increase capacity
hydraulic motor, are mounted in comparisons between this and a twin- when it is required, which also
the superstructure. On the new engined crane. The nearest is our enhances economy.”
GMK5250L, a mechanical shaft 220-ton LTM 1220-5.1, which has a
drives the superstructure pumps. 370kW engine in the chassis and an Intelligent motor
The single-engine packaging does 180kW engine in the superstructure. Terex currently offers a mix of one-
lend itself to several architectural “The goal of the single-engined and two-engined cranes. Michael
changes to simplify maintenance, design was to have no increase in fuel Klein, product marketing manager
but as the required aftertreatment consumption, and we achieved this in for all-terrain cranes, says, “In the
has expanded, it is not all plain part by using mechanical driveshafts past, most of our models were two-
sailing. However, Cremer notes, in the superstructure, with the gear engined, but emissions legislation
“There is now more onboard shafts routed from the distributor gear is increasingly driving us toward a
operator storage, and by moving in the chassis via two miter gears single-engine design, as this is a
things about we can make things through the center of the slewing ring more ecological solution.”
such as the oil sample ports more to the pump distributor gear in the To reduce fuel consumption and
accessible, and as a side effect of the superstructure. This design ensures a emissions, the firm’s single-engined
new designs, noise is also reduced – particularly high efficiency level with Explorer range features an intelligent
more welcome news for operators.” the low engine speeds that provide motor management system alongside
sufficient power for crane work. This a stop/start function. Klein explains,
Watch this space improves the overall economy, and is “We wanted to reduce the idling
Having kicked off its own slimming- also quieter than a two-engine setup.” time, so we incorporated the stop/
down process (in road-going form at Beringer also cites weight as a start technology to run the dashboard
least – see p54) with the LTM 1300- major factor in choosing one engine when the main engine is switched off.
6.2 at bauma 2013 – soon followed instead of two, as well as the long- This also has the added maintenance

ENGINES & EMISSIONS
DROP THE DEAD DONKEY ENGINE – AND ADD IN A PACTRONIC

iVT
Advanced
Lift-truck
2010 p6
IC
PACTRON
IN DETAIL
 Liebherr’s maritime cranes are also

undergoing change, as witnessed by
the introduction of the Pactronic hybrid
accumulator covers peak performance;
this leads to a more balanced utilization
of the engine, which means less fatigue.”
reliability trumps fuel costs. However, it is
true that the increasing complexity of the
aftertreatment means we are struggling
system in 2010 and the upgrades to its Looking to long-term ownership costs, to pass on the cost savings to our clients.
LHM fleet earlier in 2015. Originally Schneider continues, “If only one engine Emissions standards get ever tighter. The
designed for mobile harbor cranes, the is used, maintenance costs are naturally long-term goal is clearly to avoid exhaust
Pactronic is now also available for duty- reduced. However, real-life costs depend emissions and focus on alternative, eco-
cycle crawler cranes, as well as for its on the maintenance that is required for friendly drive systems.”
latest reach stacker, the LRS 545, which the alternative drive.” So what about the future? He concludes,
was launched in June 2015. Hybrids can help with noise reduction, “Let’s look back first. The development of
Dr Klaus Schneider, Liebherr’s too. Liebherr launched its own noise control new game-changing technologies has
director, drive systems, explains, initiative, culminating in the 2012 receipt speeded up during the past few decades.
“In crane designs, where two of the IBJ Innovative Technology Award. Hybrid drives celebrated their breakthrough
engines were necessary for Incidentally, as well as the quieter hybrid in the mobile harbor crane sector not
crane operation, hybrid setup, the machines have benefited from too long ago. It is hard to predict which
drives such as Pactronic ongoing tweaking to minimize structure- doors will open over the next 20 years,
are truly a worthy replacement borne noise. but we will definitely see some further
of a second engine. Liebherr moved to Tier 4 Final for its improvements in terms of hybrids.
“Compared with a two-engine LHM fleet in May 2015. “There are clear “However, external factors, including
solution, this can greatly reduce benefits here if only one engine is used, emissions standards and oil price, will also
fuel consumption while providing equal assuming it’s not for applications such as play a crucial role in guiding the direction
performance levels. The hydraulic offshore, where redundancy means that of new technology developments.”
ABOVE: Liebherr’s
12-cylinder engine benefit of reducing the hours. Also
combines with the important in the single-engined
Pactronic system (top) design is a reduction in the overall
to halve the number of
engines required on number of cold starts.”
maritime cranes The intelligent motor management
RIGHT: Terex Explorer
system works by altering the power
5800 – the whole range is output automatically, depending on
now a single-engine design the demands placed on the engine.
Terex has compared fuel consumption
from similar cranes operating with
one or two units, and found the most
economical is a single-engined design.
Removing an engine from the
design gives a weight saving that
isn’t wasted. Depending on regional
axle-weight regulations, Terex will
strengthen various elements of the
crane to enhance stability.
“WE WILL LIKELY SEE FEWER TWIN- Looking forward, Klein says, “We
know Stage 5 is coming, but we don’t
ENGINED CRANES AS WE STRIVE TO yet know how strict it will be. What
GET LOWER EMISSIONS AND BETTER we can say is that we will likely see
fewer and fewer twin-engined cranes
FUEL CONSUMPTION ” as we strive to get lower emissions
Michael Klein, product marketing manager for All-Terrain Cranes, Terex Cranes and better fuel consumption.” iVT

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Munich, Apr 11 – 17, 2016
Hall A4, Stand No. 343
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024_OH__ANZ_IVT_215x275.indd 1 28.10.15 16:59

SAMANTHA GRAVELLS, CUMMINS ENGINES
THE FIFTH
AMENDMENT
DO YOU RESERVE THE RIGHT TO REMAIN SILENT WHEN THE TOPIC
OF STAGE V EMISSIONS COMPLIANCE ARISES? FEAR NOT – HERE’S
EVERYTHING YOU NEED TO KNOW ABOUT WHAT THE EU’S LATEST
ITERATION OF EMISSIONS COMPLIANCE HAS IN STORE

ENGINES & EMISSIONS
The next level of emissions

standard is on its way: EU
Stage V is a hot topic and many
OEMs are wondering what it entails
and how it will influence engine
and aftertreatment designs, and
ultimately machine integration.
Although it’s still under review, what
is certain is that the regulation will
be introduced from 2019 onward,
and for the first time will include
smaller (below 19kW) and larger
(over 560kW) sized engines.
So why was there a need to add a
further stage of emissions compliance?
Many EU countries face pressure to
improve their air quality, with a
drive to reduce ultra-fine particles
that is known to result in clean air
improvements. This, in turn, is
leading to a necessity to virtually
eliminate particulate matter (PM)
emissions from diesel engines. The
focus is to clean up the air of cities
and surrounding areas, and to do
this it is necessary to go beyond just
a reduction of PM mass to actually
counting the number of particulates
emitted by an engine – in order to
better control and limit emissions.

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ENGINES & EMISSIONS
SINGLE-MINDED SOLUTION
For Stage V, Cummins has optimized its emissions solution,
creating a next-generation single-unit aftertreatment system, as
revealed at Intermat Paris in April of this year. The Single Module
from Cummins Emission Solutions will be significantly lighter
than the current Stage IV switchback aftertreatment package,
with a much smaller envelope making it even easier to integrate
into machines.
The complete Stage V solution will be provided with AdBlue
(DEF) dosers and sensors, tanks, lines and filters from Cummins
Emission Solutions.
“The Single Module is designed with the customer in mind,
allowing for ease of machine integration, while still meeting key
PM reductions and maintaining product integrity. It includes
innovative catalyst and urea dosing technologies that are unique
to Cummins Emission Solutions,” comments Jane Beaman, off-
highway commercial and distribution business leader at
Cummins Emission Solutions.
The new legislation is proposed of the UN-ECE for Euro 6 and will be PREVIOUS PAGE: The almost all of the PM and has proven
Cummins Darlington
for 2019 engine production for non- applied to non-road equipment from Technical Centre, UK,
itself in the field in both on- and off-
road mobile machinery, from 0-55kW 19-560kW. A limit of 1x1012 has been is co-located with the highway applications.
and in the over-130kW segments, and proposed by the EC. In addition, PM manufacturing facility A DPF includes a diesel oxidation
where a high volume of
will be followed by the 56-129kW mass will be reduced from the Stage IV EU Stage V engines will catalyst (DOC) that has a catalyzed
segment a year later. limit of 0.025g/kWh to 0.015g/kWh. be built wash coat of precious metals, which
A maximum PM count limit will The 0-19kW and over-560kW in turn creates the right conditions
ABOVE LEFT: Cummins
be implemented, effectively cutting sectors, regulated for the first time, is drawing on the vast for oxidation of PM soot. A wall-flow
out 99.9% of particles in the 23nm will be required to meet limits of 0.4 experience from its Euro filter follows, trapping PM soot and
6 development program
to 2.5µm range. A PM count limit is PM/7.5 NOx and 0.045 PM/3.5 NOx and bringing it to Stage V
then oxidizing it. This should have no
considered the most effective way to (g/kWh) respectively. development impact on the equipment in which it
achieve very low levels of ultra-fine is being used – the Cummins DPF, for
ABOVE: The Single Module
particulate emissions, and has been How will technology be solution features a robust, instance, is active for less than 1% of
a key requirement of the automotive impacted? integral AdBlue dosing unit operating time.
industry’s Euro 6 standard since 2014. The only way to currently achieve To reduce NOx to the required
BELOW: The timeline for
A protocol for test equipment and such a major reduction in PM is with engines and aftertreatment levels, the DPF would need to be
testing was developed by the Working the use of a diesel particulate filter to meet Stage V packaged together with a selective
Party on Pollution and Energy (GRPE) (DPF). This technology captures catalytic reduction (SCR) system.
So what else is new?

Development Production The flexibility provision, which has
allowed engine manufacturers to
continue to build a limited number
of previous-stage engines for OEMs,
‘Co-decision’ will be removed and transitional
legislative 1/1/2019 1/1/2020 engines and equipment will be
process Translations Certification limited, so older engines cannot be
and scrutiny can begin Stage V effect Stage V
held for a long time before being
Amendments date 0-55kW effect date
sold into the market. The proposed
possible over 130kW 56-129kW
new system would allow engines
built before the cut-off date to be
Full final text and placed on the market for a further
implementing acts 18 months, but for the first time
in ‘Official Journal’ there is a restriction of 12 months
on when that engine may be installed

ENGINES & EMISSIONS
in a machine – which then must be could run until mid-2016. It is hoped What’s the end result?
placed on sale within 18 months of that the regulation will be approved Stage V will see Europe adopting the
the stage change. Amendments have by the end of 2015 or early 2016 so world’s most stringent off-highway
been tabled that would increase these the industry can prepare itself for the standards, resulting in the cleanest
times by six months. changes that will need to be made. and safest equipment. We now have
The new rules will also impact Starting January 1, 2019, engine a window when engine manufacturers
gaseous fuel, petrol and dual fuel production in the 0-55kW and over- can focus on the right solution for
engines. One industry concern in 130kW segments will be affected, Stage V, be it focusing on engine
the earlier drafts of the legislation being followed by the 56-129kW optimization and/or aftertreatment,
was the removal of replacement segment from the beginning of 2020. while working on developing the
engine options at Stage V; however, Richard Payne, Cummins’ most effective envelope to meet the
it is expected that a provision will product certification and compliance equipment integration challenge.
be put in place, allowing OEMs to director, comments, “Cummins has Bryden Clewlow, director of off-
replace worn-out or damaged engines closely followed this legislative highway sales in Europe at Cummins,
with the same level of engine to avoid Cummins engines and procedure as it has passed through concludes, “Cummins has a history
problems in the field. It is also being technologies will be the institutions of the EU with the of meeting and exceeding emissions
optimized for Stage V
discussed as to whether companies timeline so far being as predicted legislations with efficient engine and
producing less than 80 units a year by the EC, and a good chance of the exhaust aftertreatment solutions. We
would be given more time for the regulation being in the official journal have already started to work with
transition period. early 2016. This gives the industry OEMs to develop machines that will
Currently, there is a period of ‘co- the time to prepare for the first be more efficient and, of course,
decision’ with the EU parliament that implementation in 2019.” Stage V compliant.” iVT
FEDERUNACOMA: “SMALL TRACTORS NEED SPECIAL TREATMENT”

Compact equipment is likely to struggle tractors will be required to conform to EC to conduct further analyses before
the most from the enforced adoption of Stage IV. extending the regulation to these models
Stage V and the aftertreatment packages The final bone of contention was the in practical recognition of the difficulties
that will be required. Perhaps the most suggestion that an increase in the profile of installing bulky aftertreatment devices.
vocal opponents of the unequivocal of the machine as a consequence of The second amendment sets forth
adoption of Stages IV and V have been compliance can be partially offset by that narrow-track tractors now on the
the narrow-track/high-clearance tractor changes to farming methods. These market will only be totally redesigned
OEMs, represented by Assotrattori, part specialist tractors must maintain their when the new regulation is enacted, to
of FederUnacoma, the Italian Federation present characteristics of maneuverability avoid the need for partial modifications
of Agricultural Machinery Manufacturers. in vineyards and orchards planted required for a brief transition period. A
This gathered pace last December with according to a high-density model – a third amendment requesting a longer
the release of a technical study by TRL, historic wine production method that delay before implementing the measures
which claimed substantial compatibility makes a huge contribution to wine was not passed.
for Stage IV and V tractors in vineyards quality and has resulted in some of the The legislative procedure now calls for
and fruit orchards. While recognizing a production territories being recognized a final phase of three-way negotiations
degree of performance reduction would by UNESCO as world heritage sites. between the members of the European
result, the report gave the EC the grounds These modifications would damage Parliament, the Council of the European
to reject requests for the extension of farming enterprises and run counter to Union and the EC. The discussions are
terms for its application. the EU policy guideline incentivizing the expected to conclude in December 2015
Assotrattori contended that the report shrinking of planting layouts and driving with final approval of a regulation for
contained errors of method and incorrect OEMs to turn out more agile machinery. mobile off-road machine engines. This
assessments. It stated that the findings Due to the specialized work and the means that there is still time to convince
were based on a type of non-agricultural size of the engine compartment, these the EU legislators of the technical and
engine that cannot be compared to the tractor OEMs cannot install the engines industrial requirements of the companies
characteristics of engines for tractors, in and the aftertreatment systems and, at manufacturing narrow track tractors.
regard to technological solutions for anti- the same time, continue to meet the FederUnacoma president Massimo
pollution in particular. It also rebutted operational requirements in terms of size Goldoni said, “The serious risk is that
TRL’s claims that the engine industry can and maneuverability without a complete the Commission is evaluating [OEMs’]
complete work on specific engines for redesign – incurring costs that could not interests with scant attention because
narrow-track tractors to make it possible be sustained by the industry, nor by they refer to a relatively limited number
to apply the new norms in time for the customers. In fact, the redesign of of vehicles, without considering the…
prescribed deadline, as the 20,000 units narrow-track tractors would drive costs consequences in terms of production
p/a of narrow-track tractors is too small up by an exorbitant 20-30%. and employment that would fall on
for the engine industry to gear up for ad This September, however, two of the this sector… a sector which would lose
hoc technological solutions. three amendments aimed at changing important market share were [OEMs]
The compulsory application of Stage the timing for implementing the new required to give up the characteristics
V in 2019/2020 also fails to take into regulation were approved by the EC. The of the agility of compact machines
account that in October 2017, these first approved amendment commits the required by farmers.”

NO ENVIRONMENTAL CHALLENGE IS IMPOSSIBLE
FOR FPT ENGINES.
MARINE ON ROAD OFF ROAD POWER GENERATION

PRODUCTS & SERVICES
SAMANTHA GRAVELLS
Conquest of the air

AIRPORTS ARE MOVING AHEAD WITH SOME OF THE MOST STRINGENT
REDUCTIONS IN EMISSIONS ANYWHERE, MAKING THE RIGHT CHOICE
OF ENGINES FOR GSE APPLICATIONS EVEN MORE CRUCIAL
This October’s Inter Airport show in Munich,

Germany, highlighted the strong presence of
Cummins engines in equipment meeting the latest
low emissions requirements. Significant productivity
improvements and fuel-efficiency gains have been
achieved by machines with the transition to EU Stage
IV (EPA Tier 4 Final) engines, effectively highlighting
how Cummins brings ‘Technology That Transforms’
to each application in the ground support equipment
(GSE) industry – not just with ultra-clean power, but
with improved response and lower operating costs.
The move to near-zero emissions at EU Stage IV
has been achieved with an additional reduction in fuel
consumption to that achieved at Stage IIIB (Tier 4
Interim). Depending on the application, Cummins-
powered machines are able to realize up to 8%
improved fuel efficiency compared with their pre-
2011 Stage IIIA (Tier 3) equivalents.
In addition, with the full potential of Tier 4
technology utilized, even higher savings have been
achieved with features such as torque shaping, idle
control and eco-operating modes.
Importantly, however, the advantages of low-
emissions engines have been made available with no
compromise to reliability. That has been confirmed by
Cummins’ in-service reports based on a large engine
population that has been in operation since the
introduction of exhaust aftertreatment.
Analysis of warranty data and service events clearly
indicates that Cummins low-emissions engines are
delivering availability levels at least equal to that of
previous Stage IIIA engines, which have a long-
established reputation for reliability.
“In-service dependability is a key attribute of
the Cummins low-emissions technology and our
tracking of the Tier 4 engine population is clearly
indicating that equipment operators are seeing
uptime availability and minimal service intervention
ord
equally impressive as what they experience with our
mature Tier 3 engines,” says Hugh Foden, executive
word director, Cummins Off-Highway Business.
Showing off
The ability to transform machine performance was
reflected in the theme of the Cummins stand at Inter
Airport, featuring a 74-400hp (55-298kW) engine
range compliant with Stage IV and Tier 4 Final

PRODUCTS & SERVICES
iVT ABOVE: Cummins’ Tier 4 line-up

r
Novembe
2013 p34 BELOW: Cummins technology that transforms
TBL 800
CASE LEFT: Kalmar Motor’s TBL 800 running at Frankfurt
STUDY Airport (photo: Gregor Schläger)
The TBL 800 can perform push-back and high-

speed towing of wide-body aircraft, and docking can
be executed with the passenger boarding bridge still
connected, with the cradle having a lift capacity of up
to 50,000kg. During deceleration, the electric motors
function as generators for charging the batteries,
transforming the aircraft’s moving mass into energy.
Given the size of the wide-body aircraft, the system
itself generates ‘free’ battery charging.
The TBL 800 can benefit from constant full power
due to the Cummins engine. The low-emissions diesel
engine charges the batteries when needed, which
ensures that full power is available at all times,
regardless of the percentage charged. It is expected
that the engine would only be used 30% of the time,
resulting in a major reduction in fuel consumption.
The TBL 800 has been running at Frankfurt
regulations. The engine line-up included the latest International Airport, under the scheme E-Port AN, a
QSF3.8, QSB6.7 and QSL9 products, targeted toward program designed to lower emissions and CO2, and
compact ground power units, aircraft tow tractors lead to cleaner aviation.
and utility equipment. The company’s key enabling Cummins worked closely with Kalmar Motor to
technologies were showcased, with complete air intake- ensure an efficient and effective installation of the
to-aftertreatment exhaust-out systems and components. engine and its aftertreatment within the vehicle,
Cummins also featured in a variety of high-profile enabling the tow tractor to have power available to
machines at Inter Airport; TLD, for instance, revealed charge the batteries when needed.
its new TMX550 tow tractor there, powered by a Magnus Johansson, sales director at Kalmar Motor,
QSB6.7 Stage IV engine and rated at 275hp (205kW). comments, “Full availability and reliability are really
Cummins power was shown in the Goldhofer AST-2 important for our airport tractors. They run all hours
P/X towbarless aircraft tractor (see page 11), using a of the day, so having a dependable Cummins engine
QSL9 Stage IV engine rated at 380hp (283kW). fitted in the hybrid TBL 800 allows the vehicle to have
Newly launched at the event, the Kalmar Motor diesel power to charge the batteries if so required.
TBL 800 diesel-electric hybrid towbarless aircraft Cummins provide a low-emission, Stage IV engine
tractor provides an alternative power solution for the and exhaust package that leads to a lower overall
industry. The vehicle uses a QSB6.7 Stage IV engine impact on the environment.” iVT
rated at 260hp (194kW) to charge its batteries when
needed and is the first-ever hybrid tractor designed to Samantha Gravells is marketing communications
handle wide-body aircraft such as the A380. manager at Cummins
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PRODUCTS & SERVICES
FLORIAN SCHAFFELHOFER
MAN and machine

WITH A SHIFT IN FOCUS TO ENSURE THAT ITS PRODUCTS CAN BE MORE
EASILY CUSTOMIZED TO MEET THE NEEDS OF ITS OEM CUSTOMERS, ONE
ENGINE MANUFACTURER IS IN SEARCH OF PERFECT HARMONY
With its engines for agricultural technology,

MAN Engines is steering away from merely
being a deliverer of products to off-highway vehicle
manufacturers and is shifting its focus to suit the
specific needs of major customers through targeted
customization. To this end, a broad portfolio of its
latest 6- and 12-cylinder engines is available with
outputs of 294-816kW (400-1,110hp).
Thanks to the incorporation of a modular exhaust
gas aftertreatment kit, individual components can
now be freely positioned to permit a variety of
installations. This modular aftertreatment kit offers
OEMs a great deal of flexibility across all series when
designing their machines.
Presented to the world for the first time at the
Agritechnica 2015 trade fair in Hanover, Germany,
the MAN D2862 LE13x 12-cylinder engine and the
MAN D3876 LE12x 6-cylinder engine will make a
considerable contribution toward expanding and
reforming the company’s engine portfolio for
agricultural technology.
The units are integrated into the overall concept of
efficient MAN engines and are designed to have a One part of the ideal
partnership: modern
high power density to provide maximum power in and clean products such
compact dimensions. Both series are based on the as the new 12-cylinder
latest MAN series, meaning that off-highway OEMs MAN D2862 LE13x
will have access to them in the long term, even well diesel engine
beyond EU Stage V.
As a result of the use of an innovative turbocharger at the MAN Engine Academy in the Nuremberg “It was back in the early 1980s that we first installed
that uses variable turbine geometry (VTG) or a International Engine Competence Center in Germany, our highly robust load-bearing structure consisting
wastegate, and the latest common-rail injection as well as at international partner training centers of the oil sump, crankcase and flywheel housing.
systems providing up to 2,500 bar, MAN engines across all continents. Together they became the load-bearing parts in
achieve a considerably more dynamic performance The company has more than 40 years’ experience agricultural tractor construction and thereby helped
characteristic, a wider usable torque range, and a as a key engine supplier for agricultural machinery create a particularly small turning circle and lower
reduction in fuel consumption. Both engines comply manufacturers – a fact that is particularly evident in vehicle weight,” explains Jürgen Haberland, head of
with the strict emissions standards of EU Stage IV or the engines it specially develops for agricultural Off-Road MAN Engines.
US Tier 4 Final and are ready for EU Stage V. A fully technology. In addition to their particularly robust Tried-and-tested engines and emissions technology
integrated EDC17 engine control system acts as a components such as auxiliary units or belt drives, the used in hundreds of thousands of MAN trucks form
single control unit for the engine and exhaust gas insulation measures on the exhaust system provide the basis for the off-road engines. Also essential to
aftertreatment system, while offering a high level of an indication of these engines’ specific design for use these engines is the standard parts concept that is
flexibility with regard to simple system integration in dusty, hot conditions. used across all engine series for service components
into highly diverse device concepts. For maximum incline positions, the company’s and component groups, such as belt drives, auxiliary
engineers create special angled oil sumps and design units and filters. Thanks to high parts availability,
Extensive diagnostics the power supply based on a 12V vehicle electrical maintenance work can be simplified, handling costs
To meet the increased market demands for servicing system commonly used in agricultural technology, are reduced, and as a result the overall cost of running
and maintenance, MAN Engines enables OEMs to besides also offering a 24V standard variant. Even the efficient MAN engines also decreases. iVT
run extensive diagnostics in their environment via integration of engines into specific installation spaces
standardized data interfaces. The company also offers and vehicle concepts is part of the MAN Engines Florian Schaffelhofer is communications officer for MAN
machine manufacturers optional self-service concepts service portfolio. Engines at its International Engine Competence Center
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PRODUCTS & SERVICES
STEPHAN GRITSCH
Table for two

WITH THE LATEST TIER 2/STAGE II VARIANTS OF THE HATZ 4-CYLINDER
H-SERIES ENGINE PLATFORM, OEMS SEEKING TO SELL EQUIPMENT INTO
LESSER-REGULATED MARKETS NOW HAVE A LIGHTWEIGHT AND FUEL-
SAVING OPTION ON THE MENU
With the launch of its 4H50TIC DPF and RIGHT: Perfectly made for
4H50TI engines, Hatz Diesel has delivered two lesser-regulated markets:
more variants of the four-cylinder turbo engine that it Hatz’s brand-new 2-liter
4H50TI diesel engine
introduced in 2013. In total, the four-cylinder 2-liter
4H50TIC industrial diesel engine, equipped with the FAR RIGHT: Plug-and-play:
Bosch common-rail system, adds up to a total of three a 4H50-series engine
variants, which, depending on the aftertreatment, are as open power unit
now available worldwide.
In addition to the H-series, the existing L/M43-
series represents the three- and four-cylinder models
of the L- and M-series, which are equipped with a DPF
to meet the stringent requirements of US EPA Tier 4F,
EU 97/68 Stage IIIB, and the OAPC in Switzerland.
This means the L- and M-series engines are the only
air-cooled engines in the 56kW class that still meet
the current emission regulations in the EU and USA.
Furthermore, Hatz diesel engines of the B-, D- and
G-series in the sub-19kW class are Tier 4F-certified.
The 4H50TI and 4H50TIC DPF

The 4H50TIC, which has been manufactured since
early 2014, was presented at Intermat 2015 in a of 173kg, the engine is about 90kg lighter than the Stage IIIB version. Because of the elimination of the
variant without exhaust aftertreatment: the 4H50TI. next competitor in its class. As a result, valuable EGR, the specific fuel consumption of 218g/kWh at
By adapting existing components such as common resources can already be saved in production, and the best point is slightly higher than the values of the
rail, injectors and high-pressure pump, and because emissions are reduced because of shorter processing basic engine.
of the elimination of sulfur-sensitive components such times and less effort being required for the preparation The 4H50TIC DPF is equipped with a separable
as those for EGR and the oxidation catalyst (DOC), of raw materials. One of the development goals was particulate filter and DOC, and is compliant with the
the engine can be operated with diesel fuel with a to optimize the fuel efficiency, not just to a best point, Clean Air Act (LRV) of the Federal Office for the
sulfur content of up to 5,000ppm – which is crucial but also to achieve maximum efficiency over a wide Environment (FOEN) in Switzerland and registered in
for many markets in Africa, South America, and Asia. and realistic speed and load range. Due to the the corresponding particulate filter list. The latest
The 4H50TI is compliant with US EPA Tier 2 and EU sophisticated injection, together with other measures, Hatz engine complies with the requirements of the Air
97/68 Stage II legislation in the range up to 62kW, as the exhaust gas is considerably cleaner before it even Pollution Control Ordinance and can be used in
well as the EU 97/68 Stage IIIA in the range below needs to run through the aftertreatment system. applications throughout Switzerland. Through the
37kW. The latter applies in particular to operation as a Based on reduced weight and increased efficiency, use of the particulate filter in conjunction with the
generator with speeds of 1,500rpm and 1,800rpm. some impressive reductions can be achieved: certificate of the FOEN, the 4H50TIC DPF may also be
As part of the development of a new engine with • In the processing of raw material: 476kWh and used in areas where special demands for the exhaust
up to 56kW, Hatz engineers challenged themselves to 160kg of CO2 per engine; aftertreatment apply – for example, for underground
fundamentally rethink the conventional concepts of • Lower effort in production: 302kWh and 169kg CO2 use, tunnel construction, and in metropolitan areas
industrial engines, and develop a unit that – in terms per engine; where a DPF is often mandatory.
of energy and resource efficiency, pollutant and noise • Fuel savings of 22,691kWh and 6,075kg CO2 per The particulate filter has been developed especially
emissions, as well as compactness and durability – is engine (at approx. 800 hours/year). with regard to environmental aspects, serviceability,
far superior to its competitors. The focus was on the Because of the elimination of exhaust aftertreatment and durability. The DPF has therefore been large-sized
environmental and economic sustainability and high and the requirements of the emissions legislation, the to ensure the deposition of particles over a long
energy efficiency throughout the entire production 4H50TI can be operated with higher performance. period of time, resulting in longer intervals between
process, through to the operation of the engine. The maximum output is 62kW and the maximum regeneration cycles. In addition, all kinds of different
The development of the 4H50TIC followed a torque 265Nm. At just 152kg, the total weight of the requirements and load profiles are covered by the
groundbreaking downsizing concept. With a weight 4H50TI is considerably less than the 4H50TIC Tier 4/ large-sized filter.

PRODUCTS & SERVICES
As a special feature, the system is separable by In addition to its technical properties, the H-Series
means of two clamps and the filter element can be can also score in terms of ecological characteristics.
removed and cleaned manually. Due to the stringent downsizing concept and the
The manual ‘Easy Clean’ reconditioning of the filter reduction in weight of about 90kg, valuable resources
element is available from Hatz as an aftersales service. and energy are already saved in the processing of raw
After ordering the Easy Clean service, a reconditioned materials and the production process. But during
filter element will be sent to the customer, who then ABOVE XXXX two-word caption operation, the H-Series engines are also extremely
returns the contaminated filter element, reducing the economical: thanks to the Bosch common-rail system
downtime of the machine to a minimum. and an in-house developed combustion strategy, the
consumption of 4H50TIC Tier4 is below 240g/kWh, in
H series open power unit a wide, usable and realistic speed and torque range.
The open power unit (OPU) option is available for all These and other characteristics of the H series are
versions of the 4H50 series. In addition to the standard why the 4H50TIC was voted among the Top 3 finalists
scope of delivery of the engine, all parts that are of the most prestigious environmental award in
required for its operation are supplied as a ready-to- Europe – the GreenTec Award.
install solution. This includes radiator- and intercooler- units, forestry machinery, drilling rigs, and stationary Furthermore, the development of 4H50TIC is
mounted vibration-decoupled, as well as the required applications such as pumps and generators. funded by the Federal Ministry of Economics and
tubing and wiring harness, meaning the customer As well as a low additional weight of just 82kg, Technology, based on a decision by the German
only needs to connect tank, pre-filter and pump, as the OPU is characterized by its small installation Bundestag as a result of the achieved and projected
well as air filter, battery and control box. dimensions. With box dimensions of just 699mm in energy and resource savings. iVT
The OPU is available in lot sizes starting from one width, 935mm in length and 807mm in height, the
piece. Its main application areas are primarily working OPU can also be used in machines with restricted Stephan Gritsch is responsible for public relations and
machines such as hydraulic lifts, hydraulic power installation space. marketing at Motorenfabrik Hatz
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PRODUCTS & SERVICES
MATHIAS ROTH
Crane of thought
INTELLIGENT MOBILE CRANES ARE ENHANCING SAFETY AND
PERFORMANCE – BUT HAVE YOU EVER WONDERED WHERE THEY
WOULD BE WITHOUT THE LATEST SENSORS?
Whether they are incorporated in mobile,

vehicle- or truck-mounted cranes, intelligent
sensors are proving to be indispensable. Accurate
detection of the support jack, the angle of the slewing
ring, the angle of the overall vehicle, the installation
angle of the booms, and the exact position of the
winch are becoming an integral function of intelligent
mobile cranes. But these systems are not only used to
meet the requirements of EN ISO 13849 or EN 13000,
complying with these safety directives and thereby
ensuring vehicle stability – for quite some time, these
sensors have also been used to considerably increase
the efficiency and performance of mobile cranes and
other industrial vehicles.
Through many years of experience in this area, Siko
has now developed a complete system of sensor
components for exactly these types of vehicles – not
only to make cranes safer to use, but also to maximize
the efficiency and performance of each machine.
With sensors designed specifically for use in their
cranes, OEMs now have the option of intelligently Redundant SG32 and SG42 wire-actuated encoders
networking their models to increase performance.
in other words they could even be fully retracted on encoders offer this improved safety by means of a
Variable support position one side of the crane while being fully extended on special and completely redundant sensor technology,
The working environment on construction sites is the other. When comparing an old crane with a new which is employed to measure the absolute position.
frequently imperfect and confined. In many cases, the crane, and based on having half the support base, the With this innovation, two completely separate sensor
outriggers of mobile cranes cannot be fully extended, latest sensors from Siko mean it is possible to achieve systems detect the exact position and display them
thereby restricting full use of the crane. It may be the a much better reach into the desired direction before separately as analog signals.
case that the mobile crane must be placed at the site the load torque limitation automatically switches off With measuring lengths between 3-6m, these
in a way that limits the outrigger width to only 60%. the crane’s movement. sensors are ideally suited to accurately determining
In the event of limited installation space, the absence To support this application, the company has been the exact position of outriggers on cranes and
of active support monitoring only allows the crane to continuously developing draw-wire sensors over the working platforms, as well as for determining the
be supported at half the outrigger length on both last three decades, hand-in-hand with its customers, position of telescopic booms.
sides, for example, so a large percentage of its actual to meet the demands of the harsh environment of In combination with safe control systems, the wire-
performance spectrum is lost. mobile cranes and to achieve an increase in actuated encoders enable the overall system to be
To specifically prevent this type of loss, it is vitally performance for the customer. Furthermore, the certified pursuant to SIL2 PL d. With MTBF values of
important to be able to precisely detect the position durable structure of the sensors is even more >100 years, these sensors are optimally suited for use
of each support jack at all times. To do so, Siko relies impressive, for mobile applications in particular. For in certified complete systems.
on wire-actuated encoders with a very high degree of example, the spring assembly is protected against the To use digital interfaces, products with CANopen
robustness. Using draw-wire sensors in the support ingress of dirt and water, and always works perfectly, featuring a simple or redundant design – SAE J1939
jacks allows for the position of every jack to be even at temperatures below freezing. or the CANopen safety interface – are available. This
continuously monitored and forwarded to the In recent years, increasingly safe wire-actuated gives the customer the option to choose from a
machine control system. encoders have been developed, based on the variety of wire-draw mechanisms. The most diverse of
This information enables the machine control changing standards. The safety assessment has sizes are available, with lengths of between 1-15m.
system to extend each outrigger of the crane to the increased considerably of late, especially for mobile Thanks to the flexible Siko attachment system, the
maximum possible reach allowed by the location. cranes – and not just since the new draft of EN 13000. wire-actuated encoders can be factory-fitted with the
This means the supports can be variably extended – The Siko SG32, SG42 and SG62 wire-actuated desired field bus interface.

PRODUCTS & SERVICES
ON THE WEB
See an animation of this sensor technology at:
Detection of slewing ring position

Another important point in the overall system is the
deflection of the crane. The position of the slewing
ring is an important factor for the load moment limit,
which must be taken into account to calculate the
tilting line, in addition to the correct jacking width. To
detect the position of the slewing ring continuously
and safely, it is important to use an absolute encoder
for this purpose.
With the WV58MR rotary encoder from Siko –
which was designed specifically for precisely this
application – special attention was given to the
encoder’s adaptation to the slewing ring. The shaft
load capacity of these encoders has therefore been
beneficially increased.
Furthermore, optional form-fitting and spring-
loaded external gears are mounted for use on
slewing rings. These serve to compensate for the
backlash of the slewing ring to the external gear,
and always provide accurate position sensing, as
a result.
Another vitally important aspect concerns selecting
the right interface. To ensure that the customer has
maximum flexibility in this regard, the slewing ring
encoders are available with completely standard
interfaces. Therefore, depending on the application,
the customer is able to choose between analog
outputs, CANopen, or an SAE J1939 interface. A
redundant version of the slewing ring encoder is
available with a redundant CANopen interface or
CANopen Safety. Well-rounded all around!
Through the examples described here, it becomes
apparent that the information that is being made
available by intelligent sensor systems will not only
increase the safety of mobile cranes, but their
efficiency and performance too.
As a result of this new flexibility, dispatchers can
better plan the deployment of their vehicles to
construction sites and thereby use the vehicles more
efficiently. So the end user will benefit directly – not
only through improved safety, but also through a
higher load capacity and a larger work area when
using the crane. iVT
Siko sensors – in use here for rotary, linear and Formerly part of the Siko R&D department, and now
angular measurement in a fire truck – make
cranes smarter and help OEMs to reach the branch manager mobile automation, Mathias Roth is
necessary safety standards responsible for sensor solutions for mobile machines
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SERVICE
www.ukipme.com/info/ivm Ref: 504 xxx

PRODUCTS & SERVICES
CINDY MACKIN-FAWCETT
Tough at the top

TAKING THE NEXT GENERATION OF ENGINE, TRANSMISSION AND
PILOT CONTROL VALVES TO AN EVEN HIGHER LEVEL ISN’T AN EASY
TASK – BUT THE NEW G3 DROP-IN CARTRIDGE VALVES WERE WELL
WORTH THE EFFORT
Powertrains, diesel engines and transmissions

for mobile equipment are tough, well-built,
and super-efficient – and suppliers to this market
must be just as tough. As a powertrain market
supplier, HydraForce well understands that success in
this market depends on continuous improvements in
performance and efficiency.
The compact, drop-in style of cartridge valves the
company manufactures has been used extensively
in diesel engine control, transmission control and
hydraulic pilot control applications since the late
1980s. HydraForce has now introduced its new G3
range of drop-in cartridge valves targeting powertrain,
diesel engine control and hydraulic pilot control
applications. The new G3 valves are designed as an
enhancement over its current product.
“Our drop-in cartridges are incredibly prolific
in the powertrain market today,” says David Price,
HydraForce marketing communications manager.
“While our current product is competitive, we wanted
to give our customers an added layer of performance
and efficiency.”
When it comes to performance, the powertrain
market is very demanding. “Hydraulic valves have to
work in very hot environments, sometimes with lower
voltage levels to ensure functionality in worst-case
conditions. And then, there’s contamination,” adds
Price. “Hydraulic valves need to be able to function G3 valves are ideal for pilot, powertrain
when there is significant contamination present in the and directional control systems, due to
their compact footprint and ability to
hydraulic oil. To do so, the force generated by the
precisely regulate pressure and flow
solenoid must be as high as possible.”
Additional enhancements provided by the G3
offering include a considerable reduction in leakage to create a rigid assembly that would be robust for The G3 line-up
when compared with other options on the market. A shipping, handling and long-term durability,” states The initial models in the new G3 cartridge valve line
typical system can incorporate 2-16 valves; reducing Nick Stabile, engineering group leader at HydraForce. include two three-way, two position solenoids – one
the leakage of these functions by up to 80% can “In the case of our solenoid valves, we were able to bidirectional and one normally closed – as well as a
therefore translate into 0.3kW of energy savings. keep a similar coil size to that of our older-generation four-way, two position solenoid. All offer flow ratings
To accomplish this, HydraForce made extensive use valves, but generate two to three times the magnetic of 8.0 gal/min (30 l/min) at operating pressures of
of theoretical modeling, encompassing finite element force with less current draw,” he adds. “In the case of 652psi (45 bar).
analysis (FEA), computational fluid dynamics (CFD) our proportional valves, the solenoid coil force is The first proportional pressure-reducing/relieving
and magnetic modeling. CFD is an important tool about the same as that of our legacy drop-in products, valves include a pilot valve with optional manual
that HydraForce has been using over the past five but with a small coil that draws less current. override, a high-flow, direct-acting valve and a high-
years that has proven to increase flow rates as well as “The actual mechanics of the valves are designed flow, pilot-operated valve.
decrease pressure drop in various valve configurations. in such a way that the actuator uses minimal current. These valves are ideal for piloting directional
With these powerful tools, the company was able Whereas a lot of valves out in the field are using controls as they have very low hysteresis, and have
to optimize the magnetic efficiency of its G3 valves, between 1.0-1.3A, ours will be in the range of 0.7- been designed to provide a repeatable and precise
focusing on actuator size and forces. “We also wanted 0.8A, so there is real potential for energy savings.” pilot pressure to the main control spool.

PRODUCTS & SERVICES
LEFT & CENTER: The enhanced flange design

allows for optimal mounting flexibility and
protection from external leakage in demanding
applications
BOTTOM: Using CFD, HydraForce was able to

significantly reduce pressure drop through the
valve assembly, while an improved actuator
design ensures efficient use of voltage – a huge
plus for battery-powered machinery
adds: “We saw the market trending this way – engine interface eliminates the need to program a complex
compartments are very tight these days. They don’t control algorithm for clutch or pilot control
have a lot of space there, so any millimeter you can applications.”
save is a good thing.” Electronics introduces comfort and fuel efficiency
Another application-driven feature of the G3 valves thanks to closed-loop control of clutch engagement.
is that they are rated to higher tank line pressures. These valves and electronic controls support the trend
“We wanted to overcome the limitation in tank of optimizing clutch and pilot-control systems, where
line pressure ratings on our older products,” Stabile fast response is necessary to ensure efficiency and
explains. “This means the G3 valves have greater long service life.
flexibility for circuit design.”
The flexibility of the G3 valves is enhanced with a Popular choice
flange-style mounting plate that can interface with The initial offering of G3 valves has found applications
existing mounting holes to provide full backward at several major OEMs, and HydraForce is already
compatibility. In addition, the round flange has been looking toward expanding the line-up to additional
designed to provide expanded options for coil models in the near future.
orientation, as coil terminations can be oriented with These efforts have not only focused on products
respect to the mounting configuration. A second though, as the evolution of various product offerings
plate design, currently under development, will allow has led the company to invest in several important
for banking two or three valves together for multiple facility upgrades. The most recent is the new purpose-
control functionality. built European headquarters in Birmingham, UK. The
The G3 valves are also engineered to offer low three-story 11,150m2 building features production
hysteresis – between 2% and 3% – as well as to be and testing areas on the ground floor, and engineering
Flow rates, depending on configuration, are 1.0 highly resistant to pressure ripples and shock loads. and sales offices, and training areas, on the first and
gal/min (4 l/min), 8.0 gal/min (30 l/min) and 9.0 gal/ Hysteresis in hydraulic valves can be avoided by second floors. There is also a new 465m2 application
min (34 l/min) at operating pressures of 435psi or reducing friction between the moving elements engineering lab.
580psi (30 bar or 40 bar). inside the valve. This friction can come from many HydraForce’s president, Jim Brizzolara, says of the
The flow ranges for these proportional valves were factors, including contact surface area, surface new facility: “We are delighted to witness this new
chosen to serve different segments of the powertrain finishes, and part alignment, to name a few. “The key stage of growth for HydraForce in Europe. Whether
market. For example, the 1.0 gal/min (4 l/min) valves to hysteresis reduction is to take all of these factors we build in Birmingham, Shanghai or Chicago, our
are used in piloting circuits while the 8-9 gal/min (30- into account early in the design process and work customers can expect the same level of innovation,
34 l/min) valves can be used for direct-acting circuits, with manufacturers to achieve optimized designs that quality and responsiveness. We are all part of the
to drive actuators efficiently without the use of any meet our targets,” explains Stabile. same family.
additional elements. HydraForce is also able to provide additional value “This new location in the Advanced Manufacturing
“All of the valves incorporate enhancements in the to transmission and pilot applications, by fitting Hub will help us bring new electrohydraulic
actuator mechanism and have the solenoid connector its electronic controls to manifold assemblies. “The technology to the European market faster than ever
mounted on top of the valve rather than the side, newly released ETDR and EVDR valve drivers are the before. It improves our global efficiency and gives us
making them more compact,” Price says. The top- perfect solution for simplifying the control of a clutch a solid base for continued growth in Europe.” iVT
mounted connector allows tighter spacing between or ancillary pilot control applications,” states Chris
valves and easier access from the top to attach the Shader, electronics product manager at HydraForce. Cindy Mackin-Fawcett is a senior technical publications
wiring harnesses. The idea for the top-mounted “Nobody understands how to control our valves specialist for HydraForce and has more than 25 years’
connectors came from the voice of the customer, he better than we do. Our valve driver’s easy-to-use experience in the fluid power industry
FREE READER INQUIRY

ENQUIRYSERVICE
SERVICE
www.ukipme.com/info/ivm Ref:Ref:505
xxx

BULLETIN BOARD
The heartbeat of Coupled up
our industry Faster’s R&D
The 31st edition of the department has
world’s leading construction launched a new
trade fair – bauma – takes ‘universal concept cartridge style’
place in Munich, Germany, from April quick-release couplings series.
11-17, 2016. All branches of the These products, designed to be
industry, all leading manufacturers, assembled inside specific cast iron
and all the important innovations manifolds with lever, are fully
will be there – because those who compliant with ISO standard
have been to the event before always 7241-1 part A.
come back. bauma is the leading The aim of this new technical
industry platform for experts who concept is to use only one cast
deal with construction and building- iron manifold, but is characterized
material machines, construction by the possibility of employing the
vehicles, construction equipment where international key players meet, 535,065 visitors and 3,421 exhibitors. same cartridge housing with four
and mining machinery. where significant new developments This event is a must for anyone in different coupler styles:
bauma Munich provides the ideal are presented and where suppliers and the construction industry! Find out • Cartridge coupler according to
opportunity for visitors to meet the solutions come together perfectly. more and book your ticket for 2016 ISO 7241-1 Standard ‘A’ series
international market leaders and see The previous exhibition in 2013 set at www.bauma.de 12.5 size (½in);
the latest pioneering innovations several new records – confirming yet • Cartridge coupler according to
from around the world. It enables again bauma’s leading role as the READER INQUIRY SERVICE ISO 7241-1 Standard ‘A’ series
trade visitors to find exactly the world’s largest trade fair. Record- To learn more about this advertiser, 20 size (¾in);
visit www.ukipme.com/info/ivm
right suppliers and solutions that breaking numbers from that edition Quote Ref: 506 • Flat-face coupler according to
meet their specific needs. This is include 575,000m2 of floor space, ISO 16028 and ISO 15567 12.5
size (½in);
• Flat-face coupler according to
ISO 16028 and ISO 15567
Energy saver 10 size (5/8in).
Recently, the market trend is to
Ideally suited improve tractor power, the reaction
for hydrostatically time of attachments, and hydraulic
driven drivetrains, system flow rate, creating the need
Spicer PowerBoost technology for a higher-performing coupler.
is an innovative hydraulic- In addition, there was the
hybrid powertrain concept possibility to create a flat-face
for both off-highway coupling with performance levels
vehicles and material- very similar to those of the high-
handling equipment. specification agricultural couplings,
It captures hydrostatic but with the added benefits of non-
energy from the drivetrain in spill during the dis/connection
accumulators by recuperating phases. Their extremely compact
energy from braking and dimensions aside, these cartridge
during low-power operation couplings are also interchangeable
of the engine, and then uses inside the most popular cast iron
this stored energy to help power the vehicle. normal operating cycles by performing at the engine’s blocks that represent the current
Construction and agricultural equipment, material optimum speed. Power Mode provides enhanced vehicle standard on the market.
handling machines, and on-highway vocational vehicles acceleration and braking performance in operations that Moreover, these cartridges are
are the optimal targets for the Spicer PowerBoost system, require maximum power by combining the output of the extremely easy to connect and
generating fuel savings of up to 40%, depending on the engine with energy stored in the accumulators. Regenerative disconnect.
application and duty cycle. Braking Mode captures and stores energy otherwise wasted
The Spicer PowerBoost system employs an advanced during vehicle braking. Finally, Stop/Start Mode shuts down READER INQUIRY SERVICE
energy-management system to evaluate the levels of the engine during prolonged idle conditions and then To learn more about this advertiser,
power needed in the entire vehicle, predict operating restarts instantly at the operator’s command. Quote Ref: 508
demands, and determine the most efficient means of
operation. The powertrain technology features a modular READER INQUIRY SERVICE
design that offers flexibility in hybrid-control performance To learn more about this advertiser,
through multiple operating modes. Dynamic Eco Mode Quote Ref: 507
enables the vehicle to achieve maximum fuel efficiency in

BULLETIN BOARD
Connected thinking The Curtiss-Wright stuff

With Bauser’s latest Curtiss-Wright’s Industrial design and a small footprint, these
displays, extensive data Group – a recognized fully encapsulated, IP69K-rated
connectivity can now leader in the design and sensors offer exceptional resistance
be enabled via CAN 2.0B, USB, manufacture of critical controls and against water, dust, shock, vibration
Ethernet or PAL/NTSC video (open assemblies for on- and off-highway and temperature
to customization requests), while specialty vehicles – has recently The C3-CE motor controller is EN
J1939, CANopen, TCP/IP, and OEM launched a number of products ISO 13849 compliant and provides
proprietary protocols are available. including a new family of rotary OEMs with a device that is ideal for
To enhance Stage IIIB/IV and Tier an ISObus application to control the sensors, a CE-marked motor small industrial vehicle applications,
4 emission standards compliance, accessory equipment of machines. controller and a single-axis including Class III pallet trucks. It
compatible DPF and SCR functions The optional rotary encoder enables paddle joystick. features Category 3 hardware
can be incorporated. the easy setting of a wide variety of The NRH271 and NRH272 architecture, including dual inputs,
Installation can be achieved with machine and accessory equipment (pictured) rotary position sensors are dual microprocessors and a
a jointed arm (surface mounted) or parameters. ideal for use by OEMs of on- and off- dedicated B+Safe output.
integrated, while up to 12 tactile Standard displays include up to highway vehicles destined for use in The robust JC1200 is a next-
buttons and an optional rotary 21 warning lamps (LED) and up to challenging environments; and as a generation, cost-effective paddle
encoder can be incorporated. 26 pins for several I/Os, such as cost-effective solution for medium- joystick that, using a long-life bearing
Bauser offers a wide range of analog, digital or frequency inputs, volume applications where a wide system and non-contacting Hall-effect
display sizes, i.e. 3.5in (320x240) to as well as FET outputs (switching range of options or degree of sensing technology, provides smooth
7in (1024x600) color transmissive capacity 24V, 500mA). customization may be required. and easy-to-operate functionality
TFT displays with LED backlight Finally, a rugged design means With a low-profile sensor body that is tested to more than 10
between 350-1,000cd/m2 over a applications can withstand rough million cycles and ideal for use
lifetime of up to 50,000 hours. The environments with high levels of in agricultural, construction and
displays can be incorporated in a shock and vibration over a wide industrial vehicle applications.
panel/cockpit, or even mounted on ambient range.
a surface by using the jointed arm. READER INQUIRY SERVICE
The displays are compatible with READER INQUIRY SERVICE To learn more about this advertiser,
To learn more about this advertiser, visit www.ukipme.com/info/ivm
CAN J1939 engine data and can Quote Ref: 510
even be used as virtual terminals in Quote Ref: 509
Keep your distance with Hansa-TMP Hard to beat

In the next few years, there achieved through the ‘back-to-back’ The compact, lightweight
will be a technology boom structure of the pump and a central and robust design of
in the segment involving distribution line. The displacement is the new J R Merritt FS1
the use of remote-controlled vehicles 17-24cc/rev with a peak pressure of finger-operated joystick controller
for operations in hazardous areas. 400 bar, and the system is optionally makes it ideal for a wide variety of
These innovations ensure the equipped with a full range of applications including in-cab control
operator’s safety comes first and are electronic sensors that transfer the panels, portable radio control boxes,
suitable for numerous applications: output signals of the pump to the and pendants.
lawn mowers on the road side and electronic box. Moreover, the system This single-axis, Hall-effect joystick
steep slopes, exploration, defense, integrates two track drive units with features a 2.2in (55mm) actuator
and mining machinery. incorporated brakes, and one axial height and glass-filled Zytel housing.
Headquartered in Italy, Hansa- piston motor for the functioning of Moisture-resistant, non-ferrous
TMP is setting a new standard in the lawn mower or other services. components and conformal-coated
the industry by manufacturing a electronics provide exceptional
complete integrated system for READER INQUIRY SERVICE durability and ruggedness for use in
remote-controlled tracked and To learn more about this advertiser, industrial vehicles, mobile machinery,
wheeled vehicles. Quote Ref: 511 on- and off-highway applications,
The system comprises a compact and for in-plant process control
triple axial piston pump TPVTC 1500 where dependability and long life for corrosive and various other
+ TPV 1000. The TPVTC 1500 is a are paramount. hostile environments. Other options
high-power-density axial piston The non-contacting, Hall-effect include a 2.6in actuator height, a
pump and a very compact solution sensors provide long life and reliable friction brake, step detent, 7-30V
that is about 6cm shorter than the control in harsh environments. The input, redundant output, and low
market standard. This is extension-style spring return offers power consumption.
smooth and precise operations.
The FS1 is sealed to IP55 and meets READER INQUIRY SERVICE
or exceeds CE EMC requirements. To learn more about this advertiser,
An optional boot sealed to IP66 is Quote Ref: 512
available, making this device suitable

Out with the cold… A brake from the norm…
Webasto anticipates As agricultural machinery safety and minimum servicing are
that plug-in hybrids and continues to grow both guaranteed,” Loipl adds.
electric vehicles will play larger and more powerful, Knott is geared up to all the latest
an increasingly important role in improved EU regulations need to be demands on brake systems used for
agricultural equipment over the introduced to guarantee its safety. agricultural machinery. In accordance
next few years. This calls for new “From increased load to ever- with its motto ‘We make your brake!’,
technologies to heat these vehicles, increasing maintenance intervals, the customer priorities are at the heart
for – unlike agricultural machinery demands on brake systems become of what it does, ensuring that its
powered by conventional IC engines more and more complex,” explains solutions are customer driven.
– alternative drive systems do not Hans Loipl, Knott system technician,
generate sufficient waste heat from integrated into its hardware and adding, “Up to now, normal braking READER INQUIRY SERVICE
the engine to allow for heating the software. Moreover, the heater is systems have quickly reached their To learn more about this advertiser,
vehicle. Webasto has now resolved continuously monitored during operating limits, which is why we Quote Ref: 514
this challenging issue with its operation. are the first manufacturer to ensure
High-Voltage Heater (HVH), a high- In addition, the compact design our systems fully comply with these
efficiency water heater that heats of the HVH allows for more flexible new regulations.
the driver’s cab of e-agricultural installation positions in the engine “We are proud to say that the first
vehicles while driving. compartment. The heater has also hydraulic brakes that will wholly meet
With a constant effectiveness been designed for fast and easy the new EU regulations are made by
level of over 95%, the HVH converts plug-and-play installation – all Knott. With our hydraulic simplex
electricity to heat with virtually no connections are located on the front and servo brake models, we offer
loss. The heater delivers a continuously of the HVH and the space required excellent solutions.”
adjustable heat output of 0.2-7kW. for installing cables and hoses has Extremely powerful solutions can
To ensure reliable operation, the also been minimized. be integrated into the tightest space
HVH is well-protected against the envelopes, such as small wheel rims.
risk of failure. To prevent ingression READER INQUIRY SERVICE “This special design means that
of its voltage onto surrounding To learn more about this advertiser, these brake systems are perfectly
components, multilevel redundant Quote Ref: 513 protected against the ingress of
safety measures have been firmly both dust and dirt. The greatest
(De)sign on the dotted line

Car Studio was founded in Today, Car Studio boasts extensive Romania, as well as a joint venture prototyping additive printing, and
1986 on its president Dario experience in many different sectors with Yaris Kabin and Yaris Otomotiv high-resolution rendered images and
Abrami’s initiative after and can offer a high level of technical for a new company and new brand videos for marketing use. Seating-
having gained more than 20 years’ competence thanks to its qualified named Car Studio Yaris Design. Its buck production and ergonomic
experience in the design industry. collaborators and avant-garde IT flexibility, quick response, and ability analyses are conducted using Creo
Expanding rapidly, it soon systems. Over the years, Car Studio to propose and to evolve, truly make Manikin Extension. The software
approached new sectors and, as a has expanded its business, adding it stand out from the rest. used includes Autodesk Alias 2016,
partnership, eventually became one new prototyping and polyurethane Headquartered in Bursa, Turkey, Showcase 2016, 3ds Max 2016,
of the leading companies in the production services using the latest Car Studio Yaris Design provides CREO 3.0, and NX 10.
automotive and agro-mechanical technology on the market. design and engineering services
sectors, serving companies such as Car Studio recently took the including reverse engineering, style READER INQUIRY SERVICE
Ferrari, Maserati, Alfa Romeo, FCA, decision to set up new engineering sketches, concept development, To learn more about this advertiser,
Same Deutz-Fahr and CNHi. offices in China, North America and technical documentation, 3D Quote Ref: 515

INDEX TO ADVERTISERS
FREE SERVICE! Ametek VIS............................................................................... 19
ASM GmbH............................................................................... 17
Bauser GmbH & Co KG............................................................ 64
LEARN MORE ABOUT Concentric Hydraulics............................................................. 10
Cummins Engines Ltd............................................................... 8
OUR ADVERTISERS Curtis Instruments Inc......................................................... 4, 38
NOW!
Curtiss-Wright Industrial Group.............................................. 25
Dana Off Highway Systems Group................. Inside Front Cover
Electric & Hybrid Vehicle
Technology Expo 2016................................. Inside Back Cover
elobau GmbH & Co KG............................................................. 36
Faster SpA................................................................................ 34
Visit: FPT Industrial SpA................................................................... 61
Hansa-TMP Srl........................................................................ 75
www.ukipme.com/info/ivm Hatz Diesel............................................................................... 58
HydraForce Inc........................................................................ 43
to request exclusive and Hyundai Heavy Industries Co Ltd............................................ 13
Industrial Vehicle Technology International
rapid information about Online Reader Inquiry Service.........................................64, 75
the latest technologies J.R. Merritt Controls Inc......................................................... 75
Knott GmbH............................................................................. 52
and services featured MAN Engines SE...................................................................... 3
Messe München (bauma 2016) Pattern
in this issue Limited...................................................... Outside Back Cover
MOTOMETER GmbH................................................................. 58
Siko GmbH............................................................................... 52
SPAL Automotive Srl................................................................ 50
The Battery Show 2016............................................................ 28
Webasto AG.............................................................................. 55
www.IVTinternational.com....................................................... 67
JRM-201511-iVT Qtr page_JRM iVT ad 10/15/15 5:02 PM Page 1
Precision-Engineered
MADE IN ITALY Control Solutions
to meet your on- and off-highway &
industrial vehicle application needs
• 1-, 2-, 3- & 4-axis joysticks
• Custom grips for your requirements
• Full range of hall-effect joysticks,
from finger-operated to heavy
industrial
• Standard and custom operator
armchair systems, rotating and
fixed models
TVP 1500 • Output options: voltage,
17 - 21 cm3/n - Max P. 400 bar current and PWM
Electronic sensors on board amplifiers, can-bus,
profi-bus, 6- or
The high performance compact pump 8-bit encoders
• Proportional
VARIABLE DISPLACEMENT CLOSED LOOP footswitches
AXIAL PISTON PUMPS
DISPLACEMENT RANGE 7-110 cm3/n
HANSA-TMP S.r.l. (Italy) Stratford, CT USA • info@jrmerritt.com
Tel.: +39 059 41 57 11 - Fax: +39 059 41 57 29
hansatmp@hansatmp.it - www.hansatmp.it www.jrmerritt.com • Int'l 1.203.381.0100
THE INSIDER
‘MADE IN CHINA’ MAY NOT HAVE THE NEGATIVE CONNOTATIONS OF OLD –

BUT DOES THAT MEAN IT’S ACCEPTABLE TO FILL YOUR LATEST PRODUCT
WITH CHINESE PARTS AS A WAY OF MAINTAINING COMPETITIVENESS?
Like many of my colleagues at
iVT, my schedule is incredibly
hectic. Apart from the endless research
that goes into preparing this column,
like most of the crew I have celebrity
appearances, book signings, dinner
dates with supermodels, endless
press junkets, and the inevitable
exhibitions and seminar lectures.
Illustration: Julie Welby

But if I can dodge some of those
trying engagements, I occasionally
spend a little time with a tank of
compressed air strapped to my back,
investigating the subaquatic realm.
One meets a wide range of people on
any scuba diving trip, and as you are if a tad extreme. The Nordic guy then Okay, so far no foul. However,
stuck on a boat together on the way concluded the argument by proudly when we start to market products
to dive sites, apart from drinking informing us that his company had under our own recognized brands,
coffee, all there is to do is talk. successfully moved 30% of its supplied and they incorporate an appreciable
I tend to stick to talking about goods from its traditional European amount of internal componentry
diving and the weather, but some like sources to Chinese suppliers. And at from China or any other low-cost
to ruin the bonhomie by launching that point it was time to don our kit country, I think that we are starting
HE HAD
into a political discussion with folks and throw ourselves off the boat, so to deceive our customers, and selling
they have only just met. Recently I thankfully the mêlée subsided. our companies short. Hmm, I can
PROCLAIMED found myself on a boat somewhere Now, while my fellow divers were already see heads shaking and hear
WITH off the coast of Thailand where two
guys were squaring up to one
spared hearing my thoughts on the
matter, you, dear reader, do not have
murmurs of ‘dinosaur thinking’,
which is the usual reaction.
RELIGIOUS another on the subject of China. that luxury! There are certain degrees But, realistically, customers come
FERVOR THAT, One had made a disparaging of acceptability when it comes to how to you in preference to your Chinese
IN RESPECT remark about Chinese industry so,

with religious fervor, the other had
a product is sourced or described,
and how acceptable that is to the
competition because they expect
better quality – so isn’t it incumbent
OF QUALITY, proclaimed that, in respect of quality, consumer. For example, if you are on ourselves to ensure they get that
THINGS WERE things were changing rapidly over offered a crabstick as part of a buffet, in the form of a product that our
CHANGING there. His credentials for making this

claim were that he had lived in China
before it even touches your lips, you
are fairly sure that it probably has as
brands stand for? If we are proud of
our engineering heritage, isn’t it time
RAPIDLY IN for four years and had seen the much affinity with a crustacean as it that we stopped looking to China to
CHINA changes personally.
It turned out that he worked for
does with a chocolate bar.
But where equipment is concerned
provide the easy option? Virtually
anyone can make their products
a Swedish company making small the line becomes less clear. I own, for cheaper by cutting wages, ignoring
horticultural support vehicles and instance, a small generator apparently quality processes and trashing
equipment – I knew it by reputation; built by a major UK construction employee welfare.
like many other Swedish outfits it equipment OEM. Now, do I believe We should be better than that.
trades heavily on performance and that its backhoe assembly line grinds Instead of CEOs committing their
quality – but I didn’t mention this to a halt a couple of times a day while companies to ‘source from LCCs to
as I’d told the assembled group I sold the guys switch to making gensets? maintain competitiveness’, wouldn’t
groceries (well, it normally kills most No, it is clear they are manufactured they be better setting the goal ‘to
conversations). and assembled somewhere in the improve the competitiveness of
With all the passion of a Baptist ‘low-cost’ universe, painted yellow current existing suppliers’? CEOs of
minister, he affirmed that gigantic and adorned with a famous logo to the major brands should recognize
strides had been made in process finish off. So when it leaks petrol or the challenge and meet it. OK, it may
control and quality management, the spark plug cap disintegrates – as impact bonuses, curb the fact-finding
and that Chinese manufacturers mine has – you inevitably shrug your trips, due-diligence meetings and JV
were committed to product quality. shoulders in acceptance of the fact junkets to Shanghai – and it would
The other opined that they produced that this is a cheap rebadged ‘not fit not be an easy option. But then again,
crap, which we were consuming to for purpose’ type product and either proper management was never
our detriment, which is of course a set about repairs or throw the damn supposed to be easy. Live with it! iVT
very interesting point of view, even thing into a skip. Comments: theinsider@ukipme.com

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THE MAGAZINE FOR INDUSTRIAL VEHICLE TECHNOLOGY, DESIGN & ENGINEERING

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